DMoneyAllstar wrote:
Any idea on how much the EDM costs?
Would be nice to see what it'd cost to build a set of axle adapters for the stock FL350 box. Would have internal Honda-25-spline, 2 holes for the axle retention, and then perhaps a type-2 VW axle (or some other popular/cheap CV). Its basically what Methodical and I have been playing with recently. Also wonder what EDM costs vs. what jknarfal had done with the shaper (?) on his alternative output shaft.
Would be slick to have an adapter like this...
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Or even one like this where you'd use the stock Honda Oddy/ATC rear wheel hub (with retention bolt holes added) and then use an adapter plate like this...
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From what I've been researching, EDM cost depends a lot on setup and machine time. EDM in generally is very slow and speed is measured in square inches per hour (accounting for depth of cut). Some people quote by the amount of area needed to be cut, so that's the total distance traveled by the wire times the depth of the cut. So cutting the external profile of large gears is going to cost much more compared to tiny gears. If you can provide the shop with the spline specs, or the mating shaft and center distance, they can be up and running the machine in short order. Other than for tiny gears, a shaper will probably overtake the wire machine by the 2nd or 3rd part. Unfortunately, Honda seems to use non standard splines, such as a 37.5 pressure angle on the CV shafts below.
From machinist forums, I found that depending on the machine, you're looking at about 0.075" per minute (newer machines may go 3-4 times as fast). So you can probably get a rough idea of cost incurred due to machine time based on the speed, the total area to cut for both roughing and finish passes, and $80.00 per hour. Factor in setup and programming time on top of that.
In addition to those four inserts, three spool gears were sent to have internal splines cut to meet up against a Can-Am shaft (the axles use a custom length shaft in addition to the inboard Can-Am and outboard Foreman 450 CV's). So for a total of 7 items with 2 different setups (both CV's have the same spline data), the value was a few hundred dollars.
That first adapter would be relatively easy to do (assuming you were only doing the splines), and for a set of 2, I'd imagine you would come in around a fraction of that cost. If you were mass producing them, I'd imagine investing in a custom broach would be nice.
I'm not quite sure how the second adapter would be used. Could you explain a little more?