I hope that you can help.
A good friend of mine has a VW split screen van that he has shoehorned a 3.0L V6 renault engine into. He is having problems with the driveshafts which he is making up from 2 existing shafts to suit. Essentially, he is trying to join one half of a renault 25 shaft to the other half of a VW shaft. He is planning to join the shafts by machining both to a common ID with a leading taper and then plug welding them into a machined sleeve.
His concern is ensuring that the welded joint is strong enough to withstand the applied torque and that the shaft balance is ok.
Has anyone out there got any advice?
Our plan was to evaluate the plug welds in shear and add a safety factor. What sort of factor would be appropriate?
Should we consider fatigue? if so, how?
Should we treat the weld as mild steel for its yeild stress?
What about hardening?
I hope you can help. If we can sort this out he will have a crazy van.