But first things first, "The Gearbox".
Having split it from the bottom of the engine before reconditioning the block and bottom end, the first job was to completely strip all the components and assess them for wear.
Although I found a missing thrust washer on the crank for the primary gear, which explains some of the whining noise, I still need to make sure there are no other maladies deeper inside the box itself.
The first of those maladies became evident very early on, the outer input shaft (1st motion shaft) bearing was starting to disintegrate, that is the plastic carrier for the rollers was in pieces, luckily the rollers were still in place and there was no sign of damage to the shaft, so a new bearing, complete with the race that sits in the clutch housing was sourced.
Once apart everything was cleaned thoroughly (good old Nitro Morse to the rescue once again), the empty casing also had a jet wash before being thoroughly dried.
Then the output (or 3rd motion) shaft is re-assembled. It's worth knowing that unless you're changing the big primary shaft bearings the Mini gearbox can be re-build without the need for a press. This is becaues the gears and syncro hubs are retained by an ingenious spring and plunger arrangement in the base of the shaft splines, it's a bit of a fiddle to assemble, but it works really well. I guess it's a system that's too expensive in today's manufacturing world (it requires a drilling in the shaft, a spring, ball, plunger and special washer, as opposed to a press fit) but it certainly makes re-conditioning a doddle.
Once it's all back together it's ready for re-assembly to the block then the whole assembly gets turned back up the right way and the head can go on!
With nice clean aluminum clutch casing and gearbox married to the shiny green block and head, it's all starting to look rather special! (even if I say so myself!)