The Nonsensical ramblings of a lunatic mind....

[Master Hack]

So the naughtagator has served well, until it stopped. The input shaft to the transaxle stripped, due to poor engineering and poor workmanship.
So the skunkworks division has copied someone's good idea in the quest for a more permanent fix. A Lovejoy coupling is whats needed but there is no room for one. The sharp thieves er ahhh I mean engineers came up with this. It allows for some wiggle room yet provides a solid coupling between the engine and transaxle. So what does this have to do with a normal Kart? You may ask. Well the answer is nothing. It may be one of those things that you young'ns might remember some day when ya need a coupling, however. If not, well ya ain't lost nuthin!
Credit for this idea goes to Someone...

 

[Whitetrashrocker]

Good out of the box thinking.

Can we get some carnage pics?

 

[Master Hack]

Pics are purdy underwhelming it’s only a 5/8 splined shaft that is no longer splined. Repair and reassembly begin tomorrow, so l’ll try for a few pics.l heard there some kinda big game on TV tomorrow so that might be a good time to seek therapy in the shop.

 

[Denny]

That’s one of those slight mis match couplers. Where the shafts don’t exactly line up by a few thousandths. Excellent solution Terry.

 

[Master Hack]

That’s one of those slight mis match couplers. Where the shafts don’t exactly line up by a few thousandths

Zackly!
Worked on this thing for a few hours today and didn't remember to take pics until
l was done. Maybe tomorrow, maybe not.

 

[ezcome-ezgo]

You had me at lunatic.

 

[Master Hack]

I worked for a few hours and got this thing mocked & tacked. I remembered to take pics. Well, I remembered to take A pic, after I was done.

 

[bob58o]

Cool stuff. And this reminded me that I wanted to ask about a specific type of bearing. They used to sell 2-speed automatic “transmissions” for minibikes using 2 clutches and one sprag / one-way / over running sprocket.

Are there any cheap solutions for someone who can’t machine to find a sprocket carrier with oneway bearings inside? When I looked before, it seemed like “hub” needed for the size and HP required for karting, costs way too much.

The finished “one-way clutch” would probably be something like 5/8 or 3/4 shaft, #420 chain, maybe 20T on the sprocket? Rated for 15-20 HP… Freewheels in one direction. I don’t really know how many teeth it would need. I’m too tired to math. Really just looking for the “hub” that I could attach a sprocket to.

https://www.parduebrothers.com/minibike/twospeedminibiketransmission.pdf

 

[Master Hack]

Are there any cheap solutions for someone who can’t machine to find a sprocket carrier with oneway bearings inside

Not that l know of, but l have'nt played much wiffem.
that looks like a purdy cool idea. I'm curious how well they work.

 

[ezcome-ezgo]

Holy smokes, an "overrunning clutch" that can handle significant torque is over $1300 on McMaster-Carr.

 

[bob58o]

Holy smokes, an "overrunning clutch" that can handle significant torque is over $1300 on McMaster-Carr.

That’s probably what I was looking at before. What’s the cheap option? Bicycle parts?

 

[ezcome-ezgo]

I would assume the China version of McMaster-Carr, if there is such a thing.

 

[Master Hack]

I don't know anyone that would spring for dat.
Cheap options end up in the trash.
Back to reality and cheap parts.
I read somewhere that sprockets should line up in the same plane so while contemplating how l might do dat, another stroke of genius hit.
That laser thingy i used to hang pictures...

 

[ezcome-ezgo]

Cool. Very techy.

 

[Denny]

OOooo! Fancy!

 

[Master Hack]

I know! We're always on the cutting edge here at MTL!
Listen in to our podcast and subscribe to MTL news, for more exciting tips and tricks from the MTL Skunkworks.
you'll know when ya found us, cuz our tips & tricks usually stink!

 

[Master Hack]

Today on MTL Workshop, we finish Rev. #95841B the transaxle input shaft malfunction.
l have been waiting on a 1/4 inch end mill to arrive.
all that was remaining is cutting a keyway in the jackshaft.
so without further BS, here are the action photos.

This is the process of cutting a key on yer shaft.
Get an end mill of the appropriate size and take .025 on a pass.
the keyway is only half the depth of key stock yer using.
there is math involved, so it can get purdy complicated.
the formula is Kw/2=depth where Kw is the width of the chosen keystock.

it is helpful to have a machine such as a mill, but a drill press and a "mill table" coupled with a little creativity will get the job done.

link to table

You are being redirected...

these are usually purdy poor quality, but keep em tight and they are OK.

here you see our Ace machinist on the final pass.






then it was on to final assembly.
here you see the jackshaft complete with overhung load, just like l say to avoid.





Final assembly is done, it works, the end!

 

[Functional Artist]

Nice solution