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Discussion Starter #1
After finishing a skid swap, on my Powder Extreme, I discovered that I have a bent track shaft. Blast!
[attachment=141798:powder_Skid_Rear_e.jpg]
Good thing that I caught it because cracks have developed radiating from the bolt holes on the speedo side.

Question is, does Cat make a larger flange? Perhaps one with 3 or more additional bolt placements? About an inch or so larger would do the trick.
[attachment=141799:Bearing_Retainer_e.jpg]
I thought about having the welded. But getting both sides flat, for proper bearing interface, would be extremely difficult given the space to work with. Don’t really think this is way to go.

Plan is to drill small holes at the end of the cracks(to stop them from getting longer), JB Weld the holes (and try to force some into the cracks) and either buy or fab some larger bearing retainers.

Of course, I’ll be picking up a new Track Shaft tomorrow, if the prop shop can’t true my existing one.

Let me know what you think about the plan. And if you know a source for larger flanges.

Cheers.
 

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Drive shafts have been known to break. Not sure I would want to use one that's been trued.
 

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Discussion Starter #5
I did pick up a new shaft today. Truing the old one scared me too. My bearing flanges have been enhance with one inch tabs on the flats. Now I have 6 bolts vs 3. Three tied into fresh meat and 3 to stabilize the compromised tunnel. I'll post pics if anyone's interested in what I did.
 

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<div class='quotetop'>QUOTE (FrozenTows @ Dec 16 2009, 06:02 PM) <{POST_SNAPBACK}></div>
I did pick up a new shaft today. Truing the old one scared me too. My bearing flanges have been enhance with one inch tabs on the flats. Now I have 6 bolts vs 3. Three tied into fresh meat and 3 to stabilize the compromised tunnel. I'll post pics if anyone's interested in what I did.[/b]
I'd be interested to see the pics. It's a good idea. Probably a market for them too!
 

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Discussion Starter #7
Here's what I'm hoping will do the trick. I took my stock flanges


[attachment=142111:Flange_Stock_e.jpg]


and added one inch tabs on the flats.


[attachment=142112:Flange_Mod_e.jpg]


Here's a dry fit shot of the clutch side


[attachment=142113:Bearing_...Clutch_e.jpg]


and one of the drive shaft side


[attachment=142114:Bearing_..._Track_e.jpg]















I drilled 1/16" hole at the end of each crack in an attempt to prevent it from growing longer.

The holes and cracks have been filled with JB Weld. The modded flanges are now painted black.

I hope to have it buttoned up this Saturday. We'll see what a season of riding will bring to this set up. At this point, I'm pretty optimistic. Thanks for the great site. Merry Christmas!
 

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FrozenTows,

Now that is the Cats Ass for a great fix...Clap
 

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Discussion Starter #11
The tabs were welded, to my existing bearing flanges, with plain Jane mild steel. Can't remember the gauge, but it's the same thickness as the flange. I'm not aware of these being manufactured this way.

With over 2000 miles, on this mod, I feel this is a very viable option.

Please note that my Powder Extreme's bearing flanges install one on each side of the frame. Not both on the same side.

If yours has both flanges, on the same side, the welds will need to be ground smooth so the flanges will seat flush against each other. Quality weld penetration is a must.
 

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Hey Frozen tows that looks like a great fix , butI guess depends on how far the cracks go out from the bearings ? Still like it looks way simpler than my fix , lets us no how it works . Good luck .
 

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Discussion Starter #13
The largest cracks are visible, in images 3 & 4 at 1 o'clock & 6 o'clock or 11 o'clock & 6 o'clock, depending upon the view.

Two seasons of riding and the fracture line has not reappeared. I purposely filled and painted the cracks so movement would be more noticeable. And it looks better that way.

This year has yet to happen due to a meager >1/16" of snow.
 

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looks great seems as though that set up should hold for the long term......
I have put some of our TX's (Granted not Cats) through some mighty high speeds and rough conditions after a fix like this and never had a problem. My fix was very close to the one Frozen Tows pulled off and the all TX's are still going strong.

I don't think this problem starts with a tunnel being weak but in other areas like the chain case, bad berrings (excessive vibration), jack shaft or drive shaft issues.
 

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My nephew boogered out the holes on his ZR440. We used a plate of .30 metal sheet, cut-out the hole for the bearing and attached it with steel rivets, drilled the three speedo drive bolt holes.
 
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