Neil Ungar had a great idea. He welded a section of square tubing on
 a plate and filled the empty volume with liquid  polyurethane.
 Polyurethane is a very tough flexible plastic used in race car
 suspension bushings.

 I incorporated it into a 1.5 inch diameter hollow gear box input
 shaft. Now one piece.

 The aluminum spacer Neil used is made longer and a star shaped cavity
 is NC milled into it. Since you MUST use six metric screws to bolt to
 the counter weight a star instead of a square shape can be larger in
 diameter reducing the stress on the Polyurethane. The input shaft is
 made from a bar of steel machined on a lathe and then the small star
 is NC milled on it.

 Most input shafts are one inch in diameter. The advantage of the 1.5
 diameter shaft is it is easier to assemble the large  gear box
 adapter plate and the sun gear fixing to the shaft is much, much
 stronger. Dave Leonard had trouble with the sun gear pins shearing
 off. This uses 10 extended point set screws instead which Chris
 Hoskins is using.

 Of course all this is hindsight based on 17 years of the news
 letter. If it can be failed some one on here will fail it :-)
 ------------------------------------------------------------------------------------



I forgot to show the essential helical sun gear thrust bearing.

 Here it is

 Ross, Tracy, Perry Mick and others  failed the built in Mazda
 e-shaft thrust bearing by not accommodating this force in the gear
 box.

 Two are used back to back to reduce the RPM the thrust bearing is
 subject to. Each bearing rotates at half e-shaft speed. Needle
 bearings do not like RPM.

 Again the reason for the extended point set screws is you need a way
 to assemble this with a one piece input shaft. Other wise it won't
 fit through the oil seal located in the large adapter plate.

 The other larger thrust bearing is for the prop thrust.

 The devil is in the details.

 Paul Lamar




 Hi Neil, How do you hold the ring gear into the housing ? is it a
 press fit ? do you use any loctite ? 648 retaining compound or
 something ? Cheers Chris Hoskins.


 Chris,  At this stage the first unit has the sprag gear to hold the
 ring gear as per Tracy's.  However the next one will be a close
 tolerance slip fit  held with loctite and 8 extended point grub
 screws.  The grub screws were Paul's idea and I like that addition.
 The second one will be ready for testing within a month, (hopefully)
 Neil Ungar

Here are some pictures to illustrate why.

Paul Lamar


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