Another snapped drive shaft and another query or two

Another snapped drive shaft and another query or two

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Discussion

scerbera

Original Poster:

102 posts

120 months

Monday 6th April 2015
quotequote all
What a pig!

At least I was only 5 miles from home this time and not 300.

I am going to machine up my own replacements this time. Out of Titanium, stronger and lighter. I can't be doing with this again. I'll put up pics and update when it's done hopefully in around 3/4 weeks.


Also, could someone who has a non leaky car put up a picture of the positioning of the door seals please? Mine were replaced by previous owner but done very badly.

Also, the drivers door has a mind of it's own and has now started to randomly open when i'm driving. It is quite precarious when it happens clearly. Any known faults with this or do i need to take the lock apart?


Many thanks.

scerbera

Original Poster:

102 posts

120 months

Monday 6th April 2015
quotequote all
I went over a set of speed bumps at 2 mph, then accelerated and bang. Cant have been above 2000 rpm, I think there was no tension on the shaft and it caught but these things are made pretty weak! This will not happen with Ti

scerbera

Original Poster:

102 posts

120 months

Monday 6th April 2015
quotequote all
Well Ti is the best shaft material by far so that should be a good choice. I still plan to rebuild the engine and turbo it so future proofing.

I will let you know cost. I have my own machine shop so cost should be ok.

This shaft has only done 2000 miles but i do spin the rears 9 out of 10 starts. It is a 13mile trip to work and i only get 11mpg so fairly heavy use. There are a couple of bumps where you spin at 6000rpm in 3rd which probably dont help but it shouldnt break as my 4.2 is only pushing 320bhp.

scerbera

Original Poster:

102 posts

120 months

Monday 6th April 2015
quotequote all
I try to be kind to the clutch. Never slip it above 1500rpm ish. Once its engaged properly then i will increase throttle.

Id love to film my daily drive but id get into trouble.

scerbera

Original Poster:

102 posts

120 months

Tuesday 7th April 2015
quotequote all
Can anyone confirm that both shafts are the same length? The snapped one is 470mm long. Broke on the land for the inner circlip. 96 4.2

scerbera

Original Poster:

102 posts

120 months

Tuesday 7th April 2015
quotequote all
Vee8ight said:
scerbera said:
Can anyone confirm that both shafts are the same length? The snapped one is 470mm long. Broke on the land for the inner circlip. 96 4.2
they are the same length. the inner circlip groove is the weak spot, they nearly always snap there. the uj's are much much stronger. the new design has a raised bit and not a circlip groove to stop the uj going down the shaft so eliminating the weak spot.

Daz
Many thanks indeed. I will make something similar.

scerbera

Original Poster:

102 posts

120 months

Tuesday 7th April 2015
quotequote all
thefrog said:
scerbera said:
This shaft has only done 2000 miles but i do spin the rears 9 out of 10 starts. It is a 13mile trip to work and i only get 11mpg so fairly heavy use. There are a couple of bumps where you spin at 6000rpm in 3rd which probably dont help but it shouldnt break as my 4.2 is only pushing 320bhp.
How do you get the oil up to temp in 13miles ? Your engine will be next ?
The temp of your oil is largely irrelevant. Colder oil will provide a thicker film with a higher resistance to shearing. And so give you higher load carrying. The only real area of concern in a cold engine, and we are only talking very initial startup is that your pistons could expand too quickly for the bore, depending of course on the tolerance. The piston and liner will warm in a few minutes and so with a 30 sec sit on the drive, a 1 min 30 mph limit and get out of the street the engine is warm enough. In my opinion of course.

scerbera

Original Poster:

102 posts

120 months

Saturday 11th April 2015
quotequote all



Broken shaft pic.

My materials chap has advised EN26W for the new shafts so that has been ordered. Does any one have a pic of the design without the inner circlip groove? I will make without but thought it would be useful to see before I design my own.

Thanks.

scerbera

Original Poster:

102 posts

120 months

Monday 4th May 2015
quotequote all

scerbera

Original Poster:

102 posts

120 months

Monday 4th May 2015
quotequote all


A couple of pics.

Can anyone tell me the thread on the cv bolts please, I forgot to order some and check thread and want to get asap!

Many thanks!

scerbera

Original Poster:

102 posts

120 months

Tuesday 5th May 2015
quotequote all
Supateg said:
M10 x 1.25 60mm long
In the bolts list above......
Thanks Supateg! I missed that, running on exhaustion at the moment.

scerbera

Original Poster:

102 posts

120 months

Tuesday 5th May 2015
quotequote all
The shafts are larger than normal so it looks like there is a large groove. There is a fillet at the end of the spline to remove the rest material from using an end mill to cut splines. There is no need for an inner circlip the splines reduce and the diameter of shaft is above mating surface.

If i was to do it again i would do a little differently. The spline d was cut 2mm too far on reflection.

The main d on these are 33 so much bigger than what its replacing.

The previous one snapped on the profile which holds the end of the boot. No point that being there at all.