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Learning how to build Lotus Seven replicas...together!
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PostPosted: September 25, 2010, 7:02 pm 
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Our Deman uses welded Ford/Miata shaft's. We had a weld crack but thankfully the axle stayed together. Has anyone found a reasonable place to make custom halfshaft's? What are other people using?

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PostPosted: September 26, 2010, 8:26 am 
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I use Moser Engineering for custom, made to order axles. It costs about $200-250/pair. Send in the axle that has not failed as a pattern with a letter making the request and contact information. This is custom work so no warranty except for machining and alloy defects.

I guess Deman uses the Tbird diff as a cheap source for the 3.08 ratio and traction loc diff.
Search for "protege" for related custom axle info.

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PostPosted: September 26, 2010, 1:13 pm 
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A bit of an update. The outside CV on the Miata end doesn't appear to be take apartable. This will make it harder for someone who want's to make a 1 piece unit. I have a quote on a set from RCV but I'm not sure that they are aware that the miata end will have to be completely fabbed.

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PostPosted: September 26, 2010, 6:25 pm 
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It is takeapartable. The lack of an exposed snap ring is typical of outer cvs.

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PostPosted: September 26, 2010, 6:45 pm 
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Well I couldn't see why they would make it non serviceable but I read in a non factory service manual that the outside cv's aren't. I will probably go this route if we break another one (hopefully this doesn't happen)

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PostPosted: September 26, 2010, 7:05 pm 
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When it is taken apart, the soft round wire snap ring is often broken. This is fine, since replacement boot kits usually have a replacement ring. As for repair, there is none for the average bloke except to clean and replace the boot.

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PostPosted: September 26, 2010, 7:19 pm 
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Yeah we've got all the boot's off but I'm talking about the actualy CV itself. The tripod section the ford end is held with a snap ring so is the miata end but I'm pretty sure there is another one on the inside of the tripod that not accessible.

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PostPosted: September 26, 2010, 10:50 pm 
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The standard way the rebuilders take them apart is clamp the shaft in a good vise and smack it with a big, oops BIG hammer. Most of the time the spring clip pops and it comes apart. Sometime though the spring clip doesn't pop and you pop the end off the shaft. The spring loaded end is much easier to take apart - pop the spring clip and it just slides apart. Main rebuilding procedure is to inspect the parts and replace the balls with oversized balls, fresh grease, new spring clip and Boots. Rebuilders don't spend a dime more than they have to. As many used parts are reused, or they don't bother rebuilding that particular unit.


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PostPosted: September 26, 2010, 11:03 pm 
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kf2qd wrote:
The standard way the rebuilders take them apart is clamp the shaft in a good vise and smack it with a big, oops BIG hammer. Most of the time the spring clip pops and it comes apart. Sometime though the spring clip doesn't pop and you pop the end off the shaft. The spring loaded end is much easier to take apart - pop the spring clip and it just slides apart. Main rebuilding procedure is to inspect the parts and replace the balls with oversized balls, fresh grease, new spring clip and Boots. Rebuilders don't spend a dime more than they have to. As many used parts are reused, or they don't bother rebuilding that particular unit.


Yup, big wooden hammer is preferable. I find the balls can often be got in a common size and if it's metric 19mm balls then go for 3/4" balls that are slightly oversize.


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PostPosted: September 27, 2010, 6:54 pm 
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I've been thinking "well what do people do when the re man these things" They must be serviceable and it sounds like you guy's know how it's done. If worst come's to worse then I will try this technique. We've allready removed the inside spring clip. I assume the reassembly technique is the same?

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PostPosted: September 28, 2010, 7:48 am 
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I use a pipe a few inches longer than the axle protruding from the outer cv. Bring the pipe down on to a board and the axle should pop right out of the outer cv. Hang on to the cv in the process.

The joint should be taken apart and cleaned to ensure no part of the soft, round wire snap was pinched off by the axle during removal.

Installation is a snap.

Exposed snaps that are stretched to release an axle (see the inner joint) need to be squeezed when off of the axle, then stretched as little as possible during installation for a tight fit when installed.

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