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Update: That small q-factor bottom bracket is to be bonded into a frame and not welded so the smooth finish wasn't going to help in that regard. Clearly it needed to be knurled and that's an opportunity for more tools. :cool: A budget (£13.99) knurling tool arrived last night at 8PM via Evri...

Found this online today..... "Now you tell me!" But of course when you only have 22mmm of shaft between the bearing faces, that's no so easy to do. I think what we have is as good as it can get W/O a proper engineering machine shop and its costs. :)

Good to know.

TBH, I would just write the vehicle off because I would never trust that it would have the same strength as an original shell/frame without repairs. Who is to say that the repaired areas will not just "pop" right off the base shell or that cracks that did not show before are not in the shell you...

Ok I leant on it to the point where I was concerned that "If" it failed I would faceplant myself onto the floor, but it did not fail. As I have enough "broken-bits" already I decided that I need a better testing method. The only other way I can test I think is to have a sling over the bar and a...

Well its is 2mm thick and the plugs are 10mm diameter and c. 6mm deep, so it got a good "melting". ;) But if it fails the gorilla test I shall look rather foolish.

Hello Sportsfans.... :) Today I fired up the electric-glue pot and filled those two holes in the outer sleeve and axle core. My goodness the whole centre inche of the axle was shining orange after each puddle had been stirred. :) As before it doesn't look at all pretty, but I am hoping it will...

I forgot to regale you all with what happened to me in the Mini on Saturday. It was VERY exciting. I was storming up a local hill (just for fun and to let the Mini stretch its legs a bit). I got to the top where it drops from 60mph to 40, then 30 and took my foot off the throttle but she kept...

As I said above (and sorry for the thread hi-jack Paul) I have milled 2 holes through the sleeve and down into the core material of the axle. There is an awful lot of case-hardening on that axle that you have to chew through. Here is a picture of one of the holes. The simple idea is to puddle...

OK, so, well, err, ummmm...... I made another sleeve, whacked the amps up to 100 and plug-welded both holes. Did my best to run a complete weld all around the ends of the sleeve tying the sleeve to the bearing seat webs. I put the end result back in the lathe to square up the bearing seats etc...

Neither am I...... or so it seems. My little TIG only goes up to 160A. I do too. It's like putting pegs into the thing.

I had thought to push the amps to 90+ for the plug welds. Not sure I can do that for the thin 1.5mm wide bearing seats though because they will just disappear. Another thought was to do all this and then.......... [pause for dramatic effect] at 90° to the initial plug welds put 2 more...

Ahhh... but they are very wild, inaccurate and preposterous guesses which is a specialty on here. ;) Actions taken today: Trim the centre sections minimally to ensure a consistent diameter across both and chamfer the ends. Make a new joiner sleeve/tube that is a snug (tap it on with a light...

We don't wash our dirty linen in public, only our successes. ;) The "plug" failed to bond with the axle, there was minimal/no decent penetration. A fine line of bright weld was visible adhering to the ends of the axle halves.

The hole was 8mm and I did have the inner/bottom surface glowing bright orange and I thought I had "stirred it around" with the tig flame before introducing any filler. Oh well, I shall go another route.

Yes, I think they are hot forged and "stamped" out as blanks and then have the bearing mounts machined and the ends drilled and tapped.

OK, I can think of 2 ways to resolve this. Use raw steel stock like Brad did, or don't weld it put a keyway in to join the 2 halves and put it in a cut-down BB-shell with screwed-in end-caps. :)

Yup, I get that completely. I have destruction tested it and it failed far more easily than I had anticipated. But I was whaling on it with my 200# on a 2 & 1/2 foot extension tube. :)

Thinking about this a little (not a lot) it seems to me that a "shock-load" like hitting something with a large mass might not be the best test. In a recumbent application the rider is not "standing astride" the opposing pedals he is pushing/pulling the pedals against the forces of...

Well you have me worried now. :( I don't want to injure anyone.