Differential Output shafts

[RickyRacer]

I was wondering if anyone has attempted running aluminum output shafts from the differential and aluminum drive axles with any sucess.

[RickyRacer]

I was wondering if anyone has attempted running aluminum output shafts from the differential and aluminum drive axles with any sucess.

[MikeWaggoner at UW]

I ran the numbers once and it seemed impossible to fit aluminum in the space, particularly considering the small size of diff/cv openings. I think to be possible you'd need steel-aluminum-steel.

[Denny Trimble]

Someone forgot to heat treat our output shafts before we ran the car the first time (4340), and they yielded within 2 hours, due to shock loading in the braking direction.

Aluminum is more efficient if you can make the part dimensions larger (i.e. Cannondale bike frames), and steel is more efficient if you're constrained by a certain OD.

[Sam Zimmerman]

We have a similar story to Denny's so just read his post again. http://fsae.com/groupee_common/emoticons/icon_smile.gif