Talk Morgan Forums Morgan Sports Cars Morgan Three Wheeler & Super 3 Supermax

Obviously NOT the first overlay lost on a Morgan! However, you are maybe the first person to report a failure to them? I'm sure mine would have failed by now if I hadn't noticed that the grub screws were coming loose and glued them into position.

Agreed, not the first by a long shot! After mine failed (I was one of the first to have one and kill one!) I took a real good look at the remaining bits and was underwhelmed. The little bolts used to lock the sprocket in place were just too small and the aluminum too soft to hold them. A few of my bolts were missing in action and the remaining ones had bent over allowing the neoprene to spin freely. For the entire time that the SuperMax was installed the belt was on the looser side of life. The SuperMax is a nice idea but I don't feel that it is up to the job.

I decided at that time to just get the steel sprocket and be done with it. As for the differences mentioned between the heavy steel and the lighter aluminum I have never really noticed them. That sucker will not wear out nor has it ever made noise.

That's the direction I went with, my losing 10lbs made a much bigger difference in unsprung weight!!!

Some peoples 'at no cost' is not the same interpretation as mine

There was no warranty as I recall. Nor was one implied. SuperMax was very clear that they didn't guarantee anything about this rebuild.

Folks - if anyone would like a worn original alloy sprocket (removed from my car after about 4,000 miles) for a SuperMax modification, then it's free to anyone but for the cost of postage. Let me know as it's in the way, thanks.

Hi Laurens, this caught me out as well just as Planenut said. Fortunately no damage to the overlay.

After stripping the wheel assembly out it was possible to remove the overlay and grub screws. I then cleaned both mating surfaces and glued them back together with 2 pack epoxy.

I then drilled all the way through the pulley and tapped it M5x1 with a taper tap being careful not to go all the way through to help the grub screws tighten into as much of the alloy pulley as possible without going through. These were also held in with epoxy.

A 400 mile test drive proved a successful repair thankfully.

The 12mm twist drill is a temporary repair on the mudguard mounting bracket as this sheared just prior to the G & G trip. Necessity being the mother of all invention.

Like R1NGA, we also have a used alloy sprocket available (for postage or pickup) for anyone going the Supermax route...was our 3rd one so a (heavy) steel one is now on a nice black hub for better alignment and an overall lower maintenance solution......

Just taken another look at my Supermax sprocket which has now done just under 16,000 miles. As you can see, there is a fair amount of wear that is probably due to the constant presence of abrasive dust that lurks around the rear wheel area. Most of the 13 grub screws that help fix the overlay to the alloy centre were loose (again). One out of every three is 1/2in long and passes through the overlay into threaded holes in the alloy. However, the two intermediate screws between these full length ones have been crudely cut down to around 8mm length and just butt up against the alloy inner so are of questionable use in my opinion. Having said that, the overlay still appears to be well attached to the alloy pulley and the whole setup still runs quietly, so in this instance I decided to just re-glue the grub screws into place with Loctite 577 which is a thread-filling adhesive supposedly good with both plastics and metals. Next time I have it out I'll probably do a full Dab-of-Oppo repair with more hefty grub screws. By the way, the standard grub screws require a 5/64in Allen key.

That grub screw sticking out can't do the belt any good - was that damaged too?