Author Topic: Harry's Buggy  (Read 2837 times)

Harrison

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Re: Harry's Buggy
« Reply #30 on: January 14, 2020, 10:24:44 PM »
I have. Hannah got me a notcher for Christmas, planned to use that. Been watching some tutorials on bending and notching.

M4wdFab

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Re: Harry's Buggy
« Reply #31 on: January 15, 2020, 07:20:14 AM »
cool.  fresh tube is fun.  get a husky digital level with zero.  must have

Harrison

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Re: Harry's Buggy
« Reply #32 on: January 17, 2020, 12:44:10 PM »
Machinist talked me out of welding. Should be plenty beef, and VW part is unmodified. My gut says I will be snapping the shaft part before anything else. I was able to pickup two spare VW flanges on ebay as well. In the event of a shaft flange failure, modified 8.8 flange can be easily swapped over to the spare shaft flange.






mr.mindless

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Re: Harry's Buggy
« Reply #33 on: January 17, 2020, 01:40:35 PM »
Curious to see the disassembled pieces. Not sure I fully understand what’s going on there.
And how do the CV flanges come out, anyway? Split the trans and c-clip?
Quote from: etk300ex
oh lord!

M4wdFab

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Re: Harry's Buggy
« Reply #34 on: January 17, 2020, 02:43:56 PM »
looks great.  stub just snaps in the either side of the trans with some type of internal spring clip?


Harrison

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Re: Harry's Buggy
« Reply #35 on: January 17, 2020, 03:32:14 PM »
First pic is what I started with, 8.8 pinion flange. Second pic is modified 8.8 pinion flange. Has slight pilot hub turned into it to match the VW flange to keep everything concentric. Standard Spicer 4.25in bolt circle flanges now bolt up to VW, and if VW part breaks, 8.8 flange easily swaps to a spare.

The VW flanges bolt into the transaxle, that was a significant factor in my choice to go VW. People have to come up with some pretty claptrappy ways of retaining standard "pop-in" CV stuff. They all work, but this is much better.






M4wdFab

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Re: Harry's Buggy
« Reply #36 on: January 17, 2020, 05:01:49 PM »
now im more confused but looks fun! 


how much they kill you for some what looks like fairly easy eye ball lathe work if you dont mind me asking?

Harrison

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Re: Harry's Buggy
« Reply #37 on: January 17, 2020, 05:31:06 PM »
Last two pics, 8.8 flange has a hub turned into it that centers it on the VW flange. Drill the 6 bolt VW pattern into the 8.8 flange, bolt together, done. Countersinking 4 of the holes keeps them below the surface so I can bolt a yoke to it. Wallah, VW transaxle ready on one side, any standard Spicer 4.25" bolt circle flange ready on the other side.

He had to shave some meat off the countersunk bolt heads to get them to not interfere with the 4.25 bolt circle.

Turn off pinion snub, add pilot bore
Drill and countersink 6 bolt VW pattern
Hardware provided, modify countsunk heads
2 times

Verbal quote was $100, ended up being $159.XX with tax and hardware. I don't have a lathe or any experience using one, didn't seem unreasonable to me.

M4wdFab

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Re: Harry's Buggy
« Reply #38 on: January 17, 2020, 10:46:28 PM »
more than reasonable and sounds like the communication was good to complete something with a little learning on the fly. 

Harrison

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Re: Harry's Buggy
« Reply #39 on: January 20, 2020, 10:14:18 AM »
On your guy's driveshaft pillow block bearings -  what kind of fit do you guys shoot for? Press? Light, tap fit?

mr.mindless

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Re: Harry's Buggy
« Reply #40 on: January 20, 2020, 11:15:30 AM »
Mine is looser than I’d like, not perfectly true, and can cause vibe issues. I think I finally got it to a good place again last tear down. Balance between rust jacking and running true. I don’t have a perfect answer
Quote from: etk300ex
oh lord!

M4wdFab

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Re: Harry's Buggy
« Reply #41 on: January 20, 2020, 02:30:40 PM »
On your guy's driveshaft pillow block bearings -  what kind of fit do you guys shoot for? Press? Light, tap fit?
able to slide in.  usually have to turn out the 2" pillow bearings so 2" DOM will fit.  I like the 4 bolt ones better than the 2 bolt saddle if you have room like we did in matts car. 


Harrison

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Re: Harry's Buggy
« Reply #42 on: January 25, 2020, 06:42:49 PM »
Minor update while I wait on tube (grumble)

Had planned to use an off the shelf Toyota rear driveline disconnect but after some research I found that the Toyota stuff was 1.09" dia which is smaller than even the VW splines so I ditched that idea.

Grabbed a rotted out Dodge 2nd gen front 60 for $150 this week and am pillaging it for parts.

The yoke shaft will get a 1480 to 1410 conversion joint and and 1410 yoke flange that will bolt to my 8.8 pinion flange assembly.

The seal surface on the coarse spline end of that shaft is a hair over 1.875 and the splines are a hair under 1.875 - will have a buddy turn that down so a 1.875 pillow block slides right over.

The other shaft and the pinion will get cut up and somehow turned to match the ID of a standard piece of DOM, will defer to my machinist on the best method to accomplish that. Cut tube to length needed and weld together. 1.25 flange bearing should slip right over the outer bearing section of the pinion. Splines will hang out the back of the chassis, standard D60 yoke will bolt on sandwiching the flange bearing and keeping that shaft in place.

Reuse Dodge fork mechanism housing with a cable shifter setup.

Lots of claptrap. I started researching 1.8T to GM trans adapters as a backup :-[ It'll be fine! I think.


mr.mindless

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Re: Harry's Buggy
« Reply #43 on: January 25, 2020, 07:40:59 PM »
I liked it when proposed and I still do!
Quote from: etk300ex
oh lord!

dubt

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Re: Harry's Buggy
« Reply #44 on: January 25, 2020, 09:50:15 PM »
I love the idea of a cable actuated disco for driveline.