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Last weekend at VIR I broke one axle at the diff--on inspection the other one was severely twisted, perhaps by the shock from the first one's breaking. Luckily I had spares with me and got back on the track.
In any case I found the following online and would appreciate any input or thoughts:
"A method of preventing axles from breaking is to have them `turned down' all along their length from the spline to the flange. Turn them down so that the diameter is the same as the distance between the bottoms of two opposite `valleys' of the splines. This means that instead of the twisting pressure only acting across the narrow section of the spline (and eventually causing it to break off there inside the diff), this twisting pressure will be evenly distributed along the whole length of the axle, and so it will not break inside the diff (or anywhere else)."
BTW they were Winner's Circle axles, though they are of the "old pattern" with a bolt through the end and were likely 10 years old.
In any case I found the following online and would appreciate any input or thoughts:
"A method of preventing axles from breaking is to have them `turned down' all along their length from the spline to the flange. Turn them down so that the diameter is the same as the distance between the bottoms of two opposite `valleys' of the splines. This means that instead of the twisting pressure only acting across the narrow section of the spline (and eventually causing it to break off there inside the diff), this twisting pressure will be evenly distributed along the whole length of the axle, and so it will not break inside the diff (or anywhere else)."
BTW they were Winner's Circle axles, though they are of the "old pattern" with a bolt through the end and were likely 10 years old.