Ok, so i should have read Mr Haynes manual and done what it said .... but i didn't.

Taking apart my push in drive shafts and instead of carefully cutting the old outer metal cup off with a hacksaw i 'carefully' used the angle grinder. Unfortunately i thought i'd just give it another go for good measure and did the following.

There are more much larger pictures in my archive. The 'simple' question is "are the drive shaft tripod joint things trashed?" They're the 25mm ones so harder to come by and i've got a distinct lack of cash.

Max depth of cut is 2mm right on the outer edge, it drops quickly to about 1mm (within the first 10mm) and then slowly peters out to nothing. I have access to a mig welder and may be able to persuade someone to tig weld the grove & turn it back down to level.




Description

(archive pictures)
http://www.locostbuilders.co.uk/photos.php?action=gal&user=MikeR&folder=driveshaft

Its not a machined surface where bits rub, I cannot see it making any difference myself, just a tad lighter

I would not weld up, this may affect the hardening.

I'd bung some chemical metal in it and forget it ever happened Cant see it doing any harm, wouldnt weld it though.

Cheers

Rich

I'm sure it'll be fine. What sort of torque will you be putting through it?

Dress any sharp edges, but i'd be perfectly happy running it. Even if it fails, it won't fail catastrophically

Mike, if its any conciliation - I shall learn from your mistake and not do the same to mine (hopefully) when I dismantle them on Friday!

[Edited on 28/3/11 by mads]

How are you going to refurbish / put them back together? I didn't think there was much you could do with them once they wore out.

They've not worn out - i'm (when i get some money) getting custom drive shafts made. I therefore need to take the originals apart and then i'll reassemble with the shortened shafts.

ford told me their system says the metal outer sleeve was no longer availble. If you can get them it would be good to know where so i can do a full strip and rebuild instead of cleaning regreasing and using universal boots.

quote:

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Originally posted by mikemph
ford told me their system says the metal outer sleeve was no longer availble. If you can get them it would be good to know where so i can do a full strip and rebuild instead of cleaning regreasing and using universal boots.

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Before you trash your existing 'cups' I've just taken two off without cutting them. I'll explain later how i did it (i took pictures as well cause I know what you're like Mads). They should be reuseable, they're not as good as new ones .... but if ford have issues supplying it may be a solution.

Got the escort axle out this morning, had a bit of a "eek bit worried doing this" to the g/f and she said "don't, sure we can afford two drive shafts if we don't need them immediately". Got to say sometimes I realise just how lucky i am. Just phoned up a bloke and for 150 quid he'll do me two drive shafts

So, escort axle stays as the backup plan ......

Now about to start welding in the roll bar once i've made a seat.