>>      Kenneth
>>      Did a little more study of splines and find
>> that 24
>>      pitch is standard. That dictates a shaft
>> diameter of
>>      1.125 with 27 teeth or 1.25 with 30 teeth.
Do
>> you
>>      think it feasible to shape internal splines
in
>> lobes
>>      using EDM to minimize distortion and stress?
>> Also did
>>      a quick calc of torsion and find a 1" shaft
>> with
>>      active length of 8" will windup about 1 deg
>> under
>>      500#' torque. Don't know what's acceptable
or
>> if I
>>      analyzed correctly. What do you think.
>>      regards, Robert
>>
>> Robert,
>> You are correct, I don't believe you would ever
have
>> success broaching a
>> spline. I personally think persuing this method
>> would be folly. By the
>> time you have made the structure tight enough to
be
>> workable it would be
>> cheaper to turn and grind a shaft using a
>> conventional method! The fact
>> is that the e-shaft is a rather simple setup. It
>> requires that someone
>> with the proper dimensions go to someone with a
>> crank lathe and grinder
>> and pony up to get one made. FWIW
>> Bill Jepson
>
>
>
> Rolf and Bill
> Thanks for the comments. Glad to get expert
opinions
> on this. I guess if this were a viable approach it
> would already have been done.
> regards, Robert



Robert



To make a broach to press through the e-shaft lobe
and bearing adapters When
you ger your spline made the desired length get them
to make a twelve inch
long tapered spline that is .002' larger at one end
and taper the outside to
the size of the valley between the teeth at the
other end You want a 1/4"
hole through the center. Cut it into one inch
numbered sections then have it
hard cased.

You then assemble the twelve pieses in the reverse
order and put a 1/4"rod
or bolt through them. You will not have difficulty
pressing this through the
drilled out lobe or bearing adapters.

I just suceeded in pressing a 3.3" 90 tooth broach
through a 3/4"section of
a hole machined in two 12A rotors.

The shaft in the following directions Is fully
enclosed within adapters or
lobes. there is very little deflection.

It requires intermediate bearings.

Instructions for making a balanced e-shaft

For general information the spline in the clutch
disk in the 12A rotary
engine is less than a .9" inside diameter.

A Mazda e-shaft lobe has approximately a 2.92"
diameter. I guess it has
about .01" hard casing around it

With driveshaft quality steel with a ¼" center oil
hole  make a 1.182"
diameter spline with eighteen teeth the desired
length of your engine.

Make a broach the same as the aforesaid spline and
have it case hardened.

Drill out the oil hole in the e-shaft lobe
sufficiently to enable pressing
the broach through creating interior teeth in the
lobe.

Also drill holes in bearing size steel (adapters)
and press the broach
through to place them as desired on the spline in
your engine configuration.

Weld whatever end type you desire to the adapters.

It is suggested that bearing support be provided at
intermediate housings.

In a two and four rotor configuration the lobes
would be placed at 0 and 180
degrees.

In a three rotor configuration the lobes would be
placed 120 degrees apart..
Kenneth McKenzie

Kenneth
This seems like a dumb question; but what is the point
of broaching thru a rotor? Is this just a test? Altho
your technique may produce an eshaft; in view of
Rolf's analysis, it will not be up to the strength
standards equivalent to a conventional eshaft.
regards, Robert

Robert, Please place your new messages at the end of the
old messages to keep thinks in chronological order.
Save time for me as I don't have to move them
around.

Paul Lamar ...No rotor no motor.

Robert
It appears that Rolf mis read the instructions.

The entire 1.182 diameter shaft is enclosed within lobes or bearing
journals. If it is made with drive shaft quality steel the only concern
would be the wishful thinking of having sufficient torque to sheer it by
using it for a six or more rotor engine..

The advantage of the shaft is it makes a six rotor engine possible.

Kenneth McKenzie


--------------------------
Maybe! Good luck :)

Here is a picture of Hurley's but I was never able
to find out how he did it.