m R g S r

I need to find out what material these polaris ATV axles I have are made out of. We contacted polaris, they said contact your dealer. We called a few dealers, of course they gave us the run around.

Anyway to test the metal to find out what it's composition is? or what treatments they went through? I need to extend the axle about 10" and was going to do so by boring out some stock so the axle will slide in, possibly key both then weld. Or just weld. This needs to transmit, from my friends calculations, around 525 ft. lbs.

BMCRace

Alot of offroad 4x4 axles for jeeps and stuff are made of 4140. When we get around to finishing off my datsun 240z setup and someday in the further future my s2k we will custom build our own shafts out of 4140 as then heat treat them.

-James

BMCRace

Check out dodge viper Gen 1 and 2 axles they are welded tube axles Heck Corvette C4 Axles are aluminum u jointed same style


You shouldn't have to worry so much about the welds, just be worried about keeping them as straight and balanced as humanly possible those should be your biggest concerns.

-James

m R g S r

so you think its safe to assume they are 4140? any special welding tips or tricks for welding 4140? i know it needs to be preheated. but i don't have an oven that will go to 700deg.

it's a low speed off road vehicle, for SAE baja. around 35mph max.

BMCRace

To properly weld it you need to pre heat and post heat it just like welding normal chromoly 4130.

I will say though that the company I had programmed and operated their robot which welded chromoly upper and lower control arms did not bother with all of this though, these cars had to meet dot approval and never once had there been anything wrong with them, we had used normal ER70S2 Mild Steel Welding Wire. These cars were mainly meant for offroad uses http://tomcar.com/ infact the UK had ordered alot of them while things were getting a bit hot in Iraq last year as they outfit them for military uses as well.

It is always bad to assume as we all know it will make an *** out of U and ME but being with the material properiets of it and its price it woul be the most economical way for the company to produce a high performance axle.

-James

SD_Lurker

iTrader: (4)

My yamaha banshee's axle is steel, and so are the after market extended ones.

DESTROYER

lsracing.com

88Hatchy

Thats a lot of torque for such a small engine. You sure this is correct?

I think two woodruff keys per socket plus welding should be enough.

Dee

Motor derived torque is not the issue with ATV's. With the ATV's you are concerned with the axles bending or breaking due jumping or just the forces placed upon the axle while riding on rough terrain. Many utility ATV's weigh 530lbs+ while the sport models can be as light as 350lbs (older 2-smoke models).

m R g S r

we are using an IRS so the axles aren't really bending when hitting a jump. the trailing arms are taking the impact.

m R g S r

he could be wrong, but i glanced at the calculations and from the reduction from the CVT, the transmission and the sprockets, it looks about right.

turbo8thgen

i had a guy bring in an axle a while back off of a brute force to c if i could make some extended ones. i checked the hardness on it n it was at 56 hrc. quiet a bit harder than ht4140. ht4140 is usually around 42-46hrc. i had quoted making those out of d-2. u have to get d-2 up 1850 deg n hold for 2 hours. thatll usually get the hardness around 56-60 depending on the cooling process. too hard tho n its just gonna snap. never got the chance to do the axles cuz of coarse he wanted 1 set n didnt want to pay what i quoted him.lol

88Hatchy

CVT transmission are great a multiplying torque but don't usually apply it abruptly. Torque spikes usually happen on a launch or when you get air. BTW have you looked into machining a set of axles out of stock. Splines are pretty easy to cut.

KFMRC

Are the factory axles forged with the ujoint yokes? Are they straight shafts with splines on the ends that go into CV joints. A pic would help of the originals.

m R g S r

straight shafts with ends that go into the CV's. we wanted to try this option first because our machining capabilities at my school suck. if the welding option doesnt work out, we will get some stock like you said and have the ends machined.