Someone asked for pictures -- I did not actually take any as I went
along, but here's a shot of the finished product.

http://picasaweb.google.com/allanstreib/Shifter#5262242323547866834

Haven't actually tried it out yet -- new shift rod bushings arrived
yesterday and I'll be installing them this afternoon.

Allan
--
1991 Vanagon GL

Allan Streib <streib@cs.indiana.edu> writes:

> Something just strikes me as "wrong" that I should have to pay the
> dealer for a new shift rod just because a little nylon piece has fallen
> off.  I mean it's basically just a piece of pipe, nothing at all to
> "wear out" otherwise.  So I decided to see if I could fabricate
> something.
>
> A small plastic/poly kitchen cutting board from Wal-Mart provided the
> source material.  I measured the bare metal finger on the shift rod
> fork, and used a jigsaw to cut a small piece out of the cutting board.
> Then using a file and sandpaper I shaped the piece, tapering one end,
> and also making it a little thinner since the stock cutting board was a
> little too thick (comparing to the other side of the fork which still
> has it's cover piece intact).  Then using a dremel tool I made a hollow
> slot (like a mortise) in the piece so it would fit over the bare metal
> fork on the shift rod.
>
> I degreased the metal with brake cleaner, filled the hollow in the
> plastic piece with JB Weld, and pressed it into place.  We'll see how it
> holds up, but I think it's worth it as an experiment.
>
> Allan
> --
> 1991 Vanagon GL
>
> "Jaime Forero" <jforero@sbcglobal.net> writes:
>
>> You should have a nylon cover on each of the 2 fingers of the fork.  I
>> bought the rod from VW about a year ago and replaced it.  Grease up
>> the contact area as well as you can.  Adjust and you will be in
>> business.
>> Cheers
>> Jaime
>>
>> ----- Original Message -----
>> From: "Allan Streib" <streib@CS.INDIANA.EDU>
>> To: <vanagon@GERRY.VANAGON.COM>
>> Sent: Saturday, October 25, 2008 1:47 PM
>> Subject: question about 4-speed shift rod front "fork"
>>
>>
>>> Is there supposed to be a plastic or nylon "finger" on each side of the
>>> fork on the front of the shift rod?  Looking at the illustration in the
>>> Bentley it seems that there is, I only have one on the 3/4 shift gate
>>> side, not on the reverse gate side.
>>>
>>> If I'm missing one, are these available?  Or would I be looking at
>>> trying to fabricate something?  Anyone know the dimensions?
>>>
>>> Allan
>>> --
>>> 1991 Vanagon GL
>>
>
> --
> 1991 Vanagon GL
>

--
1991 Vanagon GL