Angle Drive Fixed?

["content22207" <brobertson@xxxx>]

Takes us a while to complete things in the Land of Unfinished
Projects, but I think my angle drive is FINALLY back in business.
Actually have been through 4 experimental repairs in the interim.
Obviously the first 3 didn't work.

Have driven 20 miles (I know because my odometer works again. Yay), up
to 60 mph, no problem. Acid test will be trip to SEDOC. Am keeping
tach Xrefs in glove box just in case.

Final repair:
1) 1/8" male square very close to gears. Is square key from hardware
store, soldered to remaining spindle cable with tension spring as
splice (stretched slightly to aid solder). Remaining spindle cable
soldered down into gear TO PREVENT ANY MORE UNWINDING.
2) 1/8" female square drive at gear end of 8-32 drill rod (replaces
spindle cable). Is 5/32" hobby channel soldered to square filed end of
rod.
3) Wheel disc tapped for 8-32 rod, further attached with fan lock lock
washer and two jamb nuts. Already cut square drive pocket off wheel
disc (thought the whole thing was damaged), so this is only way to
attach to rod. 
Is easier to insert drill rod from outside. Plus allows self
adjustment side to side (was concerned by Dave Swingle's cracked gear
housing with solid welding rod).

Is not optimal, but is working.

For benefit of others, this is what I learned:

1) Spindle cable is definitely wound for passenger wheel (right hand
drive).
2) If your square crimped end unwinds catastrophically (80 mph), will
chew up visible portion of wheel disc, but deep inside pocket may be
OK. Check with something 1/8" square before assuming the worst.
3) Easiest repair is:
Cut off damaged portion of spindle cable.
Slide long tight fitting tension spring over remaining cable. Do not
solder or weld entire length of spring -- cable will just continue
unwinding where it ends. If spring is free, cable will try to unwind
within it but be held.
Solder or weld 1/8" square rod, key, or whatever to end of cable to
replace damaged portion. Spring can act as splice, and will expand to
accomodate slightly larger 1/8" square. Solder works better on spring
if it is stretched slightly.

When I first got my DeLo heard all the dead angle drive stories.
Thought then the problem was gears themselves. Now know weaknesses are:
1) spindle cable wound wrong way
2) pot metal housing
Gears are actually toughest part of device.

Bill Robertson
#5939