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    The next generation chain drive 930CV rear end with reverse.
    #1
    Senior Member Lance-W's Avatar
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    Over the years taking apart and servicing the as designed rear end in the Barracudas it became painfully obvious that there were boatloads of room for improvement. Some of the ever plaguing issues were:

    1. Limited chain adjustment. You truly need two links of adjustment to be able to correctly size a chain to the assembly. The sprocket would hit the bottom of the "bash plate" limiting it to about 1-1/4 links as well as there just wasn't enough adjustment in the tensioner to adjust for the full two links of travel. Which made it impossible to adjust as the chain wore and stretched.

    2. The fasteners that were used to hold the two CV adapters together while sandwiching the center drive spool were on 1/4 dia. They were inadequately sized.

    3. The fasteners that attached the sprockets to the center drive spool were flat head socket cap screws that were countersunk into the sprocket. Thus tolerance wise making it impossible for more than one fastener carry all the load till one of the parts deformed. As you continued to run the sprocket they would all work against each other and become more and more loose. May people would take their cartridges apart and find the fasteners loose. I even went to the extreme of welding the flat heads to the sprocket and it broke the welds and loosened the fasteners.

    4. The inboard brake rotor was inadequate. I was never able to lock the brakes on the rear even in desert scree. It should have easily locked up the rear end in that environment and skidded. That rotor has been replaced with a reverse drive sprocket and the brakes have been moved outboard to the wheel hubs.

    5. It was impossible to check or re-torque any of the drive sprocket fasteners or the CV adapter fasteners once you had the cartridge installed in the box that forms the rear end. This required to to remove it and disassemble it just to check whether the fasteners you were trying to check were tight?

    6. It was impossible to remove the expensive 60152RS bearings from the CV adapters as a result of having no purchase on the back side of the inside race of bearing to pull or push it off.

    7. The fine thread form used in the CV adapters to hold the CV's on would strip out when you used a "normal" torque for the very strong bolts. While fine threads usually are stronger it's not the case when you're trying to use them threaded into an aluminum adapter.


    So the last time I took the rear cartridge out of the buggy I decided I was going to fix the weaknesses. What you will see here is the result of my trying to fix all the problems. I guess we'll find out after I get the first one from the first batch. Feel free to comment and criticize as that's how we all learn and the sport of mini buggies progresses.

























    Last edited by Lance-W; 08-18-2016 at 08:14 PM.
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    Re: The next generation chain drive 930CV rear end with reverse.
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    I'd just bolt the CV's together and run the chain sprockets off the outside of the joint instead of the inside
    Last edited by PhillipM; 08-18-2016 at 08:44 PM.
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    Re: The next generation chain drive 930CV rear end with reverse.
    #3
    Millenium Member plkracer's Avatar
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    I made a ton of changes to mine too, I used through bolted socket heads for the center spool, and changed up my bearing carriers and cv cups.
    Proud owner of a two seat pucker-mobile. Funco inspired mini buggy powered by a Busa. Giving out free rides to anyone brave enough.
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    Re: The next generation chain drive 930CV rear end with reverse.
    #4
    Millenium Member nutz4sand's Avatar
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    Nice. The only thing that could make that better was if you could incorporate a cush drive like the bikes do.
    Now that NOBAMA has PROVEN he is the absolute WORST president in the history of history Jimmy Carter can thank him for stealing the dunce crown.

    Lets hope the next guy repeals NObama care along with the rest of the stupid crap this blight on our windshield has done.
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    Re: The next generation chain drive 930CV rear end with reverse.
    #5
    Millenium Member plkracer's Avatar
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    That's what the axles are for!
    Proud owner of a two seat pucker-mobile. Funco inspired mini buggy powered by a Busa. Giving out free rides to anyone brave enough.
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    Re: The next generation chain drive 930CV rear end with reverse.
    #6
    The Bob Ross of MBN Bullnerd's Avatar
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    Nice job Lance!

    The whole time I was reading the text I was dying to scroll down and see some cad porn!
    "Speed is time-time is speed"-Dennis Hopper

    Quote Originally Posted by TALON View Post
    did you use a special bigfoot camera or something ,you know all blurry could be a tree stump kinda thing .
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    Re: The next generation