It seems the parts are out there. One need only ask in the 'wanteds'. I now have the parts to make it work and so can forge ahead with the box. I even made myself another Ausmini inspired tool; the first motion shaft puller!
IMG_0111 by
Uncle Flash, on Flickr
Stripping the gearbox apart was actually quite easy. I just followed the instructions in the Haynes book and it took no time at all. I've had synchro's apart before so I was on the lookout for things that go 'ping' and shoot across the workshop. I wrap a rag around them before pulling apart. Once everything was separated I could give it all a good inspection.
Surface rust was evident on all the gears but the oil had held the water out of the bearings and inner surfaces. A quick scrub with a wire brush showed that the rust was nothing to worry about.
IMG_0113 by
Uncle Flash, on Flickr
The obvious worry here was the second gear as they can be near impossible to get hold of. Fortunately, it looks good but third has some pitting on about a third of the teeth. It's hard to see in the photo but third on the laygear also looks nasty. The synchro's look okay with minimal wear and the first motion shaft is great. Bearing surfaces are fine.
The layshaft needs replacing due to surface breakdown under one of the bearings. Likewise, the internal surface of the laygear mirrors this and will also need replacing.
As this is a 'refresh' rather than a rebuild and the engine will need extensive work, consideration must be given to cost. Luckily, parts that require replacing are not overly expensive and the end result should satisfy my requirements. So far it's layshaft, laygear, third gear and bearings. I could have gone C/R or S/C C/R but I feel standard ratios will suffice for the modest power the 1100 will produce.