Research and Development Mishap.

Several years ago I machined an adjustable cam gear for the 2.0. It was a single piece of aluminum and adjusted by having offset holes for the cam dowel in the center to alter the cam timing. To make a long story short, you will notice that there is very little material left in the center. I intended to make a support washer for this to make it more solid, but … I never quite got around to it. I had actually been running the gear for quite a while, and you can probably imagine what happened from there. While exiting the highway on the way to work: Clang! clang! clang! as it went bouncing down the road. After a quick tow to work, I saw what was left. I replaced the factory steel gear a few days later and headed home. I actually have three (new 2 piece design, and stronger of course) adjustable cam gears already in progress, so once I get one finished up I’ll see if it fares better!

pre-shear gear

remains of gear