3/28/06 The Driveline

Another milestone is reached. The driveline is complete, installed for what I hope is the last time.

It took three driveshafts to make one usuable driveshaft for the Caterham. Starting from the left, '79 RX-7 driveshaft - used only the slip yoke as it has replacable U-joints, fits the Miata output shaft and is small enough to fit through the Caterham's tunnel. Next is an unknown shaft found in the junk pile of a driveline shop. Used only the weld yoke from this one and it had to have some material removed via belt sander to make it fit through the tunnel. It was chosen instead of using the RX-7 weld yoke because it accomodates a 2" diameter tube where the RX-7 has a 2.5" tube. It also accomodates a standard RX-7 U-joint. Next is the original 2" diameter Caterham SC driveshaft. Used only the rear weld yoke, the yoke that bolts to the diff along with the original U-joint. On the right is the finished driveshaft, balanced and painted and ready for installation.

The ACT chromoly billet flywheel, 9 lb vs. 18.5 lb for the stock Miata unit. On the right is the Mazdaspeed clutch disk mounted on the flywheel. Note how much smaller it is than the area available on the flywheel. It is also smaller than the friction surface on the pressure plate. This is the factory clutch for the '04 and '05 Mazdaspeed MX-5 turbo engine.

Pressure plate in place and ready to transmit some power! On the right is the stackup of the flywheel, disk and pressure plate.

On the left, view from under the car showing the transmission and oil sump. On the right, a view of the left rear suspension. The diff now has a Quaiffe limited slip unit installed. This was obtained as part of a bulk buy of Quaiffe LSD's arranged by the UK Lotus 7 Club. Many thanks to John Howe for allowing me in on the bulk buy late in the game and for arranging to get it shipped to me without having to pay the VAT.

Two views of the shift lever. The mark on the bare aluminum was the desired position of the lever to match the existing shift boot on the transmission tunnel cover. Worked out just right. I will shorten the lever about an inch and use a knob whose threads go near the top of the knob to lower the knob for knuckle clearance with the dash board.

Next projects are the cooling and electrical systems.

The start of this project is here