Prototype D shaft FIX !!!!

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laganm21

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Ok so today i was thinking of how to fix the D shaft problem, What I came up with is to use a 8MM 6 point deep well socket and cut it down to size to to join the two shafts togeather, the 8mm fit a little better than a 5/16 but you can use either, than I drill out the stock Alu coupler to slide over the socket and drilled holes in the socket it use the set screws off the Alu coupler, the socket is now taking all the load instead of the stock Alm piece way stronger than the Alm piece , I just put everything back on and so far so good I really don't think Im going to be breaking this ever again PIC below
 
This is what happens when I get a couple of beers in me , the creative juices start flowing lol ,I really think this is going to be a Cheap easy way to fix this problem, its going to take a Hell of an impact to stip out a socket, I was thinkin about using a Impact grade socket for it but ill just give this a go for now, Hell this part is not even for me its for k20 94 dc so I made a JIG so when I make mine I don't have to measure and deal with the angles again
 
This will keep the aluminum coupler from wearing against the steel multipiece shaft but the set screws still dig into the multipice shaft right? That the problem I have is the set screws slowly dig into the multipiece shaft under engine torque causing slop so thats why I tighten them every tank or two. It looks like in your 2nd picture your set screws are digging too.
 
What happen to me was that the Stock ALU coupler striped out and the only thing keeping the shaft from moving was the set screw thats why there is a mark on the shaft where the set screw dug, But now with this fix the set screws are only there to hold on the ALU coupler so i can have breaks, the Stock ALU coupler is drilled out so it can slde over my socket, I drilled the scoket out so I can still use the set screw but there just there to keep the Alm coupler form spinning so I can use the breaks,So the set screws now really have no load on them ,if ya wanted to run fount disck breaks on your rig U don't even need the stock Alm coupler you could just run the scoket, that AlU piece is just for breaks now
 
I see. The stock one piece coupler is connected to the internal hex and set screws but your seperates the hex for accelleeration and set screws for braking. That makes sense. Its worth a try. I really like your idea of using the socket to connect the two and put the brakes somewhere else. Drink some more beer please and get the juices flowing some more. :D
 
Well i was going to give the new part a good testing today but its raining out side so thats sucks, but ill give her a go when it clears up, Also to just use the socket and run the brakes some when else you would need to spot weild each end of the socket to the shaft to keep them form sliding in and out,
 
yeah it works great but now redcat had the steel break hub assembly so thats the same idea and hell it 15 bucks so thats the way to go
 
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