How Anyone Can Make Custom Axles for Your Ride
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Hey Everyone! Welcome back to the ElectricSuperCar channel! Today we are back to Porsche building, specifically custom axles for our Tesla powered Porsche.
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▬ Contents of this video ▬▬▬▬▬▬▬▬▬▬
0:00 - Intro
3:11 - Front Wheel Splines?
7:33 - Splicing Axle Shafts
19:30 - Dutchman Axles
21:10 - Salvaging 2nd Set of CV Joints
22:57 - Reassembly
Tags: EV build,electric vehicle build,electric car build,electric car project,electric vehicle conversion,ev conversion,electric supercar,electric hypercar,electricsupercar,electric Porsche,Porsche ev,Porsche GTE,How to build an electric car,how to convert an electric car,electric conversion,Electric car conversion,porsche ev, Custom axles, DIY axles, custom driveshaft, custom axle, custom driveshafts, Porsche driveshaft, Porsche axleshaft, Porsche axleshafts, strong axles, dutchman axles, replacement axle, replacement axles, axle fix, #flexispot
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IDK man... This channel and content is way too good to not be rocking much higher numbers.
Needs better headers imo, should always mention tesla swapped or tesla swap or tesla conversion or ev conversion. Another channel I advised the guy doing a tesla boxter ev swap got 3x or more the views just mentioning tesla in every single video. 👍🏻
LOL! Tell your friends!
I totally agree
When you said to weld 2 axles together, my first thought was "how the heck do you get that perfect without any vibration"... Then watching the rest of the process with sending those in... made total sense. That's gotta be a lot easier than doing your own drawings and hoping they make your drive shafts correctly.
Thanks for the comment Rick!
I agree... but I would clamp it, rather than welding it, so I could fine-tune length.
It's amazing how many projects you are able to do in parallel! Real respect.
Thanks Friend!
Right!? And make content for And at least on camera (i mean phone 😉) look like you’re having fun!
Hi Jeremy, I was a driveshaft engineer both in GKN and Nexteer (two of the largest driveshafts companies in the world) for about 7 years. I can almost guarantee that your shaft will leak some grease through the small opening of both boots. If you check on the old shafts, there is a groove on the position that the boot seats, on the inside of the small opening of the boots there is some extra material that should seat inside this groove. Also, I have two tips for you: first, you don`t need to cut the metal omega bands, you can just use some pliers to remove it, and second, you don`t need this specialized tool to remove the joints from the shafts, you can just fixate the shaft on a vise and hit on the inner race (what you call star) with a hammer and a chisel. Great content!
Thanks for the suggestions!
One kind of thinks that the company who made the custom driveshaft should have known and fixed that.
I have never used a tool before. Just a vice and a big hammer. But that tool looks like the way to do it.
Hi leo I have a problem with gkn ev transaxle how can I contact you
I know we should all share this channel to get Jeremy's subscribers up - I've been watching since the beginning and it's such a great channel!
You're the best!
When you hammer out the driveshaft from the spindle, leave the nut on a few thread and strike that instead. Otherwise if you hit slightly off center you can damage the threads which makes for a bad day if you don't catch it in time and accidentally cross thread the nut when going back together.
Good call
or buy a copper or hide faced hammer
Im still proud of you for creating a job instead of waiting for one 💪🏿💪🏿
Thanks Friend!
It may seem obvious, but the whole boot problem could be solved by requesting that Dutchman make the thick part of the axle a little longer. Then you can just slide the boot right on. The other comment I wanted to make was that you didn't have the shafts balanced. They may give you vibration at speed. I think a driveshaft shop can balance axles.
Thanks for the comment
They very likely balanced the axles during manufacture, and as they are cut with a lathe they will inherently be balanced, as the tool makes a perfect round part. Balancing is only needed with welded axles, there they use a tube and weld on the ends, which then need balancing.
@@SeanBZA He added epoxy and a metal collar.
@@antimattergarage8147 Still round, and so small that not really going to be noticed unless that shaft gets up to 1000RPM.
Those new axles look proper OEM, looking good man!
Thanks 👍
Shaft collars were a great solution. Very creative. Also, thank you for showing the mistake and fix. I do that kind of thing all the time. It’s nice to see that others do too. "We do it nice, cause we do it twice".
LOL! 🤣
Another fantastic video Jeremy!! I love the comments coming from this one, as they really are all positive and constructive. I am glad you got the torch unit, it is a versatile setup. The mapp gas and oxygen was an interesting mix, but any fuel works. We have to get you set up with a proper workbench that will allow you to weld and work on it. Your Jerry Rigged solution is good, and Zack will probably give it a big thumbs up, but also you will be able to work at a level that will keep your back healthy. You are doing well with combining your hobby and job. The other jobs you are doing benefit from your lessons on your first car and this Porsche, and it only gets better from here. You are also making some solid connections to the suppliers you need. Keep up the great work!
