Author Topic: TECH: How I built my square driveshaft  (Read 36189 times)

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MiniSimp

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TECH: How I built my square driveshaft
« on: September 14, 2005, 01:04:44 PM »
This Thread is Featured in our Tech from our Forum Members section!

This is also a permanant "How to" on ehow.com http://www.ehow.com/how_4475628_build-square-driveshaft.html

So, because of my "Rears up front" suspension, I needed a longer front driveshaft that had more travel in it.
The affordable answer: Square driveshaft
I'm not worried about the driveshaft being ballanced, because I won't be driving very fast in 4wd.

What you need:
1: Toyota front driveshaft
2: 2"x2"x0.25" square tube (slides into the 2.5" tube)
3: 2.5"X2.5"X0.25" receiver hitch tube (no seam inside)
4: Grinder
5: Portaband saw (helpful, but not necessary)
6: Flat file
7: Welder


Here is how it was built:

Start with one front driveshaft


Seperate it


Clean off what grease you can


Cut off the shaft approx. 3/4" from the yoke



Clean out the shavings



Cut a slice off the 2"x2"x0.25" tubing to trace out the square


Don't try to use paint to mark the square, it doesn't work. Use a thin black marker.
I used a cutting wheel to grind off the edges so it would be flatter



The 2" tube will have a weld line raised in the tube, you must file this down.





Line it up and weld it to the tube




One side done


Next do the Double Cardan side, cut approx 1/2"



The DC end will be 2.5"x2.5"x0.25" Receiver hitch tubing (no seam inside)


Again, cut a slice off to trace your square


File down any burs


Trace out your square


I used a portaband saw to cut this one, there was a lot more material to cut off, grinding would have taken forever. Then I used a grinder to clean it up.


Square cut out


The slice slides over it perfect


Slide it in the tube


Line it up and tack it in place


Finish weld it


Now you have a square driveshaft.
« Last Edit: August 07, 2008, 10:48:43 AM by MiniSimp »

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Re: TECH: How I built my square driveshaft
« Reply #1 on: September 14, 2005, 01:45:29 PM »
Nice writeup!  Thanks!
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Re: TECH: How I built my square driveshaft
« Reply #2 on: September 14, 2005, 02:10:07 PM »
You didn't mention that the 2 pieces slide together and are not welded to each other. I had to re-read the buildup to figure that out. Wouldn't want someone to just take a single piece and weld the ends to it. :shocking:
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Re: TECH: How I built my square driveshaft
« Reply #3 on: September 14, 2005, 06:31:22 PM »
You didn't mention that the 2 pieces slide together and are not welded to each other. I had to re-read the buildup to figure that out. Wouldn't want someone to just take a single piece and weld the ends to it. :shocking:


 me> :slap: <rocksurfer      :shake:
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Rocksurfer

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Re: TECH: How I built my square driveshaft
« Reply #4 on: September 14, 2005, 06:38:01 PM »


 me> :slap: <rocksurfer      :shake:

I know, I know, but if you skim-read you miss that little unwritten part that there are 2 pieces of square tube, and you are welding them seperatly. Then there is no indication or full picture (I love pictures) of the finished shaft. I went whoa, wait a minute and re-read it and saw that there were 2 pieces. :qtip:
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Re: TECH: How I built my square driveshaft
« Reply #5 on: September 14, 2005, 06:40:15 PM »
but he showed two different pieces of tube. its ok old age is catching up :rofl2: . i bet your thinking punk kids rights? :rofl:
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Re: TECH: How I built my square driveshaft
« Reply #6 on: September 14, 2005, 06:46:24 PM »
but he showed two different pieces of tube. its ok old age is catching up :rofl2: . i bet your thinking punk kids rights? :rofl:

Naw it's ok, I'll just laugh my  :moon: off when some kid reads it wrong like I did at first and just goes out and makes it out of a single piece and then jumps it or something. :shocking:
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Re: TECH: How I built my square driveshaft
« Reply #7 on: September 14, 2005, 07:09:55 PM »
Minisimp, I love your new avatar but can only imagine it's only a matter of time...........
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Re: TECH: How I built my square driveshaft
« Reply #8 on: September 14, 2005, 08:23:18 PM »
this is a great qrite up, i will be doing the same thing soon to increase my amount of slip
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Re: TECH: How I built my square driveshaft
« Reply #9 on: September 14, 2005, 08:58:09 PM »
Made two of these this last weekend  :)

great write up for anyone who needs to build one and doesn't know how.

