Can someone save my sanity???? Reliant gearbox

[yukonphil]

Good afternoon peeps,
I'm in the middle of one of those "why-o-why-o-why did I do that" moments (That is a long way removed from the actual language used, believe me ).  I've got a custom prop flange made up for my Reliant bike but there's not enough clearance for it so, to try and get it to fit I thought I would unbolt the rear cover on the gearbox, take it off and file it down some then re-fit.  Anyone who knows more than me about Reliant boxes will realise that this is not possible without taking the front cover off too.  The big problem I now have is that I cannot get the back plate bolted back on and when I try it locks the whole gearbox up with no neutral anymore.  As it stands I'm looking at having to take the engine and box out but this is a monumental job to do without damaging the frame paint, can any one offer me any hope pppppppppppplllllllllllllleeeeeeeaaaaaaaaaaaassssssssssssssseeee?

[Olds]

Are you talking about the Reliant 850 box ? Don't get what you mean by rear cover / front cover. All I have on the back mine is the rear bearing/speedo drive housing. But it sounds like you are side loading the main shaft (output shaft) bearings when tightening the rear cover. Have you mislaid a gasket.

[hunter]

A picture paints a thousand words.

[yukonphil]

Yes, sorry, it is the speedo housing, the Haynes manual calls it the rear casing.  I have not taken the gasket out, I never got to housing seperated from the box just moved it around 10mm and now it won't come off and it wont go back on!