DuttonOwners

Dutton Kit Cars and their owners

For those days when your parts just can't arrive quick enough, for sunny days when the transit just isn't 'fun'...

Project X...

Coming soon to a shed near me.

1997 DOHC, weber TC, MT75 box and Sierra fixed 3.72 diff in a Phaeton 3/4 hybrid.

I did some playing on gear calc and the theoretical stats look like this.

Gear   Mph per 1000 RPM  Mph @4000 RPM Mph @6000 RPM
1 4.91 20 29
2 9.17 37 55
3 14.24 57 85
4 19.08 76 114
5 23.27 93 (buttock clench) 140 (new pants)

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Comment by Adrian Southgate on November 9, 2017 at 12:15

Be old age that hanging low Steve.... :)

can't even find an MX5 gearbox mount on our system, do you know the reg of the donor car?

Comment by Steve Kerswell on November 9, 2017 at 12:00

it hangs a bit low Ade, trying find something "alternative" :-)

Comment by Adrian Southgate on November 9, 2017 at 11:49

MX5 gearbox mount?

Comment by Steve Kerswell on November 9, 2017 at 10:44
Comment by Steve Kerswell on November 9, 2017 at 10:42
Comment by Steve Kerswell on November 9, 2017 at 10:39

on my Btype struggling with gearbox mount position. Could do with a hanging mount. I'm not sure what part has been wrecked, have had no contact for a while

Comment by Adrian Southgate on November 9, 2017 at 10:28

Which bit got damaged? I have a few spare bits including the linkage bracket. If it's the casing then :(

I can still get those gearbox mounts new but they cost me about £17 which is why I was looking at making side mounts.

I didn't realise that the Transit had a higher 5th gear... I know that 1st on my 55 plate is useless. 

Didn't think of land rover mounts but will have a look, got Mark from APM Duraflex making a pair with extra long bolts as the alloy engine mount on the DOHC is over 30mm thick.

Comment by Steve Kerswell on November 9, 2017 at 9:19

looking good Ade, mine in the Sierra was a bit far back, but I managed, just. If you need a slip joint for the prop, I have one here in very good order, surplus to my requirements now. Poor Elliot who bought my Sierra had to have new prop made and has damaged the gearbox due to prop bolt coming loose at the doughnut. That box was a good box with the Transit high 5th. gear mod. I did manage to use the escort gearbox mount after some faffing. And I used land rover engine mounts as they were small in height but very hard, almost to hard.

Comment by Adrian Southgate on November 9, 2017 at 1:02

More progress has now been made.

Engine and box are back together and sitting on trolleys between the chassis rails. Of course there are issues, how could there not be issues.

The MT75 is pot bellied, so of course it hit things. Had a play and now it doesn't hit anything but I do need to make some new bits to hold it in place.

Engine mounts need adapting from 45 degrees two bolt to horizontal one bolt so more bits need making.

IMAG0837

The engine has been moved back in the chassis to avoid fouling on the alternator / suspension mounts at the front.

IMAG0354

the gear shift on the MT75 now comes up roughly where my elbow should be. Options dwindled as I looked at the problem, wiggled stuff about and looked again. The only solution seemed to be to move the stick forward by about a foot (sigh)

IMAG0827

I looked into alternative gear sticks for the MT75 and found one by Spyder engineering that seems to do what I need. It's bulky and made to withstand a nuclear attack on the gear stick ... sadly it's priced for the lotus elan it was designed to fit :( so I decided to make my own. This is the Spyder engineering one.

MT75 Linkage Centered showing CollarThis is the back end of the gearbox selector mechanism which needs to be moved in and out as well as rotated to select gears.

IMAG0357

And this is my solution, still have a couple of bits to fettle in place, a link bar welded to the tube on the selector knob which will fit on the bottom of that clevis yoke and a brace between the two diagonals to prevent twisting.

IMAG0853

I have removed the large metal 'flywheel' but retained the rubber donut to help keep things smooth. In the picture above you can see the blue bolt sticking out of the side of the gearbox. That's the old mounting bolt for the shifter extension. I may use that as a secondary gearbox stabiliser, there is one both sides. 

Parts list.

300mm M8 316 stainless threaded rod.

M8 clevis fork with clip

M8 bore spacer tubes X2

M12 male rose joint.

M12 sleeve nut

M12 half nut (locking nut)

M12 to M8 'top hat' reducers X2

M8 316 stainless sleev nuts X2

M8 Rubber washers X2

M6 'shoulder' bolt & M5 nut / washers

3mm flat stock for diagonals

old bush crush tube and 8mm flat stock to make the critical little bit that joints the shifter to the selector.

Before I put it all together on the box I'll do measurements, diagrams and costings should anyone wish to replicate it. I'm hoping it will give me a nice, accurate gear shift. I will need to make some sort of reverse lock out as the MT75 can be binned into reverse quite easily without it. The rose joint needs to be packed with grease, I've replaced the dodgy broken selector dust cover with a large ball joint dust boot. I'd like to find some sort of cover for the clevis joint too.

That's it for tonight, hope it helps those of you planning to use the MT75 to make it fit under the S3/4, Melos and Legerra.

Comment by Adrian Southgate on September 22, 2017 at 19:03

Been and done a bit this afternoon. Put all four wheels back on and rolled the beast outside to turn it round. IMAG0346 IMAG0345 IMAG0347

Once it was back in the dry I decided to try the front calipers so dropped the front ones off ... Oops. Calipers bolt on but the discs don't fit. Not enough offset on the disc to clear the caliper. Presume I bought the wrong discs (sigh) Need to go through all the different front disc options now to work out which ones I need.

After that little setback I decided to bolt the engine and box back together and chuck it in the big hole at the front to see if that fitted ... That MT75 is a proper pot bellied box of gears. Even with the engine so far forward that the crank pulley hits the front cross rail, that box isn't a good fit. It looks like I'll have to relocate at least one crossrail either lower under the main chassis (not especially desirable on a low car) or backwards like I did on the Legerra. I'll get some photo's added. Need to see if I still have a haynes manual for a Sierra I guess.

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