This supply issue provided a dilemma for Denis Welch Motorsport, to accept the part is no longer available or to re-manufacture new ones? Enthusiast Healey owners and competitors require a fully functioning and reliable gearbox. With the growth in historic motorsport, there are many Healeys’ competing in road, race and rally competitions around the world, providing a significant number of potential customers.

Once the customer demand had been identified, work started on designing new gearbox lids for the first time. The Denis Welch Motorsport CAD team first analysed copies of the original factory drawings, a much easier start than having to reverse engineer a worn part. These provided all the necessary measurements and tolerances specified by the factory. The drawings were then digitised using design software which allows the engineers to not only view a 3D model of the part on-screen but also allows them to trial fit the part to other gearbox components in the software to check for fit and compatibility. This approach is both faster and more cost effective than manufacturing physical prototypes.

Denis Welch Motorsport are now offering complete centre change gearbox lids for BJ7 and BJ8 centre change gearboxes. The BJ7 lids suit brass gear stick bushes and the BJ8 is designed to suit nylon bushes. The fully assembled lids are supplied complete with selector shaft, gear lever shoe, woodruff keys and oil seal installed. These lids are also available bare for customers who either have serviceable parts or who wish to build up their own assembly using new reproduction components. Each is a faithful reproduction of the original, cast in aluminium and then precision CNC machined which ensures compatibility with original gearbox cases. These parts are made exclusively by Denis Welch Motorsport and are not available anywhere else.