Re: 02M into Mk1-Outer Spline/Hub combinations? (sdezego)
List clarified and added to 3/31/08
thanks Shawn and Dave:
I am not sure what 100 mm CV hub bearing inner diameter is. I'll try to research that.
Dave, I was trying to find that earlier T4 post and was remembering "T3" ...thanks for setting me straight.
FYI for those reading in the future...Mk1 (and early Mk2??) outer CV splines are 25 mm (outside diameter) 22 spline. 02M outer CV splines are 28 mm 33 spline.
So, my current possible choices (with questions yet to be answered included) for fitting 02M outer CV splines into an MK1 are:
1. Machine 02M 28mm 33 spline CV ends to fit Mk1 hubs...but weakens 02M axle by reducing diameter of splines. And every time the CV needs changing, the spline would need to be re-machined...not a great option.
2. Machine the Mk1 HUBs to accept the 02M 108mm 33 spline outer CV. Similar machining has been completed but I need to verify the 108 mm CV will spin without hitting any protuberances on the back side of the Mk1 spindle/hub. This would result in an approximate 1.5 mm (radius) thinning of the Mk1 hub between the spline and bearing from approximately 4.5 to 3 mm possibly weakening the hub strength a bit, but bearing and spindle help strengthen the area. Likely a good and fairly simple option...ship hubs to shop with appropriate tools...pay the bill.
3. Machine the Mk1 SPINDLEs to accept the VR/beetle 02m wheel bearing and hub. Bearing hole in the Mk1 spindle would have to be bored out from 64 mm up to 72 mm outer diameter of Mk2/3 bearing, a change of 8 mm diameter (4 mm radius). I need to verify Mk1 spindle has enough space around the current bearing to allow 4 mm radius change, then also verify 02M hub and CV will spin freely on the Mk1 spindle without hitting anything. Have to re-drill 02m 5 lug hub to get 4x100 lugs. Likely a good option if all fits/works, and won't result in a potentially weakened spline to bearing area in the hub.
4. Machine 02M HUB "bearing contact" diameter from 40 mm down to 34 mm to fit into Mk1 spindle/wheel bearing, a change of 6 mm diameter (3 mm radius). Outer diameter of 02M hub bearing contact area is 40 mm and axle spline is 28 mm, then there is a 12 mm diameter (6 mm radius) difference and so about 6 mm of metal between the two. Removing 3 mm radius leaves only 3 mm metal remaining between the spline and bearing. Mk1 100 mm axle spline is 25 mm diameter and bearing contact diameter is 34 mm, so when stock there is roughly 4.5 mm of metal thickness between spline and bearing. So, net result of this approach is reducing 02M hub thickness between spline and bearing, to below that of the Mk1, But this is the same thickness as option 2 above.
5. Get 02M compatible hubs in corrado/Mk2 spindles and put these spindles into Mk1 strut/ball joint. After further research, this option is not possible without modifying Mk2 spindles at the strut mount, putting larger ball joints into the Mk1 A-arms, and possible requires use of A2 tie rod ends.
6. Verify if any T4 Eurovan axle is 108 mm inner CV and indeed has or accepts an MK1 outer 100 mm CV. This would be the easiest option but axle would be weaker than 02m due to the smaller Mk1 spline.
In all cases axle shortening will be required!!
If anyone can answer any of these questions...please post up
Modified by CrewCabCaddy at 10:41 PM 3-31-2008
Modified by CrewCabCaddy at 12:26 AM 4-1-2008
