As mentioned before I had a front driveshaft pop out when mapping which called a stop to the day straight away, well once home and looked at the problem was far worse than I thought and we were lucky to get away with no damage
Here is how the shafts were when I removed the boots
Full droop
Full compression
Now before anyone sees that and think it's from poor workmanship let me just state.....
This error was in no way the fault of Andrew Gallacher and the guys at AG Motorsport nor was it the fault of the guys at MDV Specialist Engineering
Andrew set everything including driveshaft plunge spot on to suit my 4x4 standard hubs ect that I supplied when he built the shell for me and MDV's guys set up all suspension and obviously can't see under driveshaft boots and rightly assumed the would be one of the first things you check when building a car like this which Andrew did so they are not to blame
The problem lies with me changing mid build from the standard suspension set up to the wide track wrc set up and not realising the consequences with the driveshafts so I only have myself to blame and luckily no harm done other than lost time and 1 knackered tripoid joint
Anyway onto sorting the problem
I can not afford full custom machined 300m shafts right now so the next best thing and perfectly acceptable thing is to get 4 new shafts cut them all to set sizes so I can make 2 new shafts that only need to be joined in 1 place
So today's mock up shaft kit
Secure 2 halfs of shafts to the L section and slide to desired length, mark up and tac weld and send away for new shafts to be welded to this length
So all marked up
A few marks to remember what's were if I need to undo on the bench after
Bare in mind this blanks shaft is already 20mm longer than what I had in there that popped out and I've separated it 28mm so the new ones once welded need to be 48mm longer than what I had in there!
But at the new length under full droop
Nice engagement in the cup
And full compression
No chance of them popping out ever again,
That will be sent off to CPS Drivelink to be friction welded and I should have them back in about a week
