Making some CV axles

 So, nobody bothered to answer my inquiries about custom CV axles, so after a few weeks of waiting, I decided to make them myself. I mean, if I fuck up, at least I can just send the pieces to one of these shops to have them made. I think I did pretty good. I know the advice is to not make your own by cutting and welding, but I figured I don't owe anyone an explanation for why I did this, so I just made them.

They came out pretty good. The main challenge was to figure out how to machine the half-shafts down to so that the two halves matched, and I could put a DOM steel pipe over it. I used the disc sander for this task. It probably took longer than using a lathe, but with steady hands it's possible.

So, I machined the large diameter shaft down, and machined the ends down with a significant chamfer. I then slipped a DOM steel tube over it and welded it all. I tested it after install by moving the car uphill, letting it roll downhill, and engaging a gear suddenly. They didn't break, so then the kids and I drove it around the block a few times, and after some minor linkage adjustments, it's a rolling and driving machine! I plan to just use these until they either break, or I get a chance to take them to a local place to have custom ones made. Fuck people who don't bother emailing you back. Don't they want work and money? Sometimes I wonder. I'd run circles around these shops if I had one to run. They never have good online info. Everything is done via phone calls. So fucking outdated.

I even took the Dremel and created spline cut outs as the machining process ground them down significantly. After the CV install, I replaced the temp zip ties with metal CV banding. I then built the pedal to throttle linkage using an extra push-pull cable I had, connected to a bell crank, and then to a metal rod to the throttle. It has worked VERY well. Super smooth response and very solid feeling. I don't have pics of the linkage, but I will add next time.

The car right now is back in the garage. It has started raining again and I've been bonding the body to the frame. It should all be cured today. I strengthened the area around the windshield with metalwork and bonded that to the body. The result is a VERY sturdy to keep the windshield from cracking.

The next step this week is to mount the windshield. So, I need to first install the dashboard top, but before that, install the remaining metal panels separating the front of the car to the inside of the car.