Welding an output shaft?

[PacMan]

Hello,

i would like to weld two output shafts together and dont know how.

I have this coupling shaft and the two output shafts.


I have to shorten the output shaft on the right side of the picture and weld the output shaft in the center of the picture on the end of it.
On this picture you can see how long the shaft have to be after welding together.


The coupling shaft goes then on the end of the new output shaft.


The coupling shaft looks from the inside like this.


There are a lot of ways to weld them together.
Here is a list of options so far:

• 1. Shorten and milling down the output shaft on the right side of the picture and respline him to the right spline and just put the coupling shaft on it.
  This is by far the best way but nobody want to do it. Got an offer - $1500...
  
  2. Shorten the output shaft on the right side of the picture and mill a hole in the center and press/shrink the other output shaft in it after mill him a bit down to have a nice surface.
  This is how i want to do it. But i am not quit sure if that will last. And i dont have any idea how you weld that proper. Looks like both shafts are harden steel. A mate told me to drill holes through both shafts and weld them up. Then i seen somebody cutting slots in the side of the shaft and weld that up again. Or should i just weld once around where the the shafts pressed/shrinked together? And is there something special at welding on hardenen steel?
  
  3. Shorten the output shaft on the right side of the picture only a bit and mill him down and mill the splines inside the coupling shaft off and press/shrink the coupling shaft on the output shaft.
  So i would not use the output shaft in the center of the picture and i could not change the coupling shaft but maybe that is easier to make it strong.

This setup have to hold up with a LS1 and 35" tyres.
If somebody have a good idea, please let me know.

Every help would be very helpfull for me.
I dont have a milling mashine and i am not able to weld in top qualitaet. So some professional will do it, but first i would like to have your opinion to that problem.

Thanks for your help
Chris

[bubs]

I would do the cut and re-spline on the shaft for around $400

Buddy

[Rhett]

I ran a welded (shortened) counter shaft in my transfer for a few years in my zook. Its still i one peice but it don't have a ls1 in it. I got Yuri to weld it up for me.
If bubs can respline for 400 I would go with that option.

[Bush65]

I'm probably missing some info, but from what I see in the pics, and putting some other info together with them, I would make it all one piece by machining the main shaft (shown on the right side of your pics) down and cutting a rover 10 tooth spline (SAE straight side spline standard) on the end - this is assuming the finished length is as you have positioned the parts together in the pics.

BTW the ZF to LT230 spud shaft is the early type and you should use the later one with longer splines for the LT230 input gear.

[BadMav]

I would do the cut and re-spline on the shaft for around $400

Buddy

X2 you don't want alot of hard work and time to go bang when you stand on the throttle.

[PacMan]

I would do the cut and re-spline on the shaft for around $400

Buddy

Hello Buddy

Wow - that sounds good! - Thanks heaps!
Problem solved!
I get all the measurements together and give you a call, if that is allright.

Thanks for your help.

I'm probably missing some info, but from what I see in the pics, and putting some other info together with them, I would make it all one piece by machining the main shaft (shown on the right side of your pics) down and cutting a rover 10 tooth spline (SAE straight side spline standard) on the end - this is assuming the finished length is as you have positioned the parts together in the pics.

BTW the ZF to LT230 spud shaft is the early type and you should use the later one with longer splines for the LT230 input gear.

Hello John

I think you are right. I thought maybe it is better to have a replaceable coupling shaft but i think the shaft is strong material anyway.
I could maschine my adapter plate a bit down - the shaft would be long enough then.
Do you know how much longer the spline of the new style coupling shaft (FTC5090) is?

Thanks
Chris