DIY: Driveshaft Shop (DSS) Carbon Fibre Driveshaft

[F1point4]

Driveshaft Shop (DSS) Carbon Fibre Driveshaft DIY!


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.

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.

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

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.


20130615-DriveshaftShop86-005 by VictorN07, on Flickr


20130615-DriveshaftShop86-006 by VictorN07, on Flickr


20130615-DriveshaftShop86-007 by VictorN07, on Flickr


20130615-DriveshaftShop86-008 by VictorN07, on Flickr


DIY Lets go!

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


20130615-DriveshaftShop86-009 by VictorN07, on Flickr


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.

20130615-DriveshaftShop86-011 by VictorN07, on Flickr

This is the driveshaft to differential connection. It is held together with 4 bolts

20130615-DriveshaftShop86-012 by VictorN07, on Flickr

Picture of the OEM Driveshaft collar mounted to the transmission tunnel

20130615-DriveshaftShop86-013 by VictorN07, on Flickr



20130615-DriveshaftShop86-014 by VictorN07, on Flickr


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

20130615-DriveshaftShop86-016 by VictorN07, on Flickr


20130615-DriveshaftShop86-017 by VictorN07, on Flickr


20130615-DriveshaftShop86-018 by VictorN07, on Flickr


20130615-DriveshaftShop86-019 by VictorN07, on Flickr


20130615-DriveshaftShop86-020 by VictorN07, on Flickr


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.

[PhastekSport]

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

[charged86]

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

[OrbitalEllipses]

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...

[ATL BRZ]

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

[PhastekSport]

Originally Posted by OrbitalEllipses

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...

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.

Originally Posted by ATL BRZ

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

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.

[G_Ride]

Originally Posted by ATL BRZ

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

I'd like to know as well.

[swift996]

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

[F1point4]

Originally Posted by swift996

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.

[swift996]

Originally Posted by F1point4

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.

[PhastekSport]

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

[OrbitalEllipses]

Originally Posted by swift996

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.

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.

[F1point4]

More Pictures

You ask we listen (sometimes)!!!


20130622-DSS-CFDriveshaft-After-046 by VictorN07, on Flickr


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


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


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


Closeups


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


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


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


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


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

[FRSfan111]

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

In for results!