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Old December 8th, 2007, 05:28 PM   #1
CheapThrillB2
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Default machine shop work

i am in need of some machine shop work here on the west side. Pretty specific stuff.....


here is the main shaft from a BW1350 Tcase, and the small peice is an output shaft cut from a A4LD trans



heres what the end result needs to look like


sorry for the crude pics, but what i have is the main shaft and an output shaft that is 4 inches long and is all splined. So what i am looking at having done is taking the mainshaft, boring it out then splined to accept the splined output shaft from the trans. That way no welding would be needed to the shaft making it weaker. The main shaft is already hollow but would need to be enlarged and splined. I am hoping for a local to the west side place but i would ship to elsewhere if the price is right.
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Old December 8th, 2007, 06:33 PM   #2
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I don't know the actual sizes, but maybe you could talk to a machine shop about making a billet piece? It looks small enough some shop might even have a piece of scrap around, then send it off to Moser to get it splined and hardened. It would definitely be stronger.
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Old December 8th, 2007, 10:32 PM   #3
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were you talking to rulebreaker about this??? My wife has been machinning for 15 years and she can quote you a turned up version for you, if you supply her with all dimensions.
Then you can send out to spline and heat treat.
She can use both pieces and press them together and weld them, but, this weld area makes for a very possible break area. The shaft can be bored out, but, because this shaft had already been hardened, cutting a key in it is just about impossible- the hardness makes it very difficult on the cutter and the machinist must take several small cuts at a time to achieve this-thus this is a very costly way to go. U may call her @ 231-775-2370 her name is Julie
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Old December 8th, 2007, 10:55 PM   #4
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rulebreaker had the same style shaft made for the same style doubler build.

I had already had a shaft made in the past, but where it was welded it broke, and then i had another shaft made and had it keyed and then it was welded and that one broke as well.

i'll see about making a call monday. Maybe i could send the peices i have and one of my broken ones, that way the exact measurement can be made hands on by the builder
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Old December 10th, 2007, 01:09 PM   #5
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you two may have the same style of drivinghis broke before the weld, he didn't want to let my wife know her weld didn't break. They do good work there, cheaper in cost than most too.
By the way, rulebreaker is parting out his bronco II, his aerostar project is well under way.
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Old December 10th, 2007, 01:31 PM   #6
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i'd find a different way to do what you are looking for. the odds of someone being able to broach a female spline like that without being setup for a production run is slim to none. external splines can at least be cut, internal are more difficult and even more so that there is a bottom to the hole.
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Old December 10th, 2007, 02:44 PM   #7
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Quote:
Originally Posted by rockrat View Post
you two may have the same style of drivinghis broke before the weld, he didn't want to let my wife know her weld didn't break. They do good work there, cheaper in cost than most too.
By the way, rulebreaker is parting out his bronco II, his aerostar project is well under way.
yeah i follow his builds on TRS

Quote:
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i'd find a different way to do what you are looking for. the odds of someone being able to broach a female spline like that without being setup for a production run is slim to none. external splines can at least be cut, internal are more difficult and even more so that there is a bottom to the hole.

yeah i got some time to explore some options,
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Old December 11th, 2007, 12:24 PM   #8
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i didn't have any problems with the shaft until i put the lo-unit in lo and the tcase in high, i busted two shafts before i learned i shouldn't have done that





that shaft was keyed and welded, it broke at the welds
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Old December 12th, 2007, 08:27 PM   #9
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just give a call when you decide. Business is slow this time of year, they'll work with you on it.
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Old December 13th, 2007, 12:28 AM   #10
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How about sending it out to be hardened after you weld it?
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Old April 17th, 2008, 11:31 PM   #11
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Actually after welding, it should be stress relieved and then re-hardened so as to eliminate any brittle spots caused by the heat from the welding. Just my .02cents
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Old April 18th, 2008, 08:15 AM   #12
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wow back from the dead, looking into cryogenics(?) getting it frozen but myself and a few others are looking into other avenues for the shaft as well......for us ford guys. We might be able to get additional shafts made for others as well
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Old April 18th, 2008, 09:06 AM   #13
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i'm just a botanist but, if i were to make say a shaft like that one I would probably have it made 1 piece. By welding there is not a enough cross section to carry the torsional load on the shaft, especially since the load will be fully reversed. I'm not sure were this shaft is in your doubler but, a save design would be to make it out of round stock say 4140 or equivalent and carburize or induction harden (probaby for 1 piecec carburizing would be easier). If you give me the diameters and approximiate torque carried by the shaft I could give you a ball park spec on hardness and case depth needed. It looks like a short shaft from the pics but, with any heat treat you would want to check the T.I.R. and straighten if necessary.
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Old April 18th, 2008, 09:10 AM   #14
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yeah their are companys that make the kits for the doublers that make them in one peice design.....what we are looking into is female splining the one part and sliding the output shaft into it.....should have gotten your opinion on sunday being kenny and i had the parts in our hands at his house wwhile we were having lunch talking about it.
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Old April 18th, 2008, 11:08 AM   #15
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like everyone above stated internal splining would require either a vertical broach or rotary broach. Which both methods would require special tooling for the splines you need. The concept would definitely work might be hard for machine shops to do if they don't have the tooling available to them. Maybe I'm wrong but that has atlease been my experience with splines.

If it's 1 - piece then a shop could just hobb both splines or broach the bigger spline and hobb the small spline. Either way it doesn't look cheap. Maybe talk to a place that makes axle shafts they might have the tooling you need for the splines. Probably a good place to start is trying to find our what the dimensions of your splines are to begin with.

I'm no expert but I would bet money that it would be cheaper to make a new 1 - piece than to spline both pieces and put them together.

Just a thought but maybe send an email to like JB conversions, advanced adapters, and/or novak conversions and see what they say. They certainly have a lot of experience. Who knows maybe they will let you test the first prototype for free! (doubt it though)

just my $0.02.

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Old April 18th, 2008, 11:28 AM   #16
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John, you don't have rockwells and doublers are for rock crawling....ditch the doubler and wheel your ride
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Old April 18th, 2008, 11:30 AM   #17
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i ran the doubler and it was nice...........nothing like starting out in 5th gear on an incline and letting the clutch out with no hesitation of stalling
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Old April 18th, 2008, 11:52 AM   #18
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What is TIR ?
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Old April 18th, 2008, 11:53 AM   #19
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it's in case you have a crooked shaft
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Old April 18th, 2008, 11:54 AM   #20
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That's what I was afraid of, is that how you fix it?
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