Talk Morgan Forums Community Vehicle Talk (non-Morgan) M3W Homebuild

The major O.D. is turned down in the lathe, then it's off to the mill. The mill has a rotary table with indexing plates that accurately divide 360 deg. into the number of required splines. (32 in this case so 11.25 deg/index) The fit is achieved using thread wire gauges and a lot of measuring.

Yes, keep up the good work.

Got to work today on the flanges for the intermediate driveshaft. I had just enough material to make both flanges on the lathe. Now I will make the program for the mill to drill the bolt circles and mill out the pocket for the bolt heads. The tap is on order and I should have it Monday so the goal is to finish them up by then. All that's left after that is to machine on the intermediate driveshaft is a spacer/washer to lock the one coupler in place. Then it's heat treat and final assembly.

The next major assembly to work on is the intermediate housing.

You could have 3D printed the entire car!

https://drivetribe.com/p/the-czinge...ouELWMHINmpsA?iid=dbBsSDX2SeSx687JrMvTYQ

Thanks for another fascinating update

LOL my printer is't nearly big enough. 3D printing (FDM in my case) has it's place though and there will be 3d printed parts on mine.

I got the crankshaft adapters finished up except for tapping today. These are the last parts of the intermediate driveshaft to be fabricated.

This is outstanding. Conceiving such a project is admirable in itself, even more so having the courage to get on with it in real life. The speed of your work is also impressive, so many DIY projects tend to slow down or even halt after a while. Your skills as a designer and craftsman are the most impressive I have seen on this site. And I am extremely grateful for your generosity in photographing and describing your work as it progresses. Good luck with the continuation!

Thanks for the kind words. I am sure the speed will slow down a bit once the drive line is complete as I will have to then fabricate a frame building table and start figuring out the framework. I have wanted a M3W for years and am determined to have a version of one. This project I figured would take between 2 to 2.5 years to complete, hopefully with a rolling chassis by this fall. The whole vehicle has to be built, then tore completely down for paint,powder coat,and to do some work to the engine and transmission. Then it will be re-assembled for the final time and put on the road.

been a while since last post. I finally got around to milling out the adapter plates for the intermediate housing. I made a little boo boo on the BMW plate but it's cosmetic and I can fix it so no big deal. They fit well and the next step is to finalize the length of the hex tube and machine it.