Vanagon – making new syncro propshaft internal bushings – Part 2

I decided to make a split bushing for the internal location. I first turned down some Delrin to final inner diameter (23 mm to match the turned down yoke shaft), then mounted it on a mandrel to turn down OD to 28 mm (was OD of upper bushing and I guessed that the inner one was the same).

I kept the bushing on the mandrel and clamped it in my wee milling head. I also used a small C-clamp on the bushing to stop it from popping off during slot cutting. I used a 1/8″ end mill to cut the slot, made the slot 6.8 mm wide (chord length) which I estimated to be slightly more than needed.

Finished split bushing.

And as I tried to install it, I realized I had no way of holding it compressed to get into the narrow bore, no grip after it goes into outer bushing area. Oh, btw, this is how the bushing should appear when it is finally in place at the bottom of the housing.

I had an idea, some stainless shim stock to act like a funnel.

That worked and I was able to tap the bushing home. You can make it out, down at the bottom.

The yoke shaft would not fit in, I had to chamfer the end of the shaft a little more, and polish the end. But I finally was able to tap the shaft in and it is nice and snug. Quite snug actually, it takes about 20 Nm to rotate the yoke, but no radial movement at all. Oh and another thing, I removed that flange on the upper bushing, didn’t make any sense. I’m feeling quite chuffed in managing to get some sort of bushing replacement made. I hope they will wear well.


  1. #1 by Harry on June 6, 2012 - 3:30 pm

    Absolutely amaaazing… :K

    • #2 by albell on June 6, 2012 - 4:41 pm

      I’ll take that as a compliment rather than a “why the hell did he do that?” statement 🙂



  2. #3 by Angus on June 6, 2012 - 4:55 pm

    Pretty cool! All’s well that ends well…

    • #4 by albell on June 6, 2012 - 5:46 pm

      well, we’ll see for sure when I install it.


  3. #5 by Brett on June 6, 2012 - 8:16 pm

    Anytime I need a good “humbling” I just come to Alistairs blog. Thanks again for documenting and sharing your amazing work.

    • #6 by albell on June 6, 2012 - 8:24 pm

      Geez Brett, cut it out. What I don’t show in the posts are all the F-ups.



  4. #7 by David on June 7, 2012 - 10:07 am

    Great Job! I’ll be interested in seeing how it wears and how long it lasts.

    • #8 by albell on June 7, 2012 - 10:14 am

      me too.


  5. #9 by Greg on August 9, 2012 - 3:12 pm

    How is this “fix” working out?

    • #10 by albell on August 12, 2012 - 1:43 pm

      Seems to be fine Greg. I can’t say for sure unless I pull the shaft and have a look. I might do that before the fall and I will post what I find.



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