What did you do with drive shaft? [Archive]

GTiMini

03-07-2005, 09:43 AM

I designed my own and had them custom made. Cost me a bit but will handle very big HP if necessary. Therefore this one thing I should never have to worry about.

As many people know the splines in the Mini and Suzuki shafts look the same, HOWEVER, the ends are not so be carefull. If you look closely at the circlip positions, types, and depth of the spline there are differences and if you want the CV sealed and locked on the shaft then you have to do it right.

Welding the Suzuki to mini shafts is not recommneded for high performance applications as the join is always weak and imperfections can result in failure and terrible damage.

There are other ways to join the shafts with varing degrees of success, but I have never bothered personally.

miniswift

03-07-2005, 10:12 AM

Thanks Con,
I knew, I could count on you.
I am thinking of getting pair made myself.
I just wanted to know everyone else's opinion.

Cheers
Atchi

sean

04-07-2005, 10:19 AM

Atchi,

I priced to have custom shafts made but at $700 for a pair I couldn't afford it.

I ended up welding half a suzuki shaft to half a mini shaft. I took my time welding them up (about 4 hours per shaft) to avoid getting it too hot and to ensure 100% purity. I then spun them off on the lathe and they look just bought ones.

This was the only option available to me and I felt that if they broke, they broke and I would have scarificed only a few quality low hydorgen electrodes and my time.

Five months on and about 5000km I have had no problems. They haven't been tested on the drag strip though.

If you can afford to get them made, do so. If not, have a go at welding some up if your welding skills are up to the job.

Cheers

Simon

miniswift

04-07-2005, 11:21 AM

Hi Simon,

I would like to weld them up since I have all the facility avaiable at work.
We have Mig, Tig, arc, Gas & Oven.
We also have all the welding rods for most of tool steel, cast iron and so on.
What I would like to know is, did you weld it up like butt weld or cut them in halves then weld?
Did you pre heat them?
Have you weld sleaves?

Sorry about toomany questions.
I am getting very close to finalising my subframe and need drive shaft soon.

Cheers
Atchi

MattG

04-07-2005, 12:21 PM

check out : http://www.16vminiclub.com/forums/viewtopic.php?p=14492&highlight=#14492 and fbm-spec post

miniswift

04-07-2005, 01:35 PM

Thanks Matt, I should have done search :oops: .

Cheers
Atchi

evolotion

04-07-2005, 05:24 PM

Just to add, i instructed my uncle (who made my shafts) to use the above mentioned method of joining, and had no bother so far and sone aprox 6.5kmiles of HARD daily driving. though i only have just over 100ft'lb and bhp.

sean

06-07-2005, 10:38 AM

Atchi,

I cut the two shafts roughly in half and machined the ends to be welded at 30 degrees.

I then clamped them up in a V block to keep them straight and left a couple of millimetres gap to get complete penetration.

I did not have the facilities to pre heat the shafts so I took my time to avoid too much localised heat.

I did not sleeve the shafts because a good weld should be as good as the shaft itself.

My only concern is that the mini shaft is soft and the Suzuki shaft very hard as you will find out when you machine them.

Simon

turbovan

29-08-2005, 11:37 AM

I'm about to get mine machined now.
they machine a hole in the centre of the shafts and insert a rod (shrinkfit) joining them, and then TIG it. that shoud do the job.

miniswift

29-08-2005, 08:52 PM

Hi ppl,

I have started to machine mini drive shaft.
It is quite soft and mini's drive shaft is actually bigger than swift's.
Mini's was 25.3mm so say 1 inch and Swift's is 24.4mm.
So, I will be machining both to 24.1mm and I have 34mm bar to drill and bored out to 24mm inside.
Well, I have done it myself so far.
I will start to machine Swift's tomorrow and cut slot to it.
So, I will be doing fbm-spec's method.

I have mesaured that I will need about 320mm for the length.
What I'm not sure is that how much play should I have?
I looked at Mk2 Swift Gti drive shaft with all CVs and they look like 25-30mm play as in I can extend that much.
Anyone has any idea?
I will have both drive shaft to be equal lengths.

