DIY: Driveshaft Shop (DSS) Carbon Fibre Driveshaft
 

Driveshaft Shop (DSS) Carbon Fibre Driveshaft DIY!

http://farm6.staticflickr.com/5451/9...c5c86444_c.jpg
20130615-DriveshaftShop86-001 by VictorN07, on Flickr


Hey team 86. Today we have a new bit of kit in the labs, the Driveshaft Shop (DSS) Carbon Fibre Driveshaft. The purpose of replacing your OEM driveshaft with a lighter one made from aluminium and/ or carbon fibre is to reduce rotational mass and make power transfer from the gearbox to the differential more efficient. The net result is a more responsive car.

It is a single piece unit vs our dual section unit. Since the DSS kit doesn't have that pivot point like the OEM, then it can transfer energy more efficiently.

Unlike the OEM one, this carbon fibre driveshaft doesn't have a shaft collar. Normally having a collar is good in the event that your driveshaft falls out of the gearbox and catapults your car in the air. In this case, if there is failure in this driveshaft it will simply shatter/shred into many pieces.

The U joints are replacable and DSS claims this driveshaft can handle 800whp.
The ends are made from 6061-T6 aluminum. They've been in the business for a while making driveshafts for big power cars so I'll take their word this is serious business.

Is it worth it? We installed this in the Phastek Performance shop car so I'll @Chris@Phastek fill you guys in.


The goods

This is the end of the driveshaft that mates to the differential. It is a beefy joint.
http://farm6.staticflickr.com/5330/9...3c5d3b96_c.jpg
20130615-DriveshaftShop86-002 by VictorN07, on Flickr

This end slots into the gearbox. There isn't a cup on this end like the OEM driveshaft but that's okay. This end is seals the gearbox so fluid and air cannot enter or escape. Inside this aluminium end is keyed so the output shaft of the gearbox can turn the driveshaft.
http://farm4.staticflickr.com/3666/9...227e52eb_c.jpg
20130615-DriveshaftShop86-003 by VictorN07, on Flickr

The driveshaft is wrapped in this material. There is a large Driveshaft shop logo and phone number on the unit itself
http://farm8.staticflickr.com/7337/9...66e2462c_c.jpg
20130615-DriveshaftShop86-004 by VictorN07, on Flickr


Weight

The DSS driveshaft is about 1/2 the weight of the OEM driveshaft. Big savings since its rotational mass.

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20130615-DriveshaftShop86-005 by VictorN07, on Flickr

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20130615-DriveshaftShop86-006 by VictorN07, on Flickr

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20130615-DriveshaftShop86-007 by VictorN07, on Flickr

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20130615-DriveshaftShop86-008 by VictorN07, on Flickr


DIY Lets go!

Some of these are just photos of @Chris@Phastek's car.

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20130615-DriveshaftShop86-009 by VictorN07, on Flickr

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20130615-DriveshaftShop86-010 by VictorN07, on Flickr

Here is the driveshaft inserted into the rear of the gearbox. The DSS shaft will not fill that silver cup when its installed.
http://farm8.staticflickr.com/7313/9...ac63f4f3_c.jpg
20130615-DriveshaftShop86-011 by VictorN07, on Flickr

This is the driveshaft to differential connection. It is held together with 4 bolts
http://farm3.staticflickr.com/2878/9...eca5d853_c.jpg
20130615-DriveshaftShop86-012 by VictorN07, on Flickr

Picture of the OEM Driveshaft collar mounted to the transmission tunnel
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20130615-DriveshaftShop86-013 by VictorN07, on Flickr


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20130615-DriveshaftShop86-014 by VictorN07, on Flickr

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20130615-DriveshaftShop86-015 by VictorN07, on Flickr


Depending on the tools that you have you may have to put the car into gear and/or apply teh e-brake to keep the driveshaft from turning while you break loose the bolts
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20130615-DriveshaftShop86-016 by VictorN07, on Flickr

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20130615-DriveshaftShop86-017 by VictorN07, on Flickr

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20130615-DriveshaftShop86-018 by VictorN07, on Flickr

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20130615-DriveshaftShop86-019 by VictorN07, on Flickr

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20130615-DriveshaftShop86-020 by VictorN07, on Flickr

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20130615-DriveshaftShop86-021 by VictorN07, on Flickr

Finished!!!


Chris will get some more pictures of the finished product! I was occupied with other mods at the time and forgot to take finished photos.

Victor did the honors of adding post installation pictures. I had to upgrade my fog lights, so I put it on the lift again.

http://www.ft86club.com/forums/showp...0&postcount=13


DSS axles going in next!


Sent from my LG-E980 using Tapatalk 4 Beta

Wonder how fun this will be laying on the ground. Again superb DIY. By Mr. @F1point4

Yeah, this seems easy, but I'm loathe to try this on the ground... approximately how much gearbox fluid drained out? I'm also a tad concerned that trying to not lose much fluid would result in my damaging the seals...

Thanks for another great write up! Any noticeable difference in driveline response after installing the DSS driveshaft?

Approximately nothing! Victor had the DSS driveshaft in hand as I removed the stock one. I am pretty sure not a single drop hit the floor.

Seems as if all slack has been taken out. There is a Houston event this weekend where I'll welcome some people to try it out and give feedback.

I'd like to know as well.

Do you have any pics of both ends of the carbon shaft mounted?

Next time Chris's car is on the lift he'll get some, or i'll get some if I'm with him.
Sorry I just forgot.

I'd appreciate it as I plan to do the same in my driveway. Would be helpful to make sure I got everything on there right (seems pretty straight forward). As always, thanks for sharing the detail.

