spline repair: JB Weld + carborundum

[DanHoug]

this might be useful to some... needed to fix the splines on a Polaris Ranger driveshaft that had stripped out completely due to rust, you could turn the driveshaft without resistance when it was mated to the output shaft of the differential. so really stripped.

the driveshaft and differential shaft were both spendy and difficult to locate so i tried a no-cost fix that is no harm done if it doesn't last, if the fix strips out again, i'll pull it apart and replace both the output shaft and driveshaft.

onto the fix... i wanted to create interference between what little was left of the splines on each part to 'lock up' the two. carborundum is 9 hardness on the MOHS scale, diamond being 10 so i thought that would make a good filler. mixed up enough carborundum i had on hand with JB Weld to make a slurry that resembled concrete. wetted both output shaft and driveshaft and then mated them together. the grit filled the stripped splines enough to lock the shaft and the JB Weld might hold it all in place for a while. it should be noted that these splines are for a NON sliding solid axle driveshaft.

after curing, took it for a test drive and it is holding so far. next time, i'd use 3M DP-460 epoxy and carborundum as it is about 4x stronger than JB Weld but i didn't want to wait for a delivery of it. also, Loctite 660 is getting very good reviews for spline repair
https://www.henkel-adhesives.com/us/en/product/retaining-compounds/loctite_660.html
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-dan
60% of what you find on the internet is wrong, including this post.

'87 Westy & '89 Westy both 2.1 4spd

Past projects can be found at--
www.thefixitworkshop.com

[jimf909]

Brilliant! Do you think this will fix a worn rear drive spline on an ‘77 R100?
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- Jim

[djkeev]

Interesting fix but I doubt it will deliver long term service.

There is simply too much torque on a drive shaft for a glue product to last very long.

It is fascinating what people have lying around, a jar of sandpaper 80 grit?!?

Dave
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Stop Dead Photo Links how to post photos

Ghia
http://www.thesamba.com/vw/forum/viewtopic.php?t=392473

Vanagon
http://www.thesamba.com/vw/forum/viewtopic.php?p=6315537#6315537

Beetle
https://www.thesamba.com/vw/forum/viewtopic.php?t=482968&highlight=74+super+vert

[dhaavers]

Sounds like a little hometown history to me: https://www.lcnewschronicle.com/lifestyle/2682923-flashback-friday-3m-birthplace-th-recorded-plaque

(FYI: Minnesota Mining & Manufacturing, a small startup now doing business as "3M")...



- Dave
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86 White Wolfsburg Westy Weekender
"The WonderVan"
<EDITED TO PROTECT INNOCENT PIXELS>

[DanHoug]

[DanHoug]

[Butcher]

I like it!

So many people will tell you that it will not work, but will not try. I look forward for the results of this butchery. Is there a pool on how long it will last?

[Jeffrey Lee]

[DanHoug]

well... splines are still holding! the experiment continues. We now return you to your regular programming.
_________________
-dan
60% of what you find on the internet is wrong, including this post.

'87 Westy & '89 Westy both 2.1 4spd

Past projects can be found at--
www.thefixitworkshop.com

[IdahoDoug]

Hey, that's a great experiment. I've done a few less outlandish things with JB Weld and it's kinda fun to play with modern epoxies and physics to see what's possible. I carry it on remote trips and would not hesitate to use it in a component failure to get home, etc.

Well done. Once you have the new part(s), you should subject it to normal operating torque and see what it takes to fail it, providing you don't put other components at risk. Bravo!
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1987 2WD Wolfsburg Vanagon Weekender "Mango", two fully locked 80 Series LandCruisers. 2017 Subaru Outback boxer. 1990 Audi 90 Quattro 20V with rear locking differential, 1990 burgundy parts Vanagon. 1984 Porsche 944, 1988 Toyota Supra 5 speed targa, 2002 BMW 325iX, 1982 Toyota Sunrader

[DanHoug]

well, the experiment is over! axle splines finally spun out as i was bringing a load of campfire wood up some steep steps with the Ranger. yes, it goes up steps just fine and yes, it is a good torque load on all parts as the tire climbs the vertical face of the step.

so. i'd say the JB Weld plus carborundum is a good temporary repair but for the long haul, you need new steel. onward!
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-dan
60% of what you find on the internet is wrong, including this post.

'87 Westy & '89 Westy both 2.1 4spd

Past projects can be found at--
www.thefixitworkshop.com

[Abscate]

April to August isn’t a temporary repair , you just need more JB weld.
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.ssS!

[djkeev]

I know, I was the skeptic.

I thought it wouldn't hold and it turns out I was right..... admittedly it lasted far longer than I thought it would.

I dislike glue, adhesives, epoxies........ why?
My Grandfather.

He was born in the 1800's and watched technology explode and blossom as a young man.
He drove an electric car in 1919, worked for Thomas Edison who sent him to England to introduce the talking movie to the King, wired the Holland Tunnel in NYC, etc

In the 1950's and 60's he was enamoured with plastic ........ and glue.
He had the glue pot with the brush, he purchased any new tube of magic goo that hit the market and he glued EVERYTHING!!!!

Most of it failed if it ever held at all. Brown gobs oozing out of "repaired" products.
I determined as a child that I absolutely hated glue.
And I still do today. Most of it fails to work or fails to bond shortly after application, nothing has changed.

Any chemical goo just doesn't excite me. Yes, I have a drawer full of various goos, I try them and am almost always disappointed. (Except for wood glues)

Any concoction will fail, it's been proven to me.

Anyway....
Great experiment you did but sadly with the expected results!

Dave
_________________
Stop Dead Photo Links how to post photos

Ghia
http://www.thesamba.com/vw/forum/viewtopic.php?t=392473

Vanagon
http://www.thesamba.com/vw/forum/viewtopic.php?p=6315537#6315537

Beetle
https://www.thesamba.com/vw/forum/viewtopic.php?t=482968&highlight=74+super+vert

[Abscate]

Next time we hit the woods We can glue together, too.
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.ssS!

[4Gears4Tires]

Don't forget leather. You can bond that stuff so well it'll never come apart. Good porosity on both materials.
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'87 Syncro
Ferric Oxyhydroxide Superleggera Edition

[ZsZ]

It sounds a good bush repair.
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Zoltan
1.9 MTdi 2wd Multivan (ex Caravelle)
Van since 2006, engine since 2008

[ledogboy]

[Abscate]

[DanHoug]

new steel ordered for $412. differential output shaft and a drive shaft. labor cost is beer + porketta for the garage oven.
_________________
-dan
60% of what you find on the internet is wrong, including this post.

'87 Westy & '89 Westy both 2.1 4spd

Past projects can be found at--
www.thefixitworkshop.com

[drip]

This time drill and tap for a grease fitting...no more rust 😏