Next I have to liberate the end of the shaft so that I can weld it on later.
by the way, the tubing is .095 wall which was heavier than I expected. Next I need to separate the steel tube from the casting.
I assume that the shoulder under the trunion is parallel to the u joint axis so I lined the part up based on that:
Then I machined through the weld. You can see the rust peaking through right as I started to get through the tube and expose the casting:
Ready to weld with a beveled edge:
My u joint came from Amazon to convert from 1 3/16 to 1 1/16.
Once I had all that together, I would see the distance from the beveled cut to the very end and see where to cut the tube. I scored it with the cutting disk in the die grinder then finished the cut with the 4 1/2:
Then I heated the end of the tube up with a map gas torch and beat the u joint in. I used a piece of angle to line up the Ujoints at each end. I wasn't sure how close the had to be. A co-worker told me .125° or there would be big trouble. The internet doesn't seem to agree. Seems like 5° is common, which I am more inclined to believe (maybe because I have to!)
Here is the end stuck in the transmission. Pretty much right where it used to be on the yoke:
Here is the end into the pinion. Looks good. Not a lot of clearance on the e brake cable
Just need to weld it up
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