Clutch alignment tool
Discussion
You mentioned that you have a 3d printer,
- the T5 spline is 1" diameter, 23 tooth pattern, and a 15mm spigot bearing diameter. This is standard for the AJP Speed 6 and V8 engined cars with the T5 gearbox.
ChatGPT says:
Recommended design
For FDM printing, I'd make the tool in three sections:
Section Diameter Length
Handle 35 40 mm 70 mm
Clutch alignment section 24.8 25.0 mm 40 50 mm
Pilot bearing section 14.90 mm 20 25 mm
I'd add:
a 1 mm chamfer on the pilot end
generous fillets between sections
a slight taper (about 0.1 mm) on the alignment section so it slides into the clutch disc easily.
Why not model the 23 splines?
For clutch installation, it's unnecessary. The purpose is simply to center the clutch disc while tightening the pressure plate.
A smooth 24.9 25.0 mm section centers the disc extremely well because it locates on the root diameter of the spline. In fact, many commercial plastic alignment tools are smooth rather than fully splined.
Advantages:
prints on any FDM printer
stronger than a fine spline print
no support required
won't jam in the clutch disc
Material
I'd print it in:
PETG (my first choice)
ABS
Nylon
PLA would probably work for occasional use, but PETG is tougher and less likely to deform if left in a hot garage.
If you want a fully splined version
I can also generate an accurate 23-tooth involute spline model. It'll fit more like the gearbox input shaft, but I'd recommend printing it on a resin printer or a very well-tuned FDM printer with a 0.2 mm nozzle for the best results.
I can generate the files
I can produce:
? STL ready to print
? STEP file for machining or editing
? Fusion 360 model
? OpenSCAD source
I can also include a "TVR AJP 23T × 15 mm" label embossed into the handle so it won't get mixed up with other alignment tools in your toolbox.
- the T5 spline is 1" diameter, 23 tooth pattern, and a 15mm spigot bearing diameter. This is standard for the AJP Speed 6 and V8 engined cars with the T5 gearbox.
ChatGPT says:
Recommended design
For FDM printing, I'd make the tool in three sections:
Section Diameter Length
Handle 35 40 mm 70 mm
Clutch alignment section 24.8 25.0 mm 40 50 mm
Pilot bearing section 14.90 mm 20 25 mm
I'd add:
a 1 mm chamfer on the pilot end
generous fillets between sections
a slight taper (about 0.1 mm) on the alignment section so it slides into the clutch disc easily.
Why not model the 23 splines?
For clutch installation, it's unnecessary. The purpose is simply to center the clutch disc while tightening the pressure plate.
A smooth 24.9 25.0 mm section centers the disc extremely well because it locates on the root diameter of the spline. In fact, many commercial plastic alignment tools are smooth rather than fully splined.
Advantages:
prints on any FDM printer
stronger than a fine spline print
no support required
won't jam in the clutch disc
Material
I'd print it in:
PETG (my first choice)
ABS
Nylon
PLA would probably work for occasional use, but PETG is tougher and less likely to deform if left in a hot garage.
If you want a fully splined version
I can also generate an accurate 23-tooth involute spline model. It'll fit more like the gearbox input shaft, but I'd recommend printing it on a resin printer or a very well-tuned FDM printer with a 0.2 mm nozzle for the best results.
I can generate the files
I can produce:
? STL ready to print
? STEP file for machining or editing
? Fusion 360 model
? OpenSCAD source
I can also include a "TVR AJP 23T × 15 mm" label embossed into the handle so it won't get mixed up with other alignment tools in your toolbox.
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