First gear stop rivet
Dimensions and preparation

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The rivet I used is a standard 3/16" round head steel rivet, with a 1" long shank.

This type of rivet is readily available, but the minimum quantity might be a problem. I was able to buy 1000 of them and have the box delivered overnight, but what would I do with the remaining 999 rivets?

My solution was to buy a bag of 25 rivets from a US-based eBay seller who specialised in providing materials for people who made suits of metal armour. I wasn't in a hurry, so the delivery time by airmail was not an issue.

rivet-new


The original factory-fitted rivet had a head diameter of 5.72mm (0.225") and a height of 1.0mm (0.040"). The factory rivet appeared to have been a round rivet at first, with the head then reduced in height. The remaining edge of the head was not perpendicular.

The rivet I purchased had a head diameter of 8.46mm (0.333") and a head height of 3.4mm (0.134"). The fact that the head is of greater diameter is an advantage, as will be seen below.

Remove the existing rivet by filing off its head. Measure it beforehand just to make sure your rivet's size is known. Presumably it will be the same as mine, but maybe not?

rivet-prep


First step of preparation of new rivet:

Holding the shank in a vice, file off 1.37mm (0.054") to create a perpendicular flat on one side of the head. This creates a rivet head that is effectively 5.72mm in diameter, insofar as its role as a stop rivet is concerned. The main thing is that the flat surface is 2.86mm (0.113") from the central axis of the rivet.

The advantage of the larger head is that, unlike the original factory rivet, when the un-relieved tooth hits the rivet, it is hitting a flat face, rather than a point contact. The new rivet should wear at a slower rate in service. (Will the new rivet ever be subjected to another 100,000 miles of further service? Probably not!)

Optional next step (and if you have access to a lathe):

Using a sharp-pointed tool bit or a small fine file, remove the radius between the underside of the head and the shank.

Next step:

Cut the rivet shank so that the shank is 6.6mm (0.26") long.

Final step:

Again holding the rivet shank in a vice, file the top of the rivet off so that the head height is not less than 1.2mm (0.048"). Then fit the rivet into its hole in the 2nd gear synchro sleeve, and fit the synchro sleeve into the 1st-2nd operating sleeve in line with the internal relieved tooth. You will probably find that the rivet head is too high to slide into the operating sleeve.

Next, remove rivet, file a bit off the head, and repeat the test fit. Continue until the rivet head just slides into the operating sleeve. Keep the fit as tight as possible.

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