Author Topic: TECH: How I built my square driveshaft (Read 99975 times)

MiniSimp · « **on:** Sep 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.

Volcom · « **Reply #1 on:** Sep 14, 2005, 01:45:29 PM »

Nice writeup! Thanks!

Rocksurfer · « **Reply #2 on:** Sep 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.

Skinny_Pedal · « **Reply #3 on:** Sep 14, 2005, 06:31:22 PM »

Quote from: Rocksurfer on Sep 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.

me>

<rocksurfer

Rocksurfer · « **Reply #4 on:** Sep 14, 2005, 06:38:01 PM »

Quote from: Skinny_Pedal on Sep 14, 2005, 06:31:22 PM

me> <rocksurfer

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.

Skinny_Pedal · « **Reply #5 on:** Sep 14, 2005, 06:40:15 PM »

but he showed two different pieces of tube. its ok old age is catching up

. i bet your thinking punk kids rights?

Rocksurfer · « **Reply #6 on:** Sep 14, 2005, 06:46:24 PM »

Quote from: Skinny_Pedal on Sep 14, 2005, 06:40:15 PM

but he showed two different pieces of tube. its ok old age is catching up . i bet your thinking punk kids rights?

Naw it's ok, I'll just laugh my

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.

kneedownnate · « **Reply #7 on:** Sep 14, 2005, 07:09:55 PM »

Minisimp, I love your new avatar but can only imagine it's only a matter of time...........

Yota4life · « **Reply #8 on:** Sep 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

Shamb · « **Reply #9 on:** Sep 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

Makman · « **Reply #10 on:** Sep 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.

Another reference for similar tech over at PBB... http://www.pirate4x4.com/forum/showthread.php?t=90517

CTENG in KS · « **Reply #11 on:** Sep 14, 2005, 11:42:00 PM »

That's HOT!...Mini, you are becoming a regular toyowhitetrash guru. WELL DONE!

alwayzbroken · « **Reply #12 on:** Sep 21, 2005, 08:26:06 PM »

MiniSimp, how much does receiver tubing cost per foot? What are the lengths of the two tubes? Thanks.

MiniSimp · « **Reply #13 on:** Sep 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.

speedemon · « **Reply #14 on:** Dec 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".

mudaddict · « **Reply #15 on:** Dec 13, 2005, 08:32:14 PM »

i got 3 feet of each for 30 bucks from a place up the street that i found

notajeep · « **Reply #16 on:** Dec 14, 2005, 04:52:45 PM »

Quote from: MiniSimp on Sep 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.

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.

hi on lux · « **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 ?

BLACKDOG · « **Reply #18 on:** May 12, 2007, 09:55:54 PM »

Quote from: hi on lux 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 ?

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

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.

and yes, it is supposed to be 1/4" wall

83yota · « **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

MiniSimp · « **Reply #20 on:** May 12, 2007, 10:03:40 PM »

Quote from: hi on lux on May 12, 2007, 09:46:58 PM

may i know what lenght did you used for the 2.5"? 2"?

MiniSimp · « **Reply #21 on:** May 12, 2007, 10:05:18 PM »

Quote from: 83yota 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

Didn't grease mine. There is too much play in these shafts for grease to matter.

83yota · « **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

MiniSimp · « **Reply #23 on:** May 12, 2007, 10:09:06 PM »

Quote from: 83yota 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

Only time I hear noise is when the hubs are locked and I'm in 2WD (rotational clicking). Other than that, not a peep.

83yota · « **Reply #24 on:** May 12, 2007, 10:18:17 PM »

cool sounds like a good deal

tom w. · « **Reply #25 on:** May 12, 2007, 10:44:03 PM »

mine clicks at idle sometimes... other than that i never hear it.

BLACKDOG · « **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.

I wouldn't bother using grease, it wouldn't help any.

83yota · « **Reply #27 on:** May 12, 2007, 11:40:37 PM »

how about beveling the edges of the inner tube

BLACKDOG · « **Reply #28 on:** May 13, 2007, 12:11:47 AM »

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

unlikely you'd bevel that much, but I just don't see a point

Wermz84 · « **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

even though it's two years late.

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