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john vanlandingham
John Vanlandingham
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Location: Ford Asylum, Sleezattle, WA
Join Date: 12/20/2005
Age: Fossilized
Posts: 14,152

Rally Car:
Saab 96 V4



Re: re-splining hubs
October 11, 2010 11:38PM
Quote
Tom B
I think Brian has the right idea here.... John you got time to do some weld/machine work this week?

You talkin to me?
You talkin to me?
You gotta be talkin to me cause I don't sees anybody else around...
Youse talking to me?

Call now if you can..
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Tom B
Tom B
Professional Moderator
Location: Douche Canoe, WA
Join Date: 02/27/2006
Age: Midlife Crisis
Posts: 780

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VW Golf



Re: re-splining hubs
October 12, 2010 12:17AM
Parts enroute, I'll report when I have results.



-Tom
DemonRallyTeam | Fine Tuning | CTS Turbo & RP Turbos | RalleyTuned | JRM | Meister Autowerks
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mack73
Jason Wine
Mega Moderator
Location: Seattle, WA
Join Date: 02/20/2006
Age: Midlife Crisis
Posts: 448

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Started a Golf... Never Finished It


Re: re-splining hubs
October 12, 2010 10:06AM
Thanks Tom, I know there are probablly several people who are interested in what you find.



-Jason
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wildert
Brian Klausen
Godlike Moderator
Location: Denmark
Join Date: 03/21/2006
Age: Midlife Crisis
Posts: 388

Rally Car:
VW Golf GTi 16V


Re: re-splining hubs
October 12, 2010 10:13AM
What's the plan Stan?
VR6 stuff or some more elaborate Audi-based idea?



Brgrds
Brian

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john vanlandingham
John Vanlandingham
Junior Moderator
Location: Ford Asylum, Sleezattle, WA
Join Date: 12/20/2005
Age: Fossilized
Posts: 14,152

Rally Car:
Saab 96 V4



Re: re-splining hubs
October 12, 2010 10:59AM
Quote
wildert
What's the plan Stan?
VR6 stuff or some more elaborate Audi-based idea?

He's bringing some Nazi 5 bolt shit over and I'm going to plug weld the holes and do a new 4 bolt bolt circle på fräs maskin o sen håll tummarna för faen!

(jag håller på med en TUSEN HÄSTARs Volvo projekt med en dräng som köpte mina långa stakar till Volvo Rödmotor o fick ut 660hk, nu vill han bygga vitblock och 1000 hk+++det har tyligen knäckt hjärnan min....
1000 hk...herre gud.
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wildert
Brian Klausen
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Location: Denmark
Join Date: 03/21/2006
Age: Midlife Crisis
Posts: 388

Rally Car:
VW Golf GTi 16V


Re: re-splining hubs
October 12, 2010 01:29PM
Sounds like VR6-stuff then...

A milling machine... what luxury... I plugwelded those suckers with my 180 Amp MIG, and ground down the welds with me trusty angle grinder with a flap disc on it.
The most luxurious part of the process was that I own a very old lathe that I used to skim the welds the last bit.

For marking and drilling I had no fancy milling maching with a divider head and such fancy stuff. I used a cardboard template made with very-nears (I love that word :-)) and a pair of scissors. All drilled on my chinese crap bench drill, and then obviously hand-tapped with a tap bought on Fleabay from Germany.

Well - If I had access to a milling machine with a divider head I would have used that as well - but just to say to people that may have the need to do something similar, but are already abandoning the idea because of lack of access to such machinery: take your time... then you can do it with pretty basic tools (it can be done without a lathe...)



Brgrds
Brian

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john vanlandingham
John Vanlandingham
Junior Moderator
Location: Ford Asylum, Sleezattle, WA
Join Date: 12/20/2005
Age: Fossilized
Posts: 14,152

Rally Car:
Saab 96 V4



Re: re-splining hubs
October 12, 2010 01:37PM
Quote
wildert
Sounds like VR6-stuff then...

A milling machine... what luxury... I plugwelded those suckers with my 180 Amp MIG, and ground down the welds with me trusty angle grinder with a flap disc on it.
The most luxurious part of the process was that I own a very old lathe that I used to skim the welds the last bit.

For marking and drilling I had no fancy milling maching with a divider head and such fancy stuff. I used a cardboard template made with very-nears (I love that word :-)) and a pair of scissors. All drilled on my chinese crap bench drill, and then obviously hand-tapped with a tap bought on Fleabay from Germany.

Well - If I had access to a milling machine with a divider head I would have used that as well - but just to say to people that may have the need to do something similar, but are already abandoning the idea because of lack of access to such machinery: take your time... then you can do it with pretty basic tools (it can be done without a lathe...)

Joooo vissst I am lucky between Bob's machine shop which I have the key and full access to and Kevin Hawkinson aka Kevi HÃ¥kansson aka Kevvi Hoikansainalainenen with the nice dual shield (flux and gas) soooooo clean to weld and then zip zip on the nice lathe, then zing zang on the mill, lucky!


Men du drängen, you hainät using BOLTS are you?

You donät want to convert to studs???
Have you seen the nice M14 studfs i use on everything I can get my hands on?

Theyäre really lovely and fast and a huge amount stronger---Fau Vee motorsports used M14 studs, why donät you?
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wildert
Brian Klausen
Godlike Moderator
Location: Denmark
Join Date: 03/21/2006
Age: Midlife Crisis
Posts: 388

Rally Car:
VW Golf GTi 16V


Re: re-splining hubs
October 12, 2010 01:46PM
Quote
john vanlandingham
Men du drängen, you hainät using BOLTS are you?

You donät want to convert to studs???
Have you seen the nice M14 studfs i use on everything I can get my hands on?

Theyäre really lovely and fast and a huge amount stronger---Fau Vee motorsports used M14 studs, why donät you?

Well - yes and no... :-).
I have some 20 mm. bolt-on spacers at the front to be able to fit my 11" brake setup under my preferred wheel: ATS Cup (got a bunch of those - pretty strong, good offset, fair price).
Those bolt-on spaceres use... bolts.... :-). And normally you're supposed to use your regular bolts to get the wheels on.
But I converted the spacers to use studs (did milling on the lathe by the way - bit of magic to clamp the spacer in the lathe, and hey presto...) - they are nice M12x1,5 (which is stock) press-fit from... what was it? Rally Design I think - UK shop anyway.
Nice hard suckers, but obviously M14 would be stronger.

Then again: I have never ever broken one in 8 years of running either bolts in the beginning and now studs. But I'm also very careful with torque and using centering rings.
If I was to convert to M14 I'd have to redrill all my wheels. Very doable, but doesn't seem worth it to me. I have other things that are more in need of bulletproof-ness, and then I always prioritize seat time too.



Brgrds
Brian

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john vanlandingham
John Vanlandingham
Junior Moderator
Location: Ford Asylum, Sleezattle, WA
Join Date: 12/20/2005
Age: Fossilized
Posts: 14,152

Rally Car:
Saab 96 V4



Re: re-splining hubs
October 12, 2010 01:52PM
Quote
wildert
Quote
john vanlandingham
Men du drängen, you hainät using BOLTS are you?

You donät want to convert to studs???
Have you seen the nice M14 studfs i use on everything I can get my hands on?

Theyäre really lovely and fast and a huge amount stronger---Fau Vee motorsports used M14 studs, why donät you?

Well - yes and no... :-).
I have some 20 mm. bolt-on spacers at the front to be able to fit my 11" brake setup under my preferred wheel: ATS Cup (got a bunch of those - pretty strong, good offset, fair price).
Those bolt-on spaceres use... bolts.... :-). And normally you're supposed to use your regular bolts to get the wheels on.
But I converted the spacers to use studs (did milling on the lathe by the way - bit of magic to clamp the spacer in the lathe, and hey presto...) - they are nice M12x1,5 (which is stock) press-fit from... what was it? Rally Design I think - UK shop anyway.
Nice hard suckers, but obviously M14 would be stronger.

Then again: I have never ever broken one in 8 years of running either bolts in the beginning and now studs. But I'm also very careful with torque and using centering rings.
If I was to convert to M14 I'd have to redrill all my wheels. Very doable, but doesn't seem worth it to me. I have other things that are more in need of bulletproof-ness, and then I always prioritize seat time too.

Maybe I'm just spoiled from the wonderful and superior in every way Saab 96 I rallied for so long cause original was first a BIG 170mm bolt circle so the wheel exerts less leverage on the bolts, then the 5 bolts themselves were 9/16 tum which is 14,3mm, extra strong so when i went down to 4 on 4.5" bolt circle so i could use the 9 real Minilite wheels I got for under $150, I was way concerned about reducing both the number and the size of the stud so i used the VW bus sized aftermarket VW studs...
Hmmmmmmm Mongo like M14, M14 goooooood...
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Tom B
Tom B
Professional Moderator
Location: Douche Canoe, WA
Join Date: 02/27/2006
Age: Midlife Crisis
Posts: 780

Rally Car:
VW Golf



Re: re-splining hubs
April 10, 2011 07:05PM
So, this took a bit of work, but it is starting to come together relatively well. Ran into trouble with the hubs fitting right first off. The rotors wouldn't fit on the hubs, so they had to be turned down on the OD. Then, I get everything installed today and I find that while everything bolts up and the brakes fit on, the caliper carriers were touching the rotor. The caliper carriers need to be milled about 2.5mm on the mounting flange to fit properly on the bearing carrier, this is all because the hub face itself is about 2.5mm further out than the factory hub. Also I'm having a wheel fitment issue with the hubs as well, so I need to figure that out still.

Other than that, the bearings, bearing carriers and hubs work together well, everything seems to be rotating freely and well.

While staring at everything rotating I saw how warped my rotors are after 2.4 moderately attacked rallies, and that worries me about the next thing I'll need to upgrade....BRAKES!

Seems to me that if I were starting from scratch on this I would either drill and spline the mkII standard hub (unless I had machines to help me that I knew how to use and were cheap) or find the VR6 plus suspension stuff, use all four corners and go from there, then buy 5 lug wheels to fit.



-Tom
DemonRallyTeam | Fine Tuning | CTS Turbo & RP Turbos | RalleyTuned | JRM | Meister Autowerks
Spitfire EFI | Product Apparel | JVAB Imports | NLS | AP Tuning | USRT

Add us on Facebook | Next Event: 2013 Olympus Rally June 22-23 Olympia, WA
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mack73
Jason Wine
Mega Moderator
Location: Seattle, WA
Join Date: 02/20/2006
Age: Midlife Crisis
Posts: 448

Rally Car:
Started a Golf... Never Finished It


Re: re-splining hubs
April 10, 2011 11:05PM
Damn that sucks Don. Hoped it would be a much easier fix with the redrilled hubs....



-Jason
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