I have to work on a couple of things tomorrow morning. I'll probably get it on the lift again.

Sent from my LG-E980 using Tapatalk 4 Beta

This is the type of thing that is entirely possible on your driveway, but probably better with two people... let me know what you plan on doing and we can have a double date.

More Pictures

You ask we listen (sometimes)!!!

http://farm6.staticflickr.com/5492/9...343ca26d_c.jpg
20130622-DSS-CFDriveshaft-After-046 by VictorN07, on Flickr

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20130622-DSS-CFDriveshaft-After-042 by VictorN07, on Flickr

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20130622-DSS-CFDriveshaft-After-039 by VictorN07, on Flickr

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20130622-DSS-CFDriveshaft-After-064 by VictorN07, on Flickr


Closeups

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20130622-DSS-CFDriveshaft-After-003 by VictorN07, on Flickr

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20130622-DSS-CFDriveshaft-After-028 by VictorN07, on Flickr

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20130622-DSS-CFDriveshaft-After-024 by VictorN07, on Flickr

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20130622-DSS-CFDriveshaft-After-010 by VictorN07, on Flickr

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20130622-DSS-CFDriveshaft-After-005 by VictorN07, on Flickr

Definitely on my list. Lol this, brake cooling, oil cooling and final drive.

In for results!

Great install. Got one going on our silver car. :)

Fantastic write up as always Victor. Hmmmm maybe I should have tried this myself..

Great article! I assume the total portrayed by the scale includes the wooden plank so the weight difference between the two is not quite as great?

Metric Units here..
 

I think Victor is a pretty cluey guy and would have "TARE'd" off the plank in that measurement ;)

Also the weight difference between the two is around half(as stated)
I just calculated it(I'm working out my own personal weight loss regime for my car atm - I'm bored):
STOCK: 11.181035kg
CF DSS: 5.599032kg

This is certainly one of the mods I'm looking forward to myself, once I finally get my own 86. I like the idea of reducing drive train power loss and improving the underlying performance prior to upgrading power.

Lighter 17x8 rims, brace kit, cf drive shaft, lighter pulley kit and diff ratio are the first mods I'd likely make.

Just wanted to say thanks to Victor for stopping by the shop and taking some pictures. I think we were each able to knock out the work that needed to get done to our vehicles.

Now you've had this for awhile can you comment on thoughts of performance and NVH and so on please? Very curious to hear as I am doing mine soon as well. I know some fellows with the aluminum ones have commented on increased NVH or vibrations and having to turn 90-180 degrees on back plate to rid of and wondering if there are any concerns on the CF version?

How much fluid will leak from an Automatic Transmission during this conversion?
How do you refill?

I have no reason to believe that if you vehicle was level more fluid would come out of an automatic. We didn't lose any with this vehicle.

I haven't noticed an increase in vibration. Must note that he car is overwhelmingly loud (Borla UEL and Perrin unresonated / uncatted the rest of the way), and that could have taken away from my ability to notice a change with the driveshaft. Come to think of it, the vehicle had a stock header when it was installed. Didn't notice much of a difference as far as NVH.

We definitely zeroed out the scale with the plank on there. :lol:

A few in car videos of the l aluminum DS noise would be awesome. On a car without headers and has at least one cat. :P

Just so you know, Mythbusters totally busted that myth.

Having your shaft snap is still not a pleasant feeling nor a great experience :) and that comes from a person who had this happen to him on a 4x4

Does that collar (or whatever that piece is that bolts in the middle of transmission tunnel) offer any structural advantage to the chassis? Should you reinstall something to bridge that gap, that was once bolted together with the stock drive shaft?

I don't see why it couldn't hurt to add a brace. Just have to get one made. I don't notice any negative side effects at the moment.

Oh I see - that brace is actually part of the driveshaft, and not an independent piece that you can just bolt back on. Correct?

I haven't looked at it in a while, but it has a collar. I think you can shave that portion off and be left with a little brace.

Thought about it as I removed it...

Curious to ask OP and others that got this...

Did you find you needed to play with rotating the back bolt position anyone to have no vibes or weird harmonics?

Mine was a straight bolt and so far nothing weird but a few I know are going through process of turning 90, then again and swear they have vibes so in curious...

Yeah no issues at all. Bolted it straight on. Victor is the OP but it is on our vehicle. He was installing his oil cooler or something while this went on.

Sent from my LG-E980 using Tapatalk 4

Thanks a lot for the DYI! Just installed mine. So far everything is perfect, no increase in noise and or vibrations (although also installed Nameless FP/DP combo together with the DS which added loudness). The only concern, which mechanics pointed my attention to, is the lack of the protective cup on the carbon driveshaft. I allows dirt, liquid and chemicals from the road to contact the connection point of the DS with the gearbox, which is not good at all. They even recommended to cut the protective cup from the OEM driveshaft and weld it to the DriveshaftShop one. I declined for the time being but now thinking about protective measures for the DS... Let's see how it survives winter.

Purpose?

Pretty sure IIRC it was to help ensure everything is balanced. Less likely to have vibration should you go back.

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Wish I would have known that before removing mine, lol. I guess if there is excessive vibration I would just have to unbolt the driveshaft and rotate to the next hole until everything smooths out?

Correct.

Nice - good idea on marking that before removal. Thanks for tip.

I just installed mine! Thanks for the DIY! Only think I was wondering is the length of the four bolts do not thread all the way past the nut. The flange on the new drive shaft is about a 1/4 thicker making the old bolts just a tad to short. I can see a few threads on the left on the nuts.

Installed mine yesterday. Wasn't able to fit a torque wrench in there so I used a closed wrench to tighten it as much as possible. Has anyone been able to fit a torque wrench?