Just spent 2 days trying to shim the diff on a Mk2 remote box. Nearly ran out of shims to get close to 'nipping' the ball bearings.

All the old workshop manuals say the gaskets for the diff covers compress to about 7 thou of an inch meaning they would originally be just slightly thicker when new.
Problem seems to be that the gaskets now supplied are 17 thou thick. That equals 20 thou (both sides) of empty space that has to be filled by shims.

From my 'glory box' I found a pair of old gaskets that are 9 thou thick and things are getting closer to normal.

Are genuine Payen gasket kits still available for minis, or other brands that are closer to original specifications? Or have I missed something?

What I have done in the past when building this sort of thing, not just mini boxes, is get the endfloat/preload right without gaskets, then put it together with a good gasket sealant and leave the gaskets out. Then it won’t throw out your preload. Loctite 515, blue maxx etc. others may insist on gaskets but the sealants are good too. Up to you.

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1972 Mk3 Mini 1000, 1150cc supercharged.
https://www.ausmini.com/forums/viewtopic.php?f=3&t=95872

My 2 gearboxes have no side cover gaskets, I use Loctite 515 or Permatex anaerobic gasket maker. Designed for metal to metal joints.
No leaks. And far less shims needed.
I used to put a 10 thou shim on the RH side and the rest on the left with those thick gaskets.

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DrMini- 1970 wasaMatic 1360, Mk1S crank, 86.6HP (ATW) =~125 @ crank, 45 Dellorto (38 chokes), RE282 sprint cam, 1.5 rockers, 11.0:1 C/R.

Thanks for the replies. The gasket in a tube looks the best way to go with this. Have had a look on Permatex and Locktite webs for details.

I have bought the Permatex Anaerobic gasket maker and shimmed the diff without paper gaskets.
BUT what allowance do I need to make for the thickness of the cured gasket maker?

None. It is basically metal to metal when set.

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DrMini- 1970 wasaMatic 1360, Mk1S crank, 86.6HP (ATW) =~125 @ crank, 45 Dellorto (38 chokes), RE282 sprint cam, 1.5 rockers, 11.0:1 C/R.

I thought I posted a "thank you" to "hpal" and the good, but no longer young "doctor mini"! Some things come with experience....

That's helped get the diff sorted. Thanks, both!

I'll be a young 75 next week.

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DrMini- 1970 wasaMatic 1360, Mk1S crank, 86.6HP (ATW) =~125 @ crank, 45 Dellorto (38 chokes), RE282 sprint cam, 1.5 rockers, 11.0:1 C/R.

I found while doing gearbox diff etc when restoring my 'S', there a couple of useful tutorials on YouTube from Mini Mania in the US. They very helpful.
If you want a laugh, look at Classic Mini DIY. He is legend in his own lunch hour.

Have been using the Mini Mania videos. Very useful; except I hate the way he gets everything to fit so easily!

Happy to help!

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1972 Mk3 Mini 1000, 1150cc supercharged.
https://www.ausmini.com/forums/viewtopic.php?f=3&t=95872