Cheers
Atchi

sean

30-08-2005, 09:11 AM

Hi Atchi,

I think from memory I made my shafts 315mm long so you should be pretty close with you 320mm.

It sounds like your going to sleeve your shafts. I spoke to an engineer about this method when I was doing mine and he warned me against the idea.

He believes that because the shaft is so short, if it were sleeved it would be less susceptible to twist and more likely to snap. That's he theroy anyway.

I've done over 10000 km on mine now and still no problems.

Good luck

Simon

miniswift

01-09-2005, 09:08 PM

Hi ppl,

I am getting CONFUSED.

I spoke with some specialists and I wish I didn't.

First, I sopke with my mechanic friend.
He told me you just welded and it will be ok.

2nd, I spoke with weld specialst.
He told me Zuki one is Nitrided so no no to weld and use sleave with glue(JB weld or Loctite).

3rd, I spoke with tuning specialist.
He told me glass track ppl do anything and everything without worry.
They weld when you think it's not good idea and told me to just get on with it.

So, Glue or weld.....

I am doing fbm-spec method but weld or not weld.

I think I shall glue it and it will be less effect to drive shaft unlike weld...... :roll: .

Any input, ppl!?

Cheers
Atchi

fbm-spec

01-09-2005, 10:15 PM

I would still weld them...... if they break ...make some more :shock:
Even if the suzi ones are hardened, so what !!! you may get some localised ' strange' alloys formed in the welding process but there will still be plenty of good strong stuff around.

go for it ..... weld them. :D

Spag

02-09-2005, 05:33 AM

For Doris, I got the Mini & Princess shafts welded by a friend who maintains big b***ard printing presses. He tapered the ends to make a nice V join, then slowly filled them up with weld. Same process they use on big roller spindles.

Lasted for 3+ years with 200ft'lbs and some serious towing ;-)

miniswift

02-09-2005, 09:16 PM

Hi ppl,

I have done it now...
I have glued then welded.
Like you ppl said, if it break then I just make one again...

I got workmate to machine Suzi drive shaft like fbm-spec said.
You can tell that middle part of drive shaft is still soft.
So, as long as I have that, it will be ok and mini one is soft anyway.

Thank you for your help and advice ppl.

Regards
Atchi

miniswift

23-09-2005, 10:07 PM

Hi ppl,

I have now made drive shaft.
Well, I have made 3 drive shafts in total.
Each time I made, I did same method.

I cut and made half moon like fbm-spec said.
I glued them to fill any gap then weld around the tube.
http://www.16vminiclub.com/gallery/albums/userpics/DSCN2290_web.jpg

Like I said, I made 3 now.
Reason been that Mk1 gearbox has smaller inner CV joint comares to mk2.
So, me thinking bigger the better, I used mk2 drive shaft.
P/S is OK but D/s..... didn't want to know.
After carefull inspection, I found out that mk2 has 20 splines but mk1 has 19.
Hence, I have made extra drive shaft.

If any one wants drive shaft 320mm long with mini and Suzi Gti, let me know.

Cheers
Atchi

fbm-spec

26-09-2005, 08:06 AM

That looks very familiar :D

spNOam

16-09-2007, 10:11 PM

Anyone got a ball bearing for the Suzuki inner cv joint?

miniswift

17-09-2007, 07:56 AM

Hi,

Which one do you want, mk1 or mk2?
I got some but I need togo 25 miles to get it from my parent's garage.

Cheers
Atchi

spNOam

18-09-2007, 08:16 PM

Hi,
Gearbox is a mk1, meant to be better (apparently) there is no rush, steel fabricator mate who offered to make the subframe (as a favour) is off sick for a month. PM me with your contact details & I'll send you the cash for postage etc.

miniswift

18-09-2007, 09:01 PM

Hi,

Diff is better, it is a cross pin item and it is made from more stronger material.
I have been told one guy has fitted supercharger and kicking out 270 Bhp with std mk1 gearbox.
Mk2, if you have lead right foot, it dies.... especially 2nd gear.

