I want to make adapters to run phone dial wheels from a porsche on a vw. what do you think of the design? i figure studs for the outside and bolts for the inside. the cone on bolts is a 60 degree taper right?

also what do you think about machining operations? i was thinking of turning it to get the shape, then drill the holes on a cnc milling machine. then hand tap since im too lazy to thread mill that stuff in my CAM software.

lastly what about material? aluminum 7075 is surely ideal, what say you about 6061 temper 6?

i am worried about the little bit of "meat" between 2 of the holes, that the maximum amount i could get it at ... i did a FEA analysis in PRO/mechanica and with 6061 it can supposedly take 3000lbs per wheel before that area yields. that was evaluated statically so who knows with moving loads. the car is a 2800 lb vw corrado.

im basically worried about this since if engineered poorly it could have catastrophic consequences, but i do trust physics and my engineering/fab

(btw this is my first post, ive heard honda tech guys all own TIG welders and plasma cutters ... puts my homebrew machine shop to shame :-(

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by leftychang &raquo;</TD></TR><TR><TD CLASS="quote">
i am worried about the little bit of "meat" between 2 of the holes</TD></TR></TABLE>

Bingo, same thing I noticed right away when I looked at the piece

 

why not just buy the ones from H&R? i put d90's on my MKIII and i used them.

 

does HR make them? ive been looking for a design to work off of ... but havent really found anything on the 4 to 5 conversion.

link?

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by leftychang &raquo;</TD></TR><TR><TD CLASS="quote">I want to make adapters to run phone dial wheels from a porsche on a vw. what do you think of the design? i figure studs for the outside and bolts for the inside. the cone on bolts is a 60 degree taper right?

also what do you think about machining operations? i was thinking of turning it to get the shape, then drill the holes on a cnc milling machine. then hand tap since im too lazy to thread mill that stuff in my CAM software.

lastly what about material? aluminum 7075 is surely ideal, what say you about 6061 temper 6?

i am worried about the little bit of "meat" between 2 of the holes, that the maximum amount i could get it at ... i did a FEA analysis in PRO/mechanica and with 6061 it can supposedly take 3000lbs per wheel before that area yields. that was evaluated statically so who knows with moving loads. the car is a 2800 lb vw corrado. </TD></TR></TABLE>

Post up your FEA results.

 

well all the weight is never on just one wheel, right?

but what about side loads from taking hard turns and what not....?

maybe my thinking is wrong however, because the piece is always in place(once torqued properly and evenly), and it should technically never move correct? so isn't the load always static?