TSDZ2 No-Grove Axle Project (Custom Made)

[ornias]

Last week I've been working on getting some axles with decent hardness (55 HRC minimum) and good precision/tolerances (h7) produced.

By now:
- CAD is done (thanks to the jumpstart by some forum users)
- Work drawings are done
- Steel research is done (it will be 42CrMo if produced in China or 42CrMo4 when/if produced in EU/USA)
- Research is done on potential suppliers
- Second round of QA will be done in EU, for which I keep a machinist friend at hand if needed.
- Agreedment has been found with a prototype supplier with all above specifications

I wouldn't call it cheap, but I can finally get this made :-D
So i'll keep you guys posted

However a question:

If, and that's still a big if, this works out...
How much would you guys be willing to pay (if anything) for a stock-sized axle with decent specifications baring any weakening grooves?

Not planning to commercialise it though, but machining does have such a thing as "economics of scale"... So I might be open to bundle requests in the future if the design works out

 

[ornias]

Update 25-10-2022:

I just finished the planning stage with the supplier of my prototype and it has been paid...
Should arrive before the start of next year (most likely much sooner).

 

[ornias]

Update 16-11-2022:

Axle Prototype has finished manufacturing and is on-its-way to me for testing, validation etc.

 

[ornias]

Update 20-11-2022:

Prototype is due this week.

 

[ornias]

Update 21-11-2022:

A package has just arrived.
Next would be installation testing, hardness testing and tolerance testing.
Besides going over the report from manufacturing to spot any irregularities.

 

[beemac]

Update 21-11-2022:

A package has just arrived.
Next would be installation testing, hardness testing and tolerance testing.
Besides going over the report from manufacturing to spot any irregularities.

Nice! For reference here's a stock pic for comparison:

 

[ornias]

Update 21-11-2022:

A package has just arrived.
Next would be installation testing, hardness testing and tolerance testing.
Besides going over the report from manufacturing to spot any irregularities.

Nice! For reference here's a stock pic for comparison:

Thanks, so some notes on the differences people will see between these:
- You will notice it's lacking the groves, which are common known failure points. Instead of groves, this would rely on bearing glue (loctite) and MUCH (10x) tighter tolerances.
- You will notices it's not black, I've purposefully choosen not to have it blackened, because bearing glue is always pretty significantly weaker on blackened steel (as referenced by loctite itself).

I still need to do a test-fit and QA session later this week or maybe next week, which will highlight any design mistakes and/or tolerance issues. So I've not yet cross-validated the tolerances requirements send in the drawings.

 

[Ugothakd]

Since you are going custom, I can think of at least one person here who would like an isis version

 

[ornias]

The goal is to maybe do a small-batch production run.
I'm not going to design things on order or something.

Nor do I've the design experience to even alter it to ISIS spline...

Update:
- Also got the production report today, seems to be okey, though it has to be remeasured ofc.

 

[Elinx]

....
- Also got the production report today, seems to be okey, though it has to be remeasured ofc.

When are your planning to insert this axle?
I'm really curious about the fitting inside bearings and torque shaft.

 

[ornias]

....
- Also got the production report today, seems to be okey, though it has to be remeasured ofc.

When are your planning to insert this axle?
I'm really curious about the fitting inside bearings and torque shaft.

I hope next week or the week after, but we all know how the december months can be
I'm also very interested how a H7 fit works out, mostly if it's a "smooth enough" fit, but nothing ventured, nothing gained

 

[Joakim]

Hey hows it going? I am very interested in an axle replacement

 

[raylo32]

Interesting idea but how is axle supposed to be held in place? On the OEM axle the snap rings that go in the grooves that you are eliminating do that job.

 

[Joakim]

Interesting idea but how is axle supposed to be held in place? On the OEM axle the snap rings that go in the grooves that you are eliminating do that job.

There is some info about that here in the thread, mentioning loctite, if you skim through it you will find it. If that would work, I dont know

 

[raylo32]

I looked a bit but missed that somehow. But I don't believe that is a viable idea. It would never hold up long term.

There is some info about that here in the thread, mentioning loctite, if you skim through it you will find it. If that would work, I dont know

 

[Chalo]

Interesting idea but how is axle supposed to be held in place? On the OEM axle the snap rings that go in the grooves that you are eliminating do that job.

Fixing a clown-engineered mid drive's most conspicuous problem will only deliver you the next most conspicuous one. And then the next, etc. Nothing with that many moving parts and design decisions goes out with only one boneheaded mistake; the way you do one thing is the way you do everything.

I am idly curious what's the next inexcusable clown-engineer problem that shows up, though.