Good stuff.

I should probably make a writeup of my half doors but i'm to lazy   :D
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Re: TECH: How I built my square driveshaft
« Reply #10 on: September 14, 2005, 09:21:15 PM »
Well written.  If you're at risk of making a one piece "long-travel" driveshaft, you probably need to learn that lesson the hard way.   :headscratch:

Another reference for similar tech over at PBB... http://www.pirate4x4.com/forum/showthread.php?t=90517
If it never breaks, people can only speculate how much it was overbuilt.

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Re: TECH: How I built my square driveshaft
« Reply #11 on: September 14, 2005, 11:42:00 PM »
That's HOT!...Mini, you are becoming a regular toyowhitetrash guru.  WELL DONE!
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Re: TECH: How I built my square driveshaft
« Reply #12 on: September 21, 2005, 08:26:06 PM »
MiniSimp, how much does receiver tubing cost per foot? What are the lengths of the two tubes? Thanks.
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MiniSimp [OP]

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Re: TECH: How I built my square driveshaft
« Reply #13 on: September 21, 2005, 08:45:54 PM »
It cost me $30 from a welding shop that I deal with all the time, so I can't really tell you what reality cost is.
I got 2 lengths of 36" because I figure if I have enough left over I might be able to make another one for a spare.

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Re: TECH: How I built my square driveshaft
« Reply #14 on: December 10, 2005, 09:38:16 PM »
i can get ten feet for about $15 (new) from this steel salvage company i get my metal from but other places i've called have quoted me 40 for the same shirt.  call around.  look in yellow pages under "steel" or "salvage".
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Re: TECH: How I built my square driveshaft
« Reply #15 on: December 13, 2005, 08:32:14 PM »
i got 3 feet of each for 30 bucks from a place up the street that i found
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Re: TECH: How I built my square driveshaft
« Reply #16 on: December 14, 2005, 04:52:45 PM »
It cost me $30 from a welding shop that I deal with all the time, so I can't really tell you what reality cost is.
I got 2 lengths of 36" because I figure if I have enough left over I might be able to make another one for a spare.
What do you need a spare for??? I did this mod last year and you can sit the whole truck right on it and it just scratches. :driving:
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Re: TECH: How I built my square driveshaft
« Reply #17 on: May 12, 2007, 09:46:58 PM »
may i know what lenght did you used for the 2.5"? 2"?

btw isn't it supposed to be 0.25" or 1/4" and not .025" tube wall thickness ?

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Re: TECH: How I built my square driveshaft
« Reply #18 on: May 12, 2007, 09:55:54 PM »
may i know what lenght did you used for the 2.5"? 2"?

btw isn't it supposed to be 0.25" or 1/4" and not .025" tube wall thickness ?
It all depends on what the length is from your t-case flange to the pinion flange.  When I built mine, I bought 2' of each peice of tubing, I think I wound up using 15-18" of each one :dunno:  I don't remember for sure.  You just need to make sure the the smaller tubing isn't going to bottom out when your suspension compresses, or drops out when the suspension droops.

:psss: and yes, it is supposed to be 1/4" wall :thumbs:
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Re: TECH: How I built my square driveshaft
« Reply #19 on: May 12, 2007, 09:59:33 PM »
ok call me stupid but you do grease it right when you put it together? maybe a dry lube. just asking for me i have ALWAYS had my drive shafts built for me and i would like to build one
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http://board.marlincrawler.com/index.php?topic=62935.0

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Re: TECH: How I built my square driveshaft
« Reply #20 on: May 12, 2007, 10:03:40 PM »
may i know what lenght did you used for the 2.5"? 2"?

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Re: TECH: How I built my square driveshaft
« Reply #21 on: May 12, 2007, 10:05:18 PM »
ok call me stupid but you do grease it right when you put it together? maybe a dry lube. just asking for me i have ALWAYS had my drive shafts built for me and i would like to build one
Didn't grease mine. There is too much play in these shafts for grease to matter.

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Re: TECH: How I built my square driveshaft
« Reply #22 on: May 12, 2007, 10:07:49 PM »
cool how much noise is there when you first let out the clutch? is there alot of noise when your rolling down the road? how about when you hit a bump? sorry about the ?s i am just tring to figure this out before i do it :headscratch: :dunno:
85 toyta 4runner 4" allpro ft chevys with custom revolver shakle rear lincon locked front open rear running 35" toyo OC MT's on ultra wheels

http://board.marlincrawler.com/index.php?topic=62935.0

90 toyota runner 2" body lift spooled ft and rr 5.29 gears and a HEAVY right foot.

http://board.marlincrawler.com/index.php?topic=75563.60

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Re: TECH: How I built my square driveshaft
« Reply #23 on: May 12, 2007, 10:09:06 PM »
cool how much noise is there when you first let out the clutch? is there alot of noise when your rolling down the road? how about when you hit a bump? sorry about the ?s i am just tring to figure this out before i do it :headscratch: :dunno:
Only time I hear noise is when the hubs are locked and I'm in 2WD (rotational clicking). Other than that, not a peep.

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Re: TECH: How I built my square driveshaft
« Reply #24 on: May 12, 2007, 10:18:17 PM »
cool sounds like a good deal
85 toyta 4runner 4" allpro ft chevys with custom revolver shakle rear lincon locked front open rear running 35" toyo OC MT's on ultra wheels

http://board.marlincrawler.com/index.php?topic=62935.0

90 toyota runner 2" body lift spooled ft and rr 5.29 gears and a HEAVY right foot.

http://board.marlincrawler.com/index.php?topic=75563.60

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Re: TECH: How I built my square driveshaft
« Reply #25 on: May 12, 2007, 10:44:03 PM »
mine clicks at idle sometimes... other than that i never hear it.

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Re: TECH: How I built my square driveshaft
« Reply #26 on: May 12, 2007, 10:52:37 PM »
the only noise that is noticable is in 2wd with the hubs locked.   Sometimes when you atart off it'll clank pretty loud one time, as it takes up the slop, but then it is silent while under load.  Following these directions, I recently found that 60mph is doable with no vibes as long as the truck is under load, and not coasting.  :thumbs:  I wouldn't bother using grease, it wouldn't help any.
:usa: Its better to die on your feet than live on your knees :usa:

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Re: TECH: How I built my square driveshaft
« Reply #27 on: May 12, 2007, 11:40:37 PM »
how about beveling the edges of the inner tube
85 toyta 4runner 4" allpro ft chevys with custom revolver shakle rear lincon locked front open rear running 35" toyo OC MT's on ultra wheels

http://board.marlincrawler.com/index.php?topic=62935.0

90 toyota runner 2" body lift spooled ft and rr 5.29 gears and a HEAVY right foot.

http://board.marlincrawler.com/index.php?topic=75563.60

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Re: TECH: How I built my square driveshaft
« Reply #28 on: May 13, 2007, 12:11:47 AM »
:dunno:  why would you?  You want it to fit as tightly as possible, which is why Minisimp used those two tubes.  The outer dimensions of the small one are not much smaller than the inner dimensions of the bigger one, allowing for very little slop.  I don't see a point to beveling the edges, and if you beveled to much, you could wind up having the smaller shaft spinning inside the bigger shaft :dunno:  unlikely you'd bevel that much, but I just don't see a point :thumbs:
:usa: Its better to die on your feet than live on your knees :usa:

"Freedom is never more than one generation away from extinction. We didn't pass it to our children in the bloodstream. It must be fought for, protected, and handed on for them to do the same, or one day we will spend our sunset years telling our children and our children's children what it was once like in the United States where men were free. "

"I don't believe in a government that protects us from ourselves."
              -Ronald Reagan

Don't take life too seriously, it isn't permanent

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Re: TECH: How I built my square driveshaft
« Reply #29 on: May 13, 2007, 01:34:00 AM »
Damn, how did I never see this thread before  Probably cause i searched "square drive line".   good Job Mini :thumbs:   even though it's two years late.   :hammerhead:
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