For those of you "extending" the splines on the T5 mainshaft....you should remove the throwout pilot shaft (4 bolts) and use a "high speed" air cut-off tool...with a thin (1/16"X 3") cutoff wheel. Using a 4" angle grinder is going to be way-too-much for this surgical procedure. A Dremel would be better than an angle grinder!!!!
Then, MOST IMPORTANTLY....take the disc you are going to use and slide it onto the splines to verify that you have actually increased the amount of movement. It's not how much you take it off...it's where it comes off and if it INCREASES THE TRAVEL. This is a critical step to getting it right the first time.
If you've just got to slap it together without checking the disc...look up from below the flywheel sheetmetal cover and you'll be able to see if you've cut enough when someone depresses the clutch. Put it into gear, turn the output shaft by hand and make sure there is no drag.
Check my pics as my is driven every day. Hope this helps!
