What's everyone's thoughts on the best way to go about getting T2 CV's onto IRS bug axles ?

I already have the T2 flanges on the box and 944 stub axles, so it's just the axles themselves I'm stuck on. I know of 3 ways - machine the shoulder off the axle, counterbore the CV itself, or switch to SwayAway axles.

I'd planned on going with counterboring the CV's, but the hardening apparently will make that difficult (I'm not the machinist - this is based on what a mate has told me after looking at them).

Appreciate any wisdom people can share !!!

Mine were done a fourth way - weld larger Type 2 flanges on to Type 1 axles and output shafts.

Switch to Sway a Way there nice

im having the shoulder machined off mine by custom.

Another option, give me th whole box, axles and brake setup for the car. I will look after all of it for you, and will even give you my box, and brakes..... ?

i'm also going sway-away better option all round for big HP

No need for the SAW axles untill you get to a very high HP output.
I counterbored the CV joint no worries.

The CV is only hard where the balls run and easilly machined in the spline area.

I am not a fan of machining the axle due to the weakning effect
of it being smaller than the spline in one area.

good old dave! trust him he has a fast car!

BiX - how did I know you'd come up with something like that ??? Thanks, but no - my gearbox, brakes etc. have gotten used to going to the track fairly regularly...



Thanks for the info everyone - looks like I give counterboring the CV's a go like I'd planned.

Ahh, the saga continues...

It seems the CV's that I have are defnitely hardened in the spline area - apparently chews through normal (carbide?) cutters like nothing else. Am told I need someone who can "grind" them... using a tool designed for tool steel I think it was... and my mate who's done all my other machining so far just doesn't have the gear for that.

So the question is, does anyone know a machine shop they can recommend in or around Brissie who'd be able to do it ?

If you cant find anyone up there,
I can gave a go at them.(down here at Reedy Creek)
I have turned plenty of hard gear shafts with carbide tips so should be possible.

I wouldn't reccomend machining the shoulders off the axles. We broke 2 axles at Warwick last year in the Gecko and it's hardly highpo, about 140 flywheel tops. Machining the CV's sounds interesting, but for my Manx I went SAW axles. Hassle free and aren't 30 years old and pre-wound They hit the hip pocket tho at about $300 but thems the breaks (or no breaks)

Yeah - I've definitely ruled out machining the axles - it's either counterbored CV'sor SAW axles for me. I doubt my little 1916 will never put out the ponies to need the SAW axles, but there's nothing like over-engineering things... and no way to I want to introduce any new weak points !!!

My plan now is to do the ring around of the few places I know, and if nothing pans out there I might just take you up on the offer Dangerous.... what's your poison, beer or spirits ???

I dont drink or smoke.
If you can't supply the wild women,
then sweets and lollies are my "poison".

Right, OK - fair enuff.

I could try and help in that direction, but most of the "wild women" I know are of rather questionable morals, which I'm sure you wouldn't want... LOL.

Questionable morals?
I prefer no morals at all!