I broke down 4 half shafts today for cleaning.
I had heard the outer flange bends easily when removing the u-joint, so here is how I did it at home with no special tools required. I did not find it that hard. And I have zero concerns for bent flanges. Hope this helps someone.

1 more left to go. Yellow 3" set was from a race car with a dry joint, and my OEM 2-1/2" set.


I removed the first cap this way. On the half-shaft side only. Not the flange side. Lots of PB blaster. I never use a press. I like the control from a hammer and never use any more force than necessary. A few whacks knocked it loose. This is the diff side.


The second side I drove into a large socket with an old tool steel diff pin. On this outer flange side I removed the flange and the u-joint together from the half-shaft.


This is the way I supported the flange in the vise to protect it from bending. It's very loose. All the pressure is on the top u-joint cap and zero on the other side. The force goes from the u-joint crossbars, direct to the top cap only. I just "lower" the flange 1/4" . No way it could bend. But Yeah it is pitifully thin in the center. right about where the vise is. It could bend very easily if you put pressure on both ends as in the first pic.


A few whacks and the cap is ready to be twisted out in the vise. It's just hanging loosely on the u-joint crossbars.


I even double checked all the flanges for flatness with a machinists ruler. No daylight showing here. One of the 4 from my other rusty set showed some abuse marks from a prior bubba joint removal, and showed daylight on one end of the ruler. And yeah on that cap the u-joint just seemed too tight. It's only .001", I'll try and straighten it and see if that u-joint will rotate free, or I will just buy a new one.


NOTE to self: Remove zerk fitting before removal, or it will remove it self. LOL
Second note: Better not use this kind on a BB anyway.

 

Riddle of the Day:
What did we decide to make for my C3?

This is the kind of challenge that happens at 9:00 at night in the race car shop, after too many old stories, a few beers, and you just happen to have a Bridgeport laying around that you haven't used in a while. "I bet I could make that!"


Can you identify the mystery object being made?

 

beer holder

 

Any clues on whether it's a tool/installation jig or will it be a permanent part of the car when finished?

 

After too many beers last night, what started as a C3 part might look like a beer holder this morning.
There should be warnings on beer cans “do not operate equipment while drinking”.

 

OK
clue #1
It's not a permanent part of the car.

 

horn button center cap

 

Any chance it looks like this?

M

 

That kinda looks like something to do with the rear bearing carrier...

 

It does look like a flange plate tool. I made mine many years ago out of.750”steel 4”square

curious about the mill it doesn’t look like a Bridgeport with the square ways and handle At least not a series 1.

 

I'm guessing it's a weird angle making it look the Y-ways look like that, but they still seem really narrow compared to the width of the saddle there. I think maybe all knee mills are bridgies regardless of who made them

M

 

Ok we have a winner!
Mooser was first: we made a u-joint flange support tool out of 1.24* 4" steel bar - left over from adding 70lbs to the nose of one of the long wheelbase dragsters
But everyone is sharp:
OCB was also right - it was probably because of the beers we broke a tap in it - getting that out doubled how long this took
Rescue was right - the broken tap almost made this turn into a beer can holder
GTR was right - he identified the mill - I called it a Bridgeport, and so does everyone in the shop, but it actually says Cincinatti on the side, the real Bridgeport wore out and got replaced
We decided to make it because although I got the u-joints out by supporting them in a vise, there was not any way to support the flange with a vice etc. while putting them back in.

So the beer fueled discussion actually did help by resulting in this solution. But... then the bravado came out..."I can make that!"

Thanks for playing along!

So I could have just bought one, they are only $40. And I could have bought two flanges to replace the bent ones. But where is the fun or challenge in that?

If you don't enjoy solving challenges, maybe you better think twice before taking one of these 50 year old relics apart!

It is very easy to see how some get discouraged along the way, in the middle of a frame-off, and sell their dissasembled project. For me I love the process and the challenge, so I do not believe I'll ever quit. I just hope I can get it done while my back still lets me climb in it!

 

Nice, thanks for the entertainment.

 

Interesting on the Mill, I would like to see any pictures of it if you have any. Cincinatti was another great USA machine tool company. My first job out of trade school was working for the CT Bridgeport Dealer, I don't know if I have rebuilt more J & 2J heads or corvette units the past 45 years.

 

Taking things apart is cheap and easy. Someone buys a car and in a weekend with some buddies you can take a lot of stuff off.
Putting things together takes time, money and thought, frequently patience as well. That's were a lot of projects get pushed to the side and abandoned....
M

 

Spot on Mooser, There is a math relationship in there somewhere!

I am the type that would rather keep the money expenditures down, by doing as much of it myself as I can, even if it takes longer!
I already have like $40k in this project, but it is all in parts. And I still need need about another $5k in parts. And LOTS of my "free" labor, which is stretching out the timeline. But I do enjoy the process, and solving the challenges.

I was originally going to spend $40-50k and just buy a BB all done. But I looked for a long time, and could never find one I liked, with the right kind of options, mods, HP, or good enough condition. And I just knew I would have to take them all partly apart anyway, to have things done correctly, or my way. So yeah, this is more of a labor of love, than anything else, and I needed "something" to do after the boys moved out. Funny how that turned out to be the understatement of the year!

 

I’m right there with you.
I decided that when I was done with this project, every part and component would be new or rebuilt with all new parts.
I would have spent a whole lot less buying a Bloomington Gold, low mileage big block, but I doubt I would have been nearly as happy.

 

Yep that has been my achilles heel as well.
I want it to be a all-new, or properly rebuilt, so it is 100% reliable, and I can actually drive it! A lot!

My LT-1 was so reliable I would have had no problem taking it on the Power Tour.
Too bad I could not have kept it and have 2 in the garage.
My goal is to make this one that solid, and do some 1000 mile drives!
To heck with the gas prices!

 

Im with you guys on doing it your way, making tools and doing it right....we got this at work the other day....Im not qualified to use it but my boss is and my buddy is...theyve already made some stuff for my vette. Good job on the flange support. I just bolted 2 flanges together but I want to make one of these next for the next u joint change....it will work better





Brand new not installed yet

 

Im hoping to do the same!!!!