The Making of a Reverse Shifter Extension

The Making of a Champion Reverse Shifter Extension

Just for fun, I wanted to share with those of you who may not be familiar with machining; how something like a shifter extension is made.
I have made several of these ‘shifter extensions’ over the years, with the last 7 or so going to Trike Talk members. These extensions are kind of unique, in that they fit the Champion 5-speed reverse kits used on Harley-Davidson bikes and trikes. The problem is that the supplied handle is too short to use comfortably. In most cases, the handle needs to be about 4 inches longer. I originally made these extensions 5-1/2” long overall, with the extension going down over the original shifter 1-1/2”. This works for most installations, but the extension may need to be heated and bent slightly to provide the best operational, clearance, and cosmetic looks desired by the owner. Recently TT member CC wanted one slightly shorter, which was finished, and another TT member, FBTRIKE wanted one not only shorter, but with unique threads to fit a custom shifter knob he wanted to use. The pictures here are of FBTRIKE’s extension in the making.
Before I go any further, I want to point out two things. First, I’m not ‘selling’ these, and take no money for myself, but rather ask the recipient to send a ‘donation’ to TrikeTalk to support this fine site we all know and love. Secondly, I know that many of you here are well familiar with how a lathe works, and I’m certainly not trying to make anyone think I’m some master machinist. Note that these are hand made, and could be turned out on a CNC much faster, but one of those just isn’t in the budget right now, LOL

OK, we start with a chunk of .875” (7/8”) round stock of 416 Stainless steel. I have used 304 stainless in the past, but 416 stainless is easier to machine. I use stainless steel, as there is a lot of material removed, and stainless polishes up like chrome, without the expense of chrome.

After cutting the round stock to length, I bore a 1-1/2” deep .484” (31/64”) hole in one end, so the extension will be a tight press fit over the original shifter.

[IMG]http://www.triketalk.com/forum/members/ultraboy-albums-making-shifter-extension-picture2549-boring-hole-fit-over-existing-shifter.jpg[/IMG]

Then, the other end is cut down on the lathe to .500” (1/2”) The gradual taper is made with consecutive passes of a concave cutting tool as shown.

[IMG]http://www.triketalk.com/forum/members/ultraboy-albums-making-shifter-extension-picture2548-reduce-diameter-above-extension-taper.jpg[/IMG]

If an original type ½” threaded knob will be used, threads are cut into the shaft .750” (¾”) long, using the lathe and thread cutting tooling. (Usually ½-13 pitch threads) FBTRIKE wanted his to have 3/8-24 threads, so the threaded area was further reduced to .375” (3/8”)

[IMG]http://www.triketalk.com/forum/members/ultraboy-albums-making-shifter-extension-picture2547-further-reduce-diameter-correct-thread-size.jpg[/IMG]

After finishing the threads, a commercial 3/8-24 nut was threaded on, just to make sure the threads were the correct size, and I didn’t screw up the thread cutting, LOL.

[IMG]http://www.triketalk.com/forum/members/ultraboy-albums-making-shifter-extension-picture2546-cut-threads-shift-knob.jpg[/IMG]

At that point, the extension was set up in the mill, to drill and tap holes for the setscrews, which secure the extension to the original shifter.

[IMG]http://www.triketalk.com/forum/members/ultraboy-albums-making-shifter-extension-picture2545-drill-tap-holes-setscrews.jpg[/IMG]

A few spins on the polishing wheel, and it’s completed and ready to go to FBTRIKE.

[IMG]http://www.triketalk.com/forum/members/ultraboy-albums-making-shifter-extension-picture2544-polished-ready-ship-fbtrike.jpg[/IMG]

Now, wasn't that fun?

See y'all in the funny papers.

UB

Hey that is kool thanks for sharing....:yes:

Very cool, UB! I'd love to watch the process in person!

As long as you abide by the rules of the Hot Tub, you are welcome to watch me make chips any time......