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LSD Diff options...What can we use in our Zeds..


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#41 PeterAllen

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Posted 04 January 2015 - 11:02 AM

Like lampy I just machined mine to suit as I had the relative luxury of creating a new shaft to length. I have attached a file from a GT40 site which might assist with some of the dimensions.

You will really struggle to get it down to 10mm and still have structural integrity. I suggest you consider if this is doable.

- do away with the grease retainer cover. That should give you a couple of mm.

- measure the amount of protrusion of the cage at around 22-25 degrees and make that the depth of your recess. (I have assumed the inner Nissan tripod unit will facilitate plunge?) Actually if you go ahead with the next step you could just bore it through.

- WELD the S30 outer flange to the new adaptor. You may need to first make a circular plate (approx 4mm thick) to slip over, and be welded to, the square S30 outer flange. This could then be turned true prior to welding to the 930 adaptor (see sketch).

On second thoughts, the 930 adaptor and the circular-square adaptor could be manufactured as one piece.

The key to this is the depth of the cage protrusion AND minimising distortion when welding - get a pro to do it.

(edit) I just thought of another idea. Why not buy two diff output shafts from a Holden wrecker and machine off the shaft component - two ready-made 930 adaptors? Further, as you are not fitting grease retainers you could machine the face of these to the thickness of the retainers, or more.

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#42 Dan260Z

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Posted 09 January 2015 - 07:38 AM

Thanks for the advice Peter, very much appreciated.  I'd done something similar to what you suggested, planning to construct the adapter out of two pieces to avoid milling.  I found the CV cage and shaft protrusion to only be about 8mm at the absolute full extent of articulation (well beyond what it'll get to in the car), so I made the adapter out of a 6mm flange to weld onto the stock companion flange (ie. matched the 6mm companion flange thickness), then the "spacer ring" is made out of 8mm thick mild steel.  If that turns out to be too thin and yields CV cage/ball interference issues, I'll get the rings re-cut out of 10mm or thicker.

Knocked up a couple of drawings in solidworks and sent the dxf's to a local laser cutting place - who (very nicely) agreed to do it all for a slab!  2hrs after send the file through they were ready for pickup  :)

Got them to cut the holes too, however as I plan to tap them to M10x1.25 (which would normally require an 8.8mm hole), I got them cut undersize to 8mm, with a plan to drill them out to 8.8 to remove the hard crust created by the localised rapid heating/cooling due to the laser cutting, so as to avoid destroying my tap.

If this doesn't work, I also knocked up a model for a 1-piece part which would obviously require milling to produce.  Obviously the 1-piece would be stronger and has the added benefit of including a small lip to help centre the CV joint, but it was gonna be a PITA to organise the milling (and potentially expensive).

To aid with strength I extended the OD of these parts out to 115mm (instead of matching them to the 108mm OD of the CVs), and made the centre hole as small as possible (matches the 75mm ID of the CV joint - it's not a plunge joint so the ID is a perfect circle, no slots for the balls to slide in/out of that I'd need to make clearance for).

Speaking of which, I scored 2 brand new commodore outer joints for $45 each on ebay au, including new boots, grease, etc.  Another reason this conversion is so attractive to me (if it works that is!).

Oh to answer your other qn, yes the Nissan pathdfinder inner Cv's are Tripod styles with a massive amount of plunge (which should also cater easily to the two sides of the zed requiring slightly different length shafts).

Will keep you posted once I get it all welded together/tapped/assembled.  Probably in 2-3 weeks time as I'm waiting on drills, taps, etc from ebay.

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#43 PeterAllen

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Posted 09 January 2015 - 09:08 AM

Just a point we have not covered but you may have addressed. I would not assume the squares on the S30 couplings are perfectly square. I machined mine to ensure they were.

You may have to true it in a lathe after welding and then redrill the six holes in the spacer.

#44 Dan260Z

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Posted 10 February 2015 - 11:29 AM

Spot on Peter - I did try to centre up the stock flange within the new adaptor "rings"... but after welding had about 1mm of run-out on one of them (the send about half that).  So I've welded up the holes and plan in the coming weeks to turn down the outer as you suggested in a lathe, and re-drill the holes.

#45 PeterAllen

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Posted 05 March 2015 - 06:49 PM

Dan, check out these little beauties!

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#46 Dan260Z

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Posted 06 March 2015 - 08:03 AM

Wow!  Exactly what I need (pending thickness/height check as my shafts are a bit on the long side)!  Where did you find them?
Are they a one-off or an aftermarket production item?

Mine are on hold, nearly done re-drilling the holes, though I broke off a small drill bit in the last hole I had to do, so I've been waiting on an ebay order of a carbide bur to try to tear through the bit that's stuck in there.  They should get the car on the road, though I've started working on a new design that'll involve some lathe work to machine in a lip to center it on the OEM companion flange, as well as a lip to center up the CV - but still avoids milling.


#47 garvice

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Posted 06 March 2015 - 08:35 AM

Very Nice Peter. Did you also redrill your stubs for 5stud holes?

#48 PeterAllen

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Posted 06 March 2015 - 07:44 PM

Unfortunately for us they are a one-off from Finland of all places.

I've contacted the chap to see if he is interested in making any more. They are for the 260Z 27 spline pattern.

#49 Dan260Z

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Posted 11 March 2015 - 08:30 PM

Bugger - keep me posted though!

#50 PeterAllen

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Posted 12 March 2015 - 05:45 AM

The chap got back to me stating they were VERY expensive and the fit of the splines was very loose.

All that glitters...

#51 Dan260Z

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Posted 17 March 2015 - 09:06 PM

Indeed  :(

Oh well back to Plan A.  Or was it B.  Something like that  :P




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