superman22x
Plastic
- Joined
- Nov 5, 2017
I am looking for some advice from anyone who has some here. I am working on a project to adapt an engine and transmission together. Of course the "easy" answer is a custom flywheel/clutch combo. But I would like to use the dual mass flywheel and clutch that originally came with the engine. Let's ignore the bellhousing portion of this project and assume that's figured out already.
My input shaft is a 1" 23 spline. My clutch side is a 1.125" 26 spline. Is there a way to adapt the input shaft to match the clutch? My thoughts are two options (not sure if either is even remotely reasonable). Usually, it would be as simple as taking the flywheel pressure plate from the engine, and a clutch that matches the input shaft. Because this is a twin plate clutch and a dual mass flywheel, it's not as simple.
Option 1: Adapt the input shaft to the clutch. Machine off the old splines, fit a bushing with the new splines already on it (core out an input shaft with those splines?), then weld the bushing. The whole assembly would then of course require re-heat treating, at least in the welded area. Liberty Gears has done something similar to this for me before.
Option 2: Adapt the clutch to the input shaft. Bore out the clutch hub, press fit a clutch hub matching the 23 spline shaft. Pin the two together? Welding these two would not be an option I think, as re-heat treating would destroy the clutch material. I ran a couple online calculators, steel on steel, a 0.05mm (~0.002") interference would be around 800NM of torque capacity. Assuming the inner clutch hub OD is 40mm. Of course, a little more safety factor would be nice, which is where the pins would come in.
This is the 26 spline clutch that matches the engine: The hub has splines that mate to the second clutch plate. This is what makes it more difficult than just replacing the friction disc.
And the clutch and input shaft on the transmission side:
For anyone interested, transmission is Porsche, engine is GM Gen V 6.2L, around 460ft-lbs.
Again, I'm not sure if there is any possibility these things can be adapted in this way, I just thought it wouldn't hurt to ask those that know more.
My input shaft is a 1" 23 spline. My clutch side is a 1.125" 26 spline. Is there a way to adapt the input shaft to match the clutch? My thoughts are two options (not sure if either is even remotely reasonable). Usually, it would be as simple as taking the flywheel pressure plate from the engine, and a clutch that matches the input shaft. Because this is a twin plate clutch and a dual mass flywheel, it's not as simple.
Option 1: Adapt the input shaft to the clutch. Machine off the old splines, fit a bushing with the new splines already on it (core out an input shaft with those splines?), then weld the bushing. The whole assembly would then of course require re-heat treating, at least in the welded area. Liberty Gears has done something similar to this for me before.
Option 2: Adapt the clutch to the input shaft. Bore out the clutch hub, press fit a clutch hub matching the 23 spline shaft. Pin the two together? Welding these two would not be an option I think, as re-heat treating would destroy the clutch material. I ran a couple online calculators, steel on steel, a 0.05mm (~0.002") interference would be around 800NM of torque capacity. Assuming the inner clutch hub OD is 40mm. Of course, a little more safety factor would be nice, which is where the pins would come in.
This is the 26 spline clutch that matches the engine: The hub has splines that mate to the second clutch plate. This is what makes it more difficult than just replacing the friction disc.
And the clutch and input shaft on the transmission side:
For anyone interested, transmission is Porsche, engine is GM Gen V 6.2L, around 460ft-lbs.
Again, I'm not sure if there is any possibility these things can be adapted in this way, I just thought it wouldn't hurt to ask those that know more.