Cheers
Atchi

spNOam

19-09-2007, 07:10 PM

ed4ran

19-09-2007, 08:08 PM

We used the landrover bobbin mounts on my brothers, and i will be converting mine to them as well, they seem good for engine conversions, simple but strong.

Most people seem to stick the alternator under the wing off the end of the engine.

Ed

miniswift

19-09-2007, 09:17 PM

Hi,

I made drive shaft equal length of 320mm.
I positioned my engine and gearbox so that I don't have to worry about torque steer.
I'm sure you can take out by setup but I don't have that knowledge :lol: .

I am using Metro gearbox mount for back of engine and Toyota Camry engine mount for the front.
I'm using mk1 setup so gearbox can be mounted using mk1 Gti subframe.

Like evryone else, I have built alternator back to front and into the inner wing.

It will be for a while before I can start again on my car.

If I can help, I will.

There are many of you who has started after me and finshed before me....lol

Cheers
Atchi

spNOam

20-09-2007, 05:17 PM

Would it make any difference to the length of the driveshaft if you had a mk1 or mk 2 gearbox? Besides the difference in driveshaft splines.

miniswift

20-09-2007, 09:01 PM

Hi,

Answer is no.
I made 2 mk2 driveshafts before I knew mk1 driveshaft was different splines. Anyway, I made both mk1 and mk2 same length and you can actually use mk2 driveshaft for oneside even with mk1 gearbox.

I think driveshaft length is all depends on where your engine and gearbox is. What I did is I made sure both driveshaft length will be same by postioning engine and gearbox in correct place for me.
I have a gearbox shell so i could easily lift out.
All positioning is done just using both pot joints and suspension tower.

Cheers
Atchi

Pete_H

21-09-2007, 10:59 AM

Hi Atchi,
Nice to know, I have little experience of the Suzuki set up, I was lucky enough to have the whole car so I have run the engine & driven the car around so's I know everything is OK. The driveshafts are ready for modification, however I'm leaving the final cutting/machining until the engine & gearbox is in the subframe, there seems to be a difference of opinion regarding the length they should be, 320mm, 315mm & some even shorter, Smurfy has one driveshaft shorter than the other etc, etc. Looking forward to getting the subframe completed so's I can fit the engine, I'm using the landrover 'bobbin' type mountings has anyone got any feedback on how effective these are? Any tips? Anything I should look out for regarding the alternator position?
Lots of questions..

I have just finished building my driveshaft splining machine, and will be testing it this weekend.. I just have to reprogram the machine to use the new tool which is designed to take replaceable carbide tips.. even though I measured the profile of the grroves and ordered the tips to suit, they look a little oversized, so i may have to order some smaller ones which will delay things a bit.

The plan is to spline the shaft first, cut it roughly to length (but a bit oversize) try it in position with the suzuki three arm drive thingy on it and set the position of the grooves for the circlips AFTER its been in position...
The grooves can easily be turned on an ordinary lathe, so they don't have to go back in the splining machine.

It might sound a long way round to do it, but better to be safe than sorry.
Having said that, there seems to be quite a bit of travel on the inner joint, so as long as it doesn't bottom out, it should be OK.

I will post the pics on Pete's build diary once the shafts are finished.

We also set the engine dead centre, so that the driveshaftes are equal length.

Chris (Pete's dad)

spNOam

21-09-2007, 01:52 PM

Sounds interesting, if successful would you be interested in splining a pair of driveshafts for me ? (willing to pay)

Pete_H

22-09-2007, 01:01 AM

Sounds interesting, if successful would you be interested in splining a pair of driveshafts for me ? (willing to pay)

No probs.. still a bit of fine tuning (fettling) to do .. to be sure the process is as accurate as it can be..

it'l be time and materials I guess.. with a bt of a reduction for being experimental ! the pennies all go into adding to the tools in the workshop :-)

Pete won't be impressed.. I'm supposed to be putting his car together for him now he's back at uni :-)

Chris (Pete's Dad)

spNOam

22-09-2007, 06:31 AM

Great, just let me know what you want when you're ready. Anyone going to Castle Combe at the weekend?

Pete_H

22-09-2007, 08:14 PM

Cut the first full set of splines on the end of a mini shaft today, just a test at the end of the shaft.. will be cutting the splines in the right position tomorrow.

seems to work though :-)

The casting fits on, a bit tight, but thats probably good... the pic shows it in the machine, with the casting on the shaft to test fit without removing it and losing the index..

Not sure yet whether to leave a shoulder on, or machine a groove for circlips at the end of the spline.. the left hand side in the pic. I'll sort that tomorrow.

I also machined a smidgeon off the outside of the shaft over the whole length.. that will help rebalance, correcting any centering issues in the machining.

The machine is only a light affair, so it has to take 8 cuts on each of the 20 grooves... that's 160 cuts altogether !
.... I'm glad it's computer controlled, my arm would be well worn out with all that handle turning !

Once I have a complete set and the timings etc.. I'll post in the general section..

I did have a thought... what I could do is just machine the splines, and not the circlip gooves.. that way, anyone who has access to an ordinary lathe could cut the circlip grooves in the position to make the shafts the exact length they need.

Chris (Pete's Dad)

http://i149.photobucket.com/albums/s48/Iamcabaged/100_0965.jpg

ed4ran

22-09-2007, 08:27 PM

:D Cool 8)
I dont have a lathe, or access :(
If i pull my shafts and tell you the length from circlip to circlip could you do it for me :oops:

Have you worked out how much you are going to charge? ;)
How much for a rush order? :lol: :oops:

spNOam

23-09-2007, 05:32 AM

I have a lathe. Only 19 slines on a mk1 :wink:
Looks good Chris, how well did the cutter stand up?

Pete_H

23-09-2007, 12:19 PM

I have a lathe. Only 19 slines on a mk1 :wink:
Looks good Chris, how well did the cutter stand up?

The cutter tip just about lasted one shaft... which is fine, they are triangular three way disposable tips.. I designed the tool to use those so i don't have to mess about sharpening them...

I'm going to run the machine at different speeds and feeds this afternoon, to reduce the wear.. I will use a new tip for each shaft, but it should mean a more accurate profile..

No problem with 19 or 20 splines.. just adjust the program... but I don't have a 19 spline drive flange thing (I wish I knew what it was called) so I would need one to test fit..

Chris (Pete's dad)

spNOam

23-09-2007, 02:01 PM

Hi Chris,
We shall be passing on the way to Castle Combe Friday aternoon, we could call in or meet somewhere? PM me if this is any good for you, no rush for the shafts, just an opportunity to deliver.
Geoff.

Spiyda

23-09-2007, 03:32 PM

Geoff,

sounds good, will have to check times and stuff as I may be working from home, or at the office (I get back late) ..
I'll message you my phone number..

ps... Pete is getting fed up with me using his user.. so I joined in my own name..

hopefully the guys will make me a member so I can post in the build forum..

Does helping pete, and having a mini based kitcar count ? :)

BTW I just ran the final test cut, very little tool wear, and it fits pretty damn good !

The picture below shows the spline with the drive thingy just slid on.. the correct size spline is the left hand third, I cut the middle 0.1mm deeper and the right third 0.2mm deeper.. the drive dog (or whatever it is called) slides freely on to the overcut splines, but will be a drive on fit on the correct size... I estimate its about a 0.05mm interference fit.

the profile of each groove is as close as makes no difference to the original.. so close you can't see the difference.. and within 0.1mm of the original cutter diameter.. (thats as close as I can get an insert)

I would reccomend final assembly with a little epoxy just to be sure it stays on full contact...

on the down side.. each spline takes over 5 hours to machine..
Its a little CNC machine I built / converted myself, so I don't need to stand over it, but it doesn't have flood coolant so I need to be around to keep an eye on it.. (and its too noisy to run at night)

So all systems go ! (if albeit slowly ) :-)

To be sure the drive dog fits on the splines... when I get round to doing these for anyone else.. I will need the shafts to be machined AND the drive dog thingy... otherwise i won't be able to adjust the program to get a good fit.

http://i149.photobucket.com/albums/s48/Iamcabaged/100_0967.jpg

Chris (Pete's Dad)

spNOam

24-09-2007, 06:55 PM

Looks real nice Chris, I have machined the driveshafts, the short mini shaft was easy to set up but 'hard' whilst the longer shaft took some time to set up to get it to run true, the centre in the tailstock having to come into play to get anywhere, thankfully this shaft was a fair bit softer, however it did have 'hard' bits here and there (Don't know what they used to harden!!) I have left the mini shafts the standard length but have roughly undercut an area where a cutter could 'start' I can machine the circlip groove & face to length once the splines are cut.
If I could work out how to post picures I'd take some pics & post.
You are welcome to have a go, at the end of the day it's your call, it's not cost much, even though it could be a time consuming experiment!
Someone post how to upload pictures please.
Geoff

Spiyda

25-09-2007, 12:30 AM

If I could work out how to post picures I'd take some pics & post.

Someone post how to upload pictures please.
Geoff

Pete showed me how to use photobucket.com to host the pics and how to use the img tag to put them in the post.. its pretty straightforward.. photobucket even forms the links and puts them into the clipboard...

but otherwise, if you have a spare 10 mins when you pass by, i can show you

Chris (-=Spiyda=-)

spNOam

25-09-2007, 05:07 PM

OK here goes, hope some pictures appear.
I have made the driveshafts an overall length of 320mm (hope this is the correct length, somebody please confirm) here are the pictures of the machined shafts ready for splining.
http://i85.photobucket.com/albums/k63/spnoam/Driveshaft.jpg
http://i85.photobucket.com/albums/k63/spnoam/Driveshaftend.jpg[/img]

Pete_H

26-09-2007, 12:14 AM

Looks good,
don't forget to bring the drive dog, spider, thingy (I wish I knew what it was called)

doh.. just noticed I posted as Pete.. confusing.. I use Firefox for Pete and IE for me.. I'll get the hang of this sometime :-)

Chris (Pete's dad)

spNOam

26-09-2007, 04:38 PM

Hi Chris,
You have a Mk2 (spider thingy) The Mk1 that I have has an inner CV joint, I'll bring it. Will confirm times etc tomorrow, It looks like we shall be kicking off approx 4.00pm, hoping to be with you about 3 hrs later, don't know exactly how long its going to take as we shall be coming is a mini. Look out for the one below:
http://i85.photobucket.com/albums/k63/spnoam/OffSide.jpg
Hope this is convenient.
Cheers
Geoff

Spiyda

27-09-2007, 10:53 AM

]It looks like we shall be kicking off approx 4.00pm, hoping to be with you about 3 hrs later,

Hmnn... I'd be struggling to take 3 hours to get from anywhere in North Wales to me ..

I'll make sure I'm in a bit earlier :lol:

There'l be a cup of coffee and whatever to greet, but I promise not to make you delay too long

Chris

spNOam

27-09-2007, 08:06 PM

Plans are still to get away from here at around 4.00pm, routeplanner says I should get to you in approx 3hrs .....like you I reserve judgement.....

Spiyda

30-09-2007, 04:56 PM

Plans are still to get away from here at around 4.00pm, routeplanner says I should get to you in approx 3hrs .....like you I reserve judgement.....

I spent a little while checking this afternoon, and the same tool is good for both the 20 and 19 groove splines.. so good to go...

just need to get some energy from somwhere to make a start :-)

Chris

spNOam

01-10-2007, 09:02 PM

Spiyda

01-10-2007, 10:28 PM

No problem Chris were in no hurry, after we left you we found our way to the motorway & got to Castle Combe OK, we had a great day (loads of interesting stuff) & managed to get home without incident. (An achievement in itself!)

And would you believe, after missing you by an hour or so, Pete phoned me Saturday morning to say "do we need any bits from the show? I'm at Castle Combe!"
If I'd known he was going, you could have given the shafts to him and saved the diversion !

Oh well.. at least you saw the bike :-)

Chris

ed4ran

01-10-2007, 11:01 PM

I'm going to be pulling my shafts soon when i come to change the flywheel and clutch (as well as several other things)
so I'm going to measure my shafts then (that sounds rather dodgy :oops: )
also going to check that are the same splines are regular swifts :? (i have some gti ones to compare with).

Have you worked out how much you are going to charge to do this? :oops:
and can i be the next in the queue? :(

Ed

Spiyda

01-10-2007, 11:32 PM

Have you worked out how much you are going to charge to do this? :oops:
and can i be the next in the queue? :(

Ed

Geoff's are somewhat of a trial run in many respects

You can certainly be next in the queue, The trouble with working out the price is that I want it to be enough to make it worthwhile doing, and worthwhile delaying putting Pete's mini together ! but not so much it sounds greedy ! What sort of price has been quoted by engineering firms to do this.. ?

Chris

ed4ran

02-10-2007, 09:22 AM

I havent asked any :oops: :(
Im going to ring a laser cutters about getting some flanges made, so i may as well ring an engineer about that as well. :?

Spiyda

02-10-2007, 07:36 PM

I havent asked any :oops: :(
Im going to ring a laser cutters about getting some flanges made, so i may as well ring an engineer about that as well. :?

so what are these flanges ?

are they generic mini / suzui, or someting exotic :-) ?

Chris

ed4ran

02-10-2007, 10:27 PM

Inlet and exhaust flanges for the GTI engine, so you can easily make an exhaust manifold or a new inlet manifold from scratch.

Should be able to do them in Mild steel, stainless, and alloy (obviously not the exhaust in alloy :oops: )

speedy

04-10-2007, 04:27 PM

here in holland there is a guy who makes them for 280 euro
he garantees 1300 nm of torc

ed4ran

12-10-2007, 12:46 PM

I phoned a local machinest, and they couldnt cut splines, but told me of a company that does driveshafts, although they will probably just want to make new ones :?

Also waiting on a quote for the flanges.

Have you worked out what you might charge? :D :lol:

Ed.

ed4ran

12-10-2007, 01:08 PM

Just had a quote of £150 per shaft for new ones. :?
Hmmm suppose that is something to think about.

spNOam

14-10-2007, 01:43 PM

Cut & weld option £0 (OK welding rods electricity & time say £5) Have you had a go yet Chris?

ed4ran

14-10-2007, 10:45 PM

Ive already done cut and weld ones, but i dont trust them (although they have put up so far apart from the one that broke)
Its just i dont want the welded shafts when i increase the power :?

Ed.

Pete_H

14-10-2007, 11:16 PM

Cut & weld option £0 (OK welding rods electricity & time say £5) Have you had a go yet Chris?

I've written the program for 19 splines, set it up and cut 0.7mm

It cut fine, the new tool copes with the hard bits fine (if a little slowly)

It looks like I will have to take a couple more cuts as it doesn't yet fit..

Time is the issue at the moment.. Pete came back for the weekend, and we sorted the clutch cable arrangement on his mini.. his visits take priority I'm afraid...

And work just keeps piling up.. I worked most of Today (Sunday) at my proper job :-(

I'll keep you posted..

Once I have done these, I will know better how much I will have to charge too..

One thing, I wouldn't have taken quite so much off the shaft.. I think it would be better to leave it full diameter, and stretch the inboard gaiter

Chris (Pete's Dad)

ps.. can an administrator make me a member please (user Spiyda)

spNOam

15-10-2007, 06:41 PM

Know what you mean, I copied the diameters from the Suzuki shaft (which are different material & harder) Not going to be doing 1/4 mile dragstrip launches so should be OK. If I have one fails we can put it down to experience I guess.
No problems with time, Pete's project should come first. I'm a long way away from fitting driveshafts!! Got the Suzuki fuel pump into a mini tank at the weekend which is undergoing a leak test at the moment, Found a better shell that I need to collect sometime soon etc etc.

Pete_H

15-10-2007, 07:40 PM

Not going to be doing 1/4 mile dragstrip launches so should be OK. If I have one fails we can put it down to experience I guess.

You should be :D

Whyever else would we be making them ?

Chris (Pete's Dad)

ed4ran

22-10-2007, 07:03 PM

Any luck with working out a price?
I only ask as within the next 2 weeks im pulling the gearbox so shafts have to come out, and so would be good time for me to get some shafts done.

Ed.

ed4ran

29-10-2007, 02:51 PM

I pulled my driveshafts apart today, they have been out while i put a new flywheel and clutch in.
Anyway, found out the inner pot joints on mine are 19 splines and smaller than the gti 22splines (at least the other shafts i have).
The 19 spline also fits the mini outer cv end although there is a little play in it.

Have also got the measurements for my shafts, and they look like they both could be done on the short mini driveshafts as the longest one at 320mm total is just up to where the divet for the boot is, which happens to be the same diameter as the splines anyway. :lol:

So i have the measurements, and 2 short mini shafts (as long as you think the position of the splines in terms of good meat is ok) then i just need a price, but if you dont want to ill get them made new eventually. :oops: :?

Also I worked out ill be about 1 hour maybe a little more, away from you when i move to Newcastle!! :lol:

Ed

Spiyda

02-03-2008, 03:24 PM

It's been a while..

health has let me doen a bit over the last few months..
but I'm now in a position to start modifying driveshafts

These are mini driveshafts with the Suzuki spline in the inner end

The ones I made for Pete's car (MK2) 22 teeth are fine

I am part way through a set (MK1) 19 teeth for Geoff

What I need to be able to do these more regularly is one each of the bits that go on the inner end of the driveshaft.

They are needed to test fit on the last couple of cuts...

Once I have them, I can keep a few sets in stock, leaving the circlip cutting until I have the exact lengths.

They don't need the bearings or balls, just the bit with the splines on the inside.

Once I have those, it's full steam ahead...

so... Does anyone have any spare that I can have or buy ?

ps any spare decent mini driveshafts would be useful too !

Chris (-=Spiyda=-)

For anyone interested, I turn down the diameter by hand, between the original centres.

If the shaft is out of true, I will skim a little off all the way along.

Then the splines are cut on my CNC'd micro mill, using a tool I made which takes carbide tips the correct shape.

Then once the length is known, I turn the circlip grooves by hand.

I don't cut any relief for the rubber gaiter to fit into.. that just weakens the shaft. Better to stretch it over the slightly bigger diameter.

I don't do any heat treating, I don't think its neccesary for a standard GTi engine, but it could give a little extra strength if you wanted to do it.

C

miniswift

02-03-2008, 09:26 PM

Hi,

I have a spare inner shaft housing in my garage somewhere when I got my gearbox.
If I have CV joint housing(cage) I will send it to you.

Cheers
Atchi

Spiyda

02-03-2008, 09:29 PM

Cheers Atchi

just the bit that slides onto the inner spline is the bit I need

cheaper to send it without the rest (less weight)

Chris (-=Spiyda=-)

miniswift

02-03-2008, 09:31 PM

Hi Chris,

I shall check when I can.
I have 5 mk1 Gtis gearbox so i should be able to help you out....lol

Cheers
Atchi

Spiyda

02-03-2008, 09:56 PM

I have 5 mk1 Gtis gearbox

Now thats just plain selfish !

think of all the people that would be building 16v minis if you didn't keep them all to yourself ! :D

Chris (-=Spiyda=-)

miniswift

03-03-2008, 07:48 AM

Well Chris,

If I didn't buy it, it was going to go in a skip!

Beside, 1 is in my everyday run about Mk1 Swift Gti, 1 spare, 1 with Suzuki Sports LSD which I will be using, 1 just casing due to synchro is gone and 1 just bought recently saved from skip!

I could have 2 more if I could be bothered....
If you need anything, let me know.
I might be able to help.

Cheers
Atchi

Spiyda

03-03-2008, 11:21 AM

Atchi.

You could always fit one to this ....
http://cgi.ebay.co.uk/ws/eBayISAPI.dll?ViewItem&rd=1&item=140211962554&ssPageName=STRK:MEWA:IT&ih=004

Chris (-=Spiyda=-)

same chassis as my kit-car in avatar

C

Pete_H

03-03-2008, 11:39 AM

with justy box and make it 4 wheel drive :)

Spiyda

03-03-2008, 11:44 AM

Good idea Pete..

it lends itself well to that..

the chassis is 80 x 40 box section steel, very easy to cut and weld...

Plenty of room in the engine bay

Plenty of steel round the back end to modify the suspension (it doesn't use a mini subframe at the back)

Why don't we do that to mine ?

C

miniswift

07-03-2008, 09:17 PM

Hi Chris,

I don't think my wife will be happy for me to start any more project while I haven't finsihed even one I started in 2000......

I like your idea but I like to keep me warm!
Being a Jap, not good with cold weather and my girls won't like wind in hair experience! I think I will stick with roof on!

Cheers
Atchi

Spiyda

11-04-2008, 11:27 PM

I'm still looking for one of the bits that slides onto the inner end of the driveshaft on a MK 2

I now have the bit off a Mk 1 thanks to Geoff.

once I have it I will make some shafts for stock.

the price is £50 exchange per shaft, just because of the time it takes.

Chris (-=Spiyda=-)

Purtsi

12-04-2008, 06:25 AM

One quick question regarding shafts: Is it possible to use metro shafts or shafts from mini with drum brakes as I have those laying around?

btw. I'm not interested in cutting and welding those together, so machining is the only option here...

EDIT:

http://www.kolumbus.fi/timo.purmonen/kuvia/minizuki/metroshaft01.jpg

I just took one metro shaft apart. Should be doable? Also, how do I detach that thingie from the other end? I was thinking about using the metro CV joints and everything so that I don't need to dissemble the current mini driveshaft setup. Would this work?

Spiyda

12-04-2008, 10:59 AM

They look plenty long enough, but I can't tell if there is enough diameter from the pic !

the only way would be to try it and see

C

Purtsi

12-04-2008, 11:39 AM

I dissembled the other driveshaft also and used a bigger hammer to get than thingie of from the end :)

http://www.kolumbus.fi/timo.purmonen/kuvia/minizuki/metroshaft02.jpg

Shaft diameter is 22mm, just measured it.

Spiyda

13-04-2008, 03:14 AM

I dissembled the other driveshaft also and used a bigger hammer to get than thingie of from the end :)

Shaft diameter is 22mm, just measured it.

22 is tight (actually a tiny bit smaller than ideal) but I think it is worth a go

my micrometer reads 22.08 over the splines..
that is partly due to the way they are made on the original shafts

but I don't think the splines are the weak point... so maybe its close enough

Chris

Purtsi

13-04-2008, 07:42 AM

OK, so these shafts are usable. Thanks Chris :)

spNOam

25-06-2008, 05:07 PM

Just an update for Chris & Pete, 3k miles & the driveshafts are fine. Hope all is well with you guys & the build, hows it going?

Pete_H

26-06-2008, 10:21 PM

nice one...glad they are up to the job. Dad did have a few problems with the latest ones he did for someone. Turns out there are three different types of shafts, all with a different number of splines :?

Build is getting there. Few set backs with dead mpi pump, megasquirt not fully working and stubbon shock bolt not coming out.

Aiming to have it running for avon park..but not ready for strip :cry:

Pete_H

26-06-2008, 10:22 PM