TECH: How I built my square driveshaft

[MiniSimp]

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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]

Nice writeup!  Thanks!

[Rocksurfer]

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]

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]

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]

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

[Rocksurfer]

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]

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

[Yota4life]

this is a great qrite up, i will be doing the same thing soon to increase my amount of slip

[Shamb]

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]

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]

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

[alwayzbroken]

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

[MiniSimp]

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]

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]

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

[notajeep]

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]

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]

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]

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]

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

[MiniSimp]

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]

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]

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]

cool sounds like a good deal

[tom w.]

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

[BLACKDOG]

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]

how about beveling the edges of the inner tube

[BLACKDOG]

  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]

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.