Any spline cutting specialists on Channel 11?

[xschop]

I now have done enough Middle drives to where I feel comfortable in the dimensions needed for an adapter that will go between the factory middle drive housing and inner middle drive gear for a 100% bolt-on solution to the FJR-1300 swingarm that MathH pioneered and now Mr. freeze is working on.... 30mm spacer is where it is at.... but luckily, the insertion depth on all the middle drives that I have removed are all within 0.75 mm of each other....

I need to know the shaft spline pattern to finalize the adapter drawing....hopefully we have a gear cutter on board....



As you can see, the middle drive shaft insertion depths on all these shafts are exactly the same with plenty of play for various spacers of which I have already machined one at 30mm with oiling ports included for the middle drive gear oil....

[motoman]

Seems you have become as innovative in a correct way as some across the pond!.....Interesting.

[mro]

Just curious, you have a hobbing machine
or can you do em with your current equipment?

mro
pipe dream to have chop's chain drive on my hot rod XS...

[xschop]

I have a rotary indexer and can cut the outside splines but not the inner. The spline pattern is metric and has spline angles and peaks and valleys that have to be exact.

[jmnjrpa]

Yeah,

I have cut all but haven't any access to the equipment at present. A Bridgport with a slotter head can cut the inside but it is slow. Best way is a broach for internal. Tool costs alone would be $1500/2000.

[xschop]

The Mic don't lie

With a 30mm width middle drive-to-engine case spacer.....this is the ticket....

[BigDick]

I have no equipment and minimal experience. The outside splines would be cake comparatively if you have the indexer and the proper cutter to get the profile you need on the splines. I've never done anything with internal splines, it seems a broach would do it but might be a headache getting one that's profiled correctly. . . . I do remember seeing one for internal operations that was a 360* cutter (it cut completely around the periphery of the broach) but I'm pretty sure it was only round, square, rectangular, hexagonal, or octagonal. . . you might be stuck with having a through hole, making a open sleeve to get your internal splines in it via broach then welding it to bar stock to put the external splines on that. . . (purely speculation) Let me know if you have any questions, like I said I'm no expert and I only have a bit of experience but I am very mechanically inclined.

[WMarshy]

I worked for a company in Elmira NY that has some OLD equipment they use to do internal-blind hole spline cutting, I could make some calls. What exactly are you looking for, someone to cut spline on a batch of parts? Wouldnt a machinst handbook have the profile your looking for?

[mxmikie]

i use to send my shafts to ed moser he use to cut and spline axles for $50.00 each with a 48 hr turnaround

[red bandit]

Wire burn, slang for EDM. Of course you would need the dimensions profile. Not sure what the cost would be. Getting the computer program might cost a few dollars. But if you would do a batch it might not be to bad. JAT

[Ivan]

I would think EDM would be the way to go, especially for production. If you can cut external, then the carbon block and oil tank (can't recall the name for it right now) would probably be the best way, especially in a blind hole.

The other option would be to replicate the shaft with a longer dimension, cutting two sets of external splines instead of an internal.

[jmnjrpa]

Yeah

Die sinking was the word Ivan was most likely groping for. It would be the best way to go for blind holes. The longer shaft is the best idea as you would not have a balance or wear issue. Cost would be comparable and should run $250 +/- 20% in small lots (up to 25) and $150 in lots over a couple hundred.

[xschop]

Shafted

As long as the shaft splines are cut to very close tolerances to mimick the XS11 middle shaft splines, I do not see a problem with XSive wear in the spline interfaces as 20mm is the depth that the factory splines ride..... This is going on the assumption that your Middle drive spacer is within tight tolerances for shaft concentricity location which I have covered....

[xschop]

Spacer the correct way....

The 30mm wide spacer has a reciprical indexing where the factory middle drive inserts for shaft concentricity (+- 0.0007). It also will use the same factory middle drive gasket.....And has 2 large oil passages for the oil flow right where the factory drive locates them....







100% Bolt-on....

[psycoreefer]

I would be super interested in these parts once you find a shop that can fabricate those splines for you.