Question for the gear shift experts: big scrap in R-1st shift plane on side shifter Options

[raynekat]

I've got a 71 914-4 that I converted to a 914-6.
The problem is a very loud annoying squeak when I'm in the R-1st plane.
Something is really scraping badly.
Pulled the shifter which looks to have been changed out from an early shifter to a later shifter.
Greased it very well and that didn't seem to help.

So I looked a bit deeper and put a flashlight in the tunnel where the shifter sits pointing backwards.
Using a small mirror about 6-9" rearward, I see that the shift rod goes through a circular opening in a small bulkhead that is welded into the tunnel.

Looks like the scraping/squeaking is when the rod is hitting the edge of the circular opening in the bulkhead in the R-1st plane.
If you don't pull the lever all the way to the left, then you don't hear the scrape.

Is this typical of a side shifter conversion for an early 914?
Am I shifting incorrectly by pulling the lever hard to the left for the R-1st plane?
Does that bulkhead need to be removed by opening up the shift tunnel from above?

Any thoughts or ideas are welcome.
Thanks in advance.

[mepstein]

Wont a jigsaw blade come close to the metal tubes?
What about a die grinder with a small cutting disk?

[raynekat]

Wont a jigsaw blade come close to the metal tubes?
What about a die grinder with a small cutting disk?

Yeah, I'll likely try that.
Certainly don't want to cut anything valuable inside the tunnel.
I'll be looking a lot inside with my mirror as I go.
Should be quite doable.
Will happen this weekend.
The scraping while shifting is driving me crazy on this car.