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Old 01-14-2011, 10:22 PM   #1
AirSpeed
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Join Date: Jul 2007
Location: Fall River California
Posts: 2,027
Home built shift aluminum shift lever

I bought a new steering wheel yesterday, its smaller than the one I had and the stock shift lever looked kind of ugly next to it, not to mention it stuck out past the new wheel.
I built a small foundry a while back so I decided to cast a new lever out of aluminum. Its a pretty simple process, I simply cut out some Styrofoam the shape I wanted, added a sprue and a couple vents, buried it in sand and pour molten aluminum into the center sprue.
I let it cool a couple minutes, cut off the aluminum from the sprue and vents, I then did a little shaping to the end that fits into the little hole in the linkage. I then did a little shaping on my vertical 1" belt sander, smoothing the edges, After that I sanded the entire lever smooth with my 6"X48" horizontal belt sander, and finally sanded it to 180 then 220 then 400. I need to polish it still but I wanted to see how it looked when installed, I will polish it up tomorrow.
It is a perfect fit and actually has no slop like the stock lever had. It is the perfect length now, just right to use my finger to pull it back to shift. I have a couple pics of it mounted but I couldnt get my flash turned on. I will post a better pick tomorrow of it mounted. I am going to make a new turn signal lever, door handles and window cranks over the next few days if I get the time. Take a look!







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