one of my custom driveshaft builds: (pix)

[Tamago]

found an old set of pictures on one of the first "custom" shafts i did at work. this is for an F22 powered AE86 corolla. the original design (not by me) failed and almost punctured through the floor of the car. the second try is what we see below

we start with the CV end from an S2000.. it's made from what we call "propellor" style shafting, small on the ends, larger in the middle. we cannot use this tube because it's metric, and all our tubing is inch. because of the very high RPM requirements, i must step the tube diameter up to 3" .083 wall tube for strength and integrity..

here's how the shaft started out.


i remove the CV end:


and cut the stub off the metric tubing, leaving a little tubing to work with.


then begin welding: (keep in mind, all im' doing is weld on top of weld, slag and crap is not a concern at this point as it gets burned off in the process)




next, chuck the stub up in the lathe

and begin turning.. my target diameter is around 2.85 since i want a press fit into an .083 wall tube

annnd all done cutting:



then i take the stub over to the press, and use good ol hydraulics to force the stub into a piece of 3" tubing:


then cut the tube to length and press on the "other" end. bolt up to the balancer and start welding




all welded, balanced and painted flat black per customer request:


car is making around 500whp and have had no issues to this day. (original work was about a year ago)

C/C welcome