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#41
1st August 2017, 02:15 PM
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I did think about casting some but then I found the skoda ones and they just need a simple adapter. And I thought I'd my time and money would better spent doing something else. It would be nice to get some Cnc'd up but who would ever see them? My MOT man is very hard to impress! Many people on the Internet are making them out of steel they look great too.
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 2002 S8 silver with black half leather 2000 d2 S8 in Racing green pearl, RS4 manual gearbox, 2003 A4 avant TDi 1997 Volvo V40 2.0T 1992 Mazda eunos v spec 1976 Reliant Kitten 1965 Porsche 911 
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#42
20th August 2017, 04:59 PM
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Hi I've made some temporary steel gearbox adapters, (just until i see my neighbour and borrow his 4 jaw chuck to make some nice alloy ones) but they could stay on permanently. this has allowed me to check my drive shaft lengths 635mm and 675mm total including the splines, but so far I've not found any the right lengths.
I'm going to try A8 parts JR driveshafts any ideas who else to try anybody? at the moment i don't want order custom shafts until I'm convinced there is no alternative. the n/s is very close with some A4 A6 shafts. does anyone know of any good online websites/catalogues that have the lengths. cheers Dave
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2002 S8 silver with black half leather 2000 d2 S8 in Racing green pearl, RS4 manual gearbox, 2003 A4 avant TDi 1997 Volvo V40 2.0T 1992 Mazda eunos v spec 1976 Reliant Kitten 1965 Porsche 911
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#43
22nd August 2017, 11:49 AM
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Nice work
 good to see its moving forward.Are the driveshafts you need longer than most stock ones? Have you tried something like Audi Allroad, they are supposed to have long driveshafts due to raised suspension. Are the rear shafts off a A8 D2 too long?
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#44
22nd August 2017, 08:59 PM
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Hi Goran yes longer, I've not found the allroads length out yet. i'm not sure about D2 rears if the splines fit. maria is having a look through the shafts in stock for me.
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2002 S8 silver with black half leather 2000 d2 S8 in Racing green pearl, RS4 manual gearbox, 2003 A4 avant TDi 1997 Volvo V40 2.0T 1992 Mazda eunos v spec 1976 Reliant Kitten 1965 Porsche 911
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#45
27th August 2017, 09:47 PM
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maria from A8 parts very kindly checked there stock but unfortunately none are long enough. I've ordered a rear d3 shaft so i can pull it apart and measure the actual shaft and splines. I'm still not happy about having to goto custom shafts for various reasons.
i see this as a second best option due to excellent quality of the A4 B7 shafts i thought cut one up to see how it was made as its hollow and has several different wall thickness down its length. it has a weld at one end so i could make one longer shaft out of 2, use a 25.4mm tube inside weld the join then slide a 32.4mm id CDS collar over the top staggering the weld so it is welded in 3 places. even if the weld broke the shaft can't flail about, it would just lose drive. obviously i,d like to use genuine audi shafts but at the moment i can't find them. I'm sure out of all the cars that the massive vag group make some must fit. but at the moment it's holding me up and i want to move on.
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2002 S8 silver with black half leather 2000 d2 S8 in Racing green pearl, RS4 manual gearbox, 2003 A4 avant TDi 1997 Volvo V40 2.0T 1992 Mazda eunos v spec 1976 Reliant Kitten 1965 Porsche 911 Last edited by awolfinsheepsclothes; 27th August 2017 at 09:50 PM.
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#46
27th August 2017, 09:54 PM
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Those shafts are interesting - never seen them hollow all the way through before. Usually they're a machined stub friction-welded in to a tube.
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#47
27th August 2017, 10:24 PM
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Thats what i was expecting or maybe hoping to see! but when i cut them in half (in length) the tube was too thin so i had too investigate. i thought i might be able to cut the ends off clean them up in the lathe and weld or friction weld a new pipe in. (if friction welding is available for one-off) these aftermarket shafts would be simple to lengthen.
I'm just looking into using 2 small brembo master cylinders for the clutch. next to each other like a bias pedal box but fixed. s8 manual master cylinders are like hens teeth and expensive.
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2002 S8 silver with black half leather 2000 d2 S8 in Racing green pearl, RS4 manual gearbox, 2003 A4 avant TDi 1997 Volvo V40 2.0T 1992 Mazda eunos v spec 1976 Reliant Kitten 1965 Porsche 911
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#48
27th August 2017, 10:47 PM
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I've got a D2 master cylinder if you want a look at one. Its a pretty awkward shape though, not easy to integrate. That Brembo one looks much easier to work with
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#49
28th August 2017, 06:47 PM
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yes a couple of pictures would be nice thanks, but i'll probably go with the brembo with genuine S8 manual parts becoming unobtainable.
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2002 S8 silver with black half leather 2000 d2 S8 in Racing green pearl, RS4 manual gearbox, 2003 A4 avant TDi 1997 Volvo V40 2.0T 1992 Mazda eunos v spec 1976 Reliant Kitten 1965 Porsche 911
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#50
30th August 2017, 02:38 PM
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Dave I hope you find the right drive shaft, its frustrating for us too we want to see it running! Any cheap Allroad shafts of ebay.de?
Definitely don't bother with the D2 master cylinder, it won't fit into the RHD pedal box, and would be difficult to integrate into a custom pedal box. In my design I used an off-the-shelf A4 metal master cylinder, cant remember if it was B6 or B7. It was only around £100. For that master cylinder a custom bracket was needed which can be bolted (or welded) onto the existing RHD pedal box. Also the design used an A3 over-centre spring. The Brembo master cylinder looks good too.
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