[The_Acid_Beaver]

He starts de-burring transmission parts, starting with his mFactor 1st gear:

Stock "root" of the tooth:



After chamfering with a cheap diamond file:



That is really all that is needed.

Another view with both chamfered and un-chamfered:



Starting on the tooth edges:



The flat, cheap diamond file I am using for the edges:



W(hy)TF am I doing this? Well, because I am anal retentive about some things. This operation will increase teh fatigue strength of the part by eliminating stress risers doing at all the edges of the part where it was machined. It will also very slightly improve the efficiency of the transmission. If I had the money, after I do every tooth on ever gear and shaft, I would have the all the internals, including the bearings, WPC treated:

WPC - Metal Surface Treatment/Micro Shot Peening/FPSP(Fine Particle Shot Peening)

I'll post more pics as I get more done. I have one side mostly done. It is slow because you have to be careful not to nick the face of the teeth. It takes patience and time. I've got both. Don't try this if you don't have either.

The really hard part is going to be trying to smooth out the Synchro teeth!

Yes, there are ways to do this with tools designed for the job, but I don't have access or the money budgeted for those kinds of tools. I'm just nuts. Ok?

For the interested, my for the transmission will be:
-4.25FD (Courtesy of Mista Bone.)
-mFactory 3.083 1st
-ZC 2-4
-Si 5th
-OEM ZC LSD
-Halfshaft and axles

If I had the money, I would also be throwing in an mFactory LSD and 3rd gear. I don't have the money for that right now. I will hopefully by the end of the year. =)

This will be coupled to my NA'ed SOHC engine, which, I finally gaining a bit of momentum on. I have the money to order the cam (Exo Stage 4), then I can figure out how far I can whack the head.

[Jesse (Fizz)]

Very nice work Beave.

[The_Acid_Beaver]

It's only a start. I've got a looooooong way to go.

[Jesse (Fizz)]

The_Acid_Beaver, on 22 March 2010 - 06:12 PM, said:

It's only a start. I've got a looooooong way to go.

Updates?

[The_Acid_Beaver]

I should have Gear-X 3/5/1 combo coming. I will likely use the 3rd, but not the 5th. Haven't touched the tranny since this. Trying to get the block in the shop next week.

[Jesse (Fizz)]

The_Acid_Beaver, on 01 July 2010 - 07:44 AM, said:

I should have Gear-X 3/5/1 combo coming. I will likely use the 3rd, but not the 5th. Haven't touched the tranny since this. Trying to get the block in the shop next week.

Sweeet. Vitaras right?

[The_Acid_Beaver]

Pfft. No. PDNs. But you knew that.

Jackass.

[gtpilot]

Acid - why just not get them REM treated? My gears came out looking like mirrors!

Kirk

[The_Acid_Beaver]

Cuz that costs money. This is free. I have looked into different treatments, and I think I would go with this one:

http://www.wpctreatment.com/

If I was gonna spend money on something . . .

[gtpilot]

Hmmm..interesting - a little bit like snake oil and shot peening mixed together ...I will have to do more research on the process.

Kirk

[The_Acid_Beaver]

It's not snake-oil. It's been around for a while. Many legit race teams use it. It makes sense, to me, from a metallurgical perspective. It's not even terribly expensive, I would just prefer to not ship a whole tranny to Cali and back. =/

[gtpilot]

Shot peening has been a serious business for reducing inherent stresses caused by machining processes for years and I have no doubt that this process can improve the surface finish/fatigue life of parts. I happen to like REM because it removes the varation in the surface finish as a polishing step...perhaps I should send my REM parts out to have this done afterwards...

Kirk

[The_Acid_Beaver]

I think both processes would be redundant. I just read more about the ISF process REM does. I think both processes yield similar results, however, I think the WPC treatment is probably "better" for gears. This is pretty subjective, though, so, I could be wrong.

I hate shipping transmissions . . .

[gtpilot]

The_Acid_Beaver, on 08 July 2010 - 07:38 PM, said:

I think both processes would be redundant. I just read more about the ISF process REM does. I think both processes yield similar results, however, I think the WPC treatment is probably "better" for gears. This is pretty subjective, though, so, I could be wrong.

I hate shipping transmissions . . .

Ship gears, not transmissions!

The REM process doesn't have the surface hardening benefit that you would get from the shot peening process - it simply removes the high points in the surface finish to get the difference between the peaks and valleys smaller. Depending on the shot size in the ISF process (I couldn't find the bead size anywhere) it would make it easier to produce an even better surface finish...more searching to do...

Kirk

This post has been edited by gtpilot: 09 July 2010 - 10:55 AM

[The_Acid_Beaver]

A whole tranny gearset is still expensive to ship. Welll, I wonder if the shafts would fit into a large flatrate box. Dang. . Thinking sucks sometimes . . .

[gtpilot]

The_Acid_Beaver, on 09 July 2010 - 01:28 PM, said:

A whole tranny gearset is still expensive to ship. Welll, I wonder if the shafts would fit into a large flatrate box. Dang. . Thinking sucks sometimes . . .

Hmmm...I never did both the shafts, only the pinion shaft...

Kirk