Thanks friend
Be careful tapping axles out of a hub with a hammer. It is a good idea to thread the nut back on to protect the threads and get them going with a composite hammer (or another appropriate tool) . Just want to avoid boogering up the threads on the axle if you intend to re-use them. As always, I enjoy your channel! Thanks for sharing.
Thanks for the suggestion
Another great video! Great information and entertainment! Keep it up!
Thanks Friend!
Very impressive work. Just had my ZE0 CVs removed. This video is like a guided tour! Thanks for great content, as always!
Great to hear!
Very brave cutting your existing axles shafts! Amazing how much thicker the Tesla shafts are over the Porsche.
Yes they are!
The Tesla weighs about twice as much as the Porsche, so at least some difference isn't surprising. Also, the longer the shaft the larger it needs to be in diameter, and the Tesla is wider so the shafts are long.
ive not yet seen any awd electric motors swaps ill like to see how it works! what an amazing work.
Thanks for watching!
Commendable engineering skills, really calmly impressive!
Thanks Friend!
Another great video. The youtube ads were really loud, and/or your video audio was too quiet. Had my speakers at 100% and was just able to hear you. Keep up the great content!
Noted!
Suggestion, drill a small divet in the axle to give the set screw in the collar something to bite into. 😊
Thanks for the suggestion
Oh boy! Getting closer to road testing. Continued success.
50% done with 90% to go 🤪
thanks for this video. we will need to make custom axles for ours so this was really helpful.
Glad it was helpful!
Great timing on this video because I'll be doing this on my Tesla LDU build in the coming weeks. It's really helpful to see almost the exact procedure shown here.
Thanks for the support!
Great content and presentation, Porsche and electrification are an awesome match and, with all wheel drive!! WOW
Thank you very much!
You will go though those small oxy tanks super fast. You'll need to stock them like 3:1 vs the fuel. Gets expensive. My shop teacher alwaya told me: "A before O or up you go!" (for acetylene setup)
At $14 a tank that will get expensive. That little pencil tip isn't the best either but it got the job done I guess.
If you remove 1-2 M8 sized rusty fasteners a year, that setup is OK. Anything else, go full Vic setup
Awesome and outstanding as always
Thanks again!
Nicely done🎉
Thanks Friend!
Well done... Just remember, when programming the torqueoutput of that frontmotor, that these shafts are MUCH smaller in diameter, than the Tesla Model S ones... If you go full beans on these, you will either twist the shaft or stripp the splines in the wheel bearings or both.
Thanks for the input
It's not likely that the motor could produce enough torque for that, or that there would be enough tire traction for that, but it is valid concern.
Good work, amazing content as usual. Can’t wait to see the car up and running.
You and me both!
Pleasant to watch you work. You are a master.
Thanks David!
Heck yes. nice work!
Thanks!
Great content. I really enjoy your channel.
Holy cow! Thank you for the support!
Great video!!
Thanks!
awesome🔥🔥🔥
Thanks 🔥
GREAT VIDEO ❤
Thank you!!
1) Use an impact next time. Heat is not always a good answer. 2) Count the splines, there is a good chance the tesla hub end would fit the Porsche spindle. Metric hubs tend to be even numbered MM sizes. We do this in the honda community quite often.
Diameters were quite different. Definitely wouldn't fit
Being an ME I enjoy your thought process!
Thanks Friend!
Making progress
Little by little
Awesome 😎😎😎 You are doing great 🤩🤩🤩 Keep it up 💪🏻💪🏻💪🏻
Thank you so much 😁
This is an amazing channel!!!
Thanks Friend!
The old expression is A before O or up you go. As in acetylene before oxygen so you don’t have issues. In your case as this is not oxy-acetylene its oxy-mapp it would be mapp first as you correctly said.
Thanks for the comment!
Cheers Jeremy 👍💪✌
Thanks Robert!
Very cool. I need to get axles made for C8 corvette trans to McLaren 600LT, so great to see the process!
Thanks sir!
I call that tuition. You only really learn by making mistakes. And those costly mistakes you only make once. (Usually) 😁
So true!
@@ElectricSuperCar anyway, awesome progress miste and really inspiring! Another milestone. And your welding seems to be getting better as well.😎
Agree with choosing right chair. I work from home, used to have cheap gaming chair, back was hurting me. Bought myself more expensive ergonomic chair and with right posture those problems are away. Great build, keep going man
Thanks
Next time, tell the axle shop to keep the larger diameter out past the boot... and to put the grooves in the shaft that should be there to keep the boots from sliding on the shaft.
i have one of those flexispot chairs, indeed it is very comfortable.
Nice!
This channel is just so enjoyable to watch and follow along with the build. I’m hoping that you can get more content out quickly with the 2 new builds too. Maybe you’ll be able to hire a cameraman and editor eventually.
Definitely need more money/viewers to meet that goal. Maybe one day
Do you not risk destroying the wheel bearings when using the torch? Love youre video's!
Nope. Heat is not getting that far
Thanks for the update Jeremy! Video looks good (assuming this is phone?). Audio was a bit low. Have you tried steel wool instead of tin foil? Just watched Tavarish's newest video, he bought a laser cleaner thing! Crazy.
I will check it out
Did you consider 3D printing an adapter? You could make it a clam shell and it would seal and not add any asymmetrical loading.
Interesting 🤔
Jeremy, Great job. It's so nice actually watching you film and do the work behind the scenes myself and others do to make these dream cars come true.
I appreciate that!
Hahahaha this video took me way back to when i was in high school working at my dads auto shop and my job was rebuilding axles. Still have ptsd from all the grease. Btw you should look up the correct boot because theyre all generic. So you could most likely find a boot for the porsche end and the new shaft diameter. They come in all styles and sizes. Might be able to find it at an autozone. We used to get a huge shipment of an assortment of boots. The way you put the collar might be a failure point in the future.
Thanks for the comment!
If you would like a less labour intensive approach to cleaning the rust on those axles. Get a wire wheel disk for your grinder and wear proper ppe as those needles hurt if they come off. It will clean it up fast and gives a really nice shine to it.
Thanks for the tip!
Great work and I really enjoy watching your channel. As I plan out my own EV conversion I was wondering if you could please tell me the weight (KG) of one of the complete axels? Thank you and looking forward to the next video.
They are installed. Sorry I don't know
LOL @ making your own axle but can't remove an axle nut without a torch. This is why I still have compressed air tools. Buying a 3/4" electric impact costs a mint but the air version is dirt cheap and WAY faster than a torch. The ONLY downside is they don't work at your friend's house haha.
If it was me I would have installed the half shaft to create equal length shafts. Reason for this is it stop torque steer under acceleration, it’s even more important on an AWD application.
I have equal length shafts. I mounted my motor in the middle so lengths are equal (unlike Tesla)
@@ElectricSuperCar The motor is not centred in the drive unit, so it seems likely that if the shafts are equal then the motor is not centred, and vice versa. Did you mean that you centred the drive unit?
The motor is not centrally mounted in the car. The motor outputs are positioned to be centrally mounted.
Was there a reason you decided to make the axle shaft thickness match the thinner Porsche shaft versus the thicker Tesla one?
They have to match both. Dutchman axles have the experience to know what size to make them
@@ElectricSuperCar I agree that the axle shop should be able to make this call, but in this case they got it wrong, forcing ou to add those collars. They also missed grooves for the boots, but they were not provided with the boots or locations for them. For strength, it will be limited by the thin Porsche end, so it probably makes sense to keep that smaller diameter for most of the length (but not into the boot area).
23:00 "I'm gonna need some pliers and a set of 30-weight ball bearings." - Fletch
With the collars and the boots did you put the boot clamp 180 from the set screw? Curious if that would decrease vibration. Great content! You rock!
I am not sure I paid attention to orientation
Awesome entertainment. Thank you. What interests me the most is what you'll do to make the body panels. Next video ... ask the question ... "what interests you the most ... put it in the comments below."
Don’t forget to replace those tires before you hit the road! 😅
👍
Where did you get new retainer clips? I had to buy a whole new/used Tesla axle just to get a new retainer.
EV west sells them
As soon as you started epoxying that collar on I started thinking "sure hope he measured it off camera". At least it was an easy enough fix though!
🤦
Been working the axles on the 924s this week also, nothing but work and grease. How long did Dutchman take to build the axles?
1-2 weeks with shipping
With the collars that you put in place for the CV boots; will you need to worry about vibration if they are not perfectly balanced because of the set screw?
The boot clamps will be more cause for concern as they are further away from the axis of rotation
Not sure if part store loan-a-tool program has a cv puller, but for specialty tools i always ask. Saves money buying a tool you only use a few times. You didn't mention trying the axle on the passenger side, i assume you did, but curious.
Yep, the video was getting long
Man, I really miss Miss Researcher doing the ads.
Coming soon!
I love your videos. I know you are starting your KZheadr career , but could you work a little bit on video volume level balance thorough the all video parts? First part is too silent, so I crank up volume and then I was blasted after intro segment.
Not sure if you watched my last video, but I am trying to adapt to a new microphone setup
Hope you took in account the outer diameter of your shaft due to much more potential torque....thats why the tesla ones are much havier!
Good call
Hmm .. why not weld the collar ring instead of poxy for the unique boot ??
I was worried about messing up the heat treated steel
Nicely done :) But i wonder what is written on your shirt at 30:08?
Check out my channel store teespring.com/stores/electric-supercar-store-2
Axle and you shall receive. 😇
LOL!
I think the axle needs a clip that you can put it only if you open the diff
🤔
The clip into the diff really is a use once part, they deform when you pull them out, so best to replace with new every time.
Hey the sponsored /advertisement I couldn`t hear what you were saying because the volume was way lower than the rest for the video.
You need a big impact buddy!
Yes sir! Do you know a sponsor?
Our gas bottles are left handed thread here. Nothing new to our upside down country 🤣
And do the boot clips really have to be butchered off ???? Always thought some pliers would help
The Porsche ones are not accessible with pliers
Why heat? Isn't steel shrinks when its get colder?
The expansion and contraction breaks the rust/corrosion that is causing it to be stuck
Yes, but if you heat the nut it expands, loosening it on the shaft (which isn't heated as much).
why do I have the sneaky suspicion your Axle mod is better than what I would do for my subaru brats axles HAHAHA .
LOL!
haha I was right yours didnt involve a pipeline welder
Aren't you worried that they made the axles the thickness of the Porsche ones and not the Tesla ones? I'd think the Tesla shafts are thicker because of the higher and instantaneous torque vs the gas car. I'd be worried about snapping these things.
Yes, that is a concern. I checked high hp Porsche builds and their axles seem to hold up.
Very nicely done and I'm looking forward to seeing more videos and seeing the finished product A couple of things to remember when doing welding and using gases (the flammable gas will always have a reverse thread (LPG, propane, MAP, acetylene, hydrogen)) and I always turn the fuel gas off first before turning off the oxygen
Thanks for the tips!
That's really cool. I am a welder and on large oxygen tanks the threads are right hand and propane and acetylene tanks are left handed to avoid explosions. I have never used oxygen in tiny tanks because I didn't know they existed. As far as the axles, that's very interesting and I was curious if they were the same length on both sides? That's cool you could get them made. I could enjoy knowing what it cost for custom axles. I see a lot of videos where people use CV axles for their homemade quads and side by sides. They always just cut them down and sleeve them inside a piece of pipe but your way is much better.
Go to their website and ask for a quote. I was quite surprised at the affordability
Those hose clamp pliers are finger pinchers.
Here in Phoenix, there is "Dave's Drive line" or now known as "Phoenix Rack and Pinon" and they do CV Axles and I'm pretty sure they do custom work. The do custom driveshafts, so not sure why they wouldn't do custom CV too. Amazing and very good priced work. Old school guys who know what they do very well!!
I've had them do custom work on my GTO half shafts since you can buy anything for GTO after GM bankruptcy in 08 and for my GTO over the years I've purchased a ton of eBay parts since you can't get anything new for it. I love my GTO and my C7. :)
Thanks for the comment!
I’m hurt that you ain’t believe me… I mean, you had to of on some level since you went cayman… but I told you porsche uses dummy shafts in the front hubs.
👋👍
✌️
You may have damaged your wheel bearings. It looked like you put the weight of the car without those stub hubs in. You should never put that weight on an empty bearing.
Down in front, trying to watch this. Watch your camera angle and where you stand
Noted
For algo😊
✌️
Went through this some time back. kzhead.info/sun/ir2ulcWMen2XZHA/bejne.htmlsi=IjaWmiVIy6cH8fqU The stubs are from Zero EV in the UK. They convert the Tesla spline to a Porsche 930 CV.
I will be using for the large drive unit in the rear
youtube pro tip : Always Put "Tesla" in the title of the video. it's a keyword for the algorythm.
👍
You don't need to weld, so why MAPP/oxygen instead of just propane/air? That's a very hot flame for what you're doing; it seems like an invitation to damage. Just seeing the flame pointed at brake lines while you adjust the gas valves makes me nervous. Please don't randomly guess at the use of compressed flammable gases and oxygen - people get injured that way, even with "idiot proofing" design features such as the opposite threads. If the torch doesn't come with instructions, take it back and report the manufacturer and retailer to appropriate authorities. And why resort to massive heat before just trying an impact wrench? If you don't own one, it's probably worth the price, and you can even rent them (battery or corded electric, if you don't have and air compressor) for a day.
Hot n heavy grinding on some big hard shafts with lots of lube! 😂 did I mistake this channel for your new onlyfans or something? On a serious note the gt3-E cayman is looking more and more like a real car again. Cannot wait to see this thing tearing it up later this year? On ev related news how about that lotus evija nurburgring record posted today? 3rd fastest vehicle ever around the green hell and the fastest EVER based on a production intent road legal chassis. Evs have now ended the ice age! 😎
Very nice!
I love the way you adjust the flame with it pointed at the flexible hoses what a muppet
They look pretty but look so weak. 🥹🥹🥹🥹🥹 Axles that is
Should be good enough for 300 hp
It's an AWD sports car, not an off-road truck.