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Old 02-13-2008, 03:55 PM   #10 (permalink)
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I just looked at the escort site again and noticed that there was a whole page dedicated to the failure. I'll have to talk this over with some of the guys at work. Its nice to have experts around.

The actual modification hopefully won't be too horrible. I'll have to bore out both of the 2nd gears, turn the teeth off of the 5th gears, and then press them together. Pretty much exactly what they did in the escort article. Luckily I work at a gear manufacturer and I can get access to machinery, or find someone to do it for me (more likely). I also have access to liquid nitrogen and heating equipment to press them together with a tighter interference fit. I don't know yet if any welding will be done, however I would like to stay away from it mainly due to the heat treating of the gears. I also got some tips from our FEA guy at work on how to get better interference fits with more evenly distributed stress so the fit won't fail as quickly.
Current project: A better alternator delete
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