i hate wheel hop

[Boosted Escort]

What ever happened to that traction bar group buy. That would of helped with the wheel hop.

[FE3-323]

^ still working on them. i'll have something by july

[therieldeal]

The spot where it broke is the same size as the stock BG axle (26.8mm spline OD), since the splines fit our stock hubs. The stock axle shaft is slightly smaller in diameter (24-26mm depending on brand), while the Toyota axle shaft is extra beefy at ~29mm OD.

I believe this is why it failed where it did. With the stock mazda/ford axles the entire shaft was the "weak point", as it was smaller in diameter when compared to the splined ends. Being ~12 inches long it could safely twist slightly to absorb the sharpest of torque spikes without damage.

Since my weak point is now only ~1/2" long, it didn't cope very well with twisting/absorbing shock loads. I ran my theory by our engineer at work and he agrees with me.

I have been talking to Ferdi and we came up with a potential solution, but it's going to take some machine work to make a custom hub. There is an outer CV joint available with a big 30mm spline, that will fit onto the alltrac axle shaft. The only problem is that the hub that goes with it has all the wrong dimensions (too big) and the wrong lug pattern. There should be enough meat to turn it down, though. For now I'll just be putting in another alltrac axle, and doing what I can do avoid wheel hop. If it breaks it breaks I guess... it is a racecar after-all. Its better than a broken trans .

As far as traction bars go, I wouldn’t want to run them on the street, only the track. The solution Ryan told me about the other day sounds promising though :D.

[FE3-323]

dun dun dun...........

[therieldeal]

two good things:

discovered that if i leave the flanged stub in the transmission and unbolt the 6 allen head bolts, the DS axle can be removed/installed WITHOUT UNBOLTING ALL THE TRANS MOUNTS. this is awesome and would have saved me tons of time back in october. not sure why i didnt try it then. lining it back up is annoying and messy, but easier than taking all the other stuff apart....

found my MR2 passenger side axle that was buried in the garage (worn out inner cv, junk... came with my intermediate shaft). it is actually SHORTER than the ST185 shaft. this is the outer cv i was talking about above, 30mm OD on the hub splines. so... if i can make a custom hub to fit these axles, they will drop right in as is. the length difference is enough that you could probably even use stock ball joints!


in the picture i carefully aligned the inner end of the shaft
Broken alltrac axle
MR2 axle

yes thats a busted off speaker basket in the picture, i ripped the magnet off a junk woofer to help me get all the axle shards out of my wheelbearing... worked pretty well. i'm going to leave the bearing... if it frys, it has a warranty lol

[FE3-323]

post a picture with the broken stub next to the MR2 axel please

[therieldeal]

the outside diameters of the two spline ends are:
27mm - alltrac, BG
30mm - MR2t

more good news, i took some more detailed measurements and there should be JUST ENOUGH material in the stock BG hubs to re-broach them with the MR2 splines. Now finding someone to do it for me will be the interesting part .

[CaymenEGT91]

jon ur a crazy S.O.B. lol gotta love your ingenuity tho!

[Racerboy]

jon ur a crazy S.O.B. lol gotta love your ingenuity tho!

[wgnths]

way to come up with custom setups.... only when you break your current ones hahaha

[therieldeal]

well its difficult to predict where the next weak link will be once you are working with such beefy components...

[wht95scort]

Time to call the driveshaft shop...

[therieldeal]

i'm hoping a local wire EDM shop will be able to modify the hubs for me. from what ive been told, in order to re-broach them they would need to be annealed first, then broached, then re-heat treated. with wire EDM i may not have to do any of that.

i did send an email out to DSS to see if they can help, though.

[FE3-323]

what is wire EDM?

[Rocketman]

Electrical Discharge Machining... etching and erosion of material using a electrified copper wire drawn thru the part being machined...different types of EDM too

http://en.wikipedia.org/wiki/Electrical_discharge_machining