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gear level spline coupling for fabrication

Submitted by stan_thomas on Sun, 04/06/2023
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Commando

Other than chopping up existing levers, can anyone suggest a source for the gear lever spline coupling. No lever, clamping eyes not necessarily required. Unplated steel (or aluminium). Something to weld a fabricated lever onto.

I.e. the splined end of these:
Commando gear levers

Submitted by stan_thomas on Tue, 13/06/2023

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Some interesting pieces on the RGM site, something to bear in mind for the future. Unfortunately not what I'm after at the moment. There must be a bin full of raw splined 'donuts' somewhere, just have to find them.

But thank you for your suggestions gentlemen.

Submitted by peter_shand on Wed, 14/06/2023

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What exactly are you after? A round steel boss with splines cut in the middle? I cut the splines for my rearset levers from alloy but can do steel as well.  

Hello Peter,

I did wonder whether this might be something in your line.

I'm after some donuts (boss if you prefer) with a spline cut through the middle. I can then slot and add a clamping loop (or whatever you'd call that brazed on bit the bolt goes thru) and braze on a piece of 5mm flat to make the lever arm. I can weld aluminium but steel is easier to mess around with. I did wonder whether I could use an old shift shaft as a broach and wack it thru with a flypress - might work with aluminium. But if you can make them we should talk. I'll PM you with a bit more of an idea of what I have in mind.

On one of Alan Millyard videos he makes the rear set link bar by forcing/broaching the spline through some aluminium flat bar with a press 

I believe it was on the honda rc30 race replica video on YouTube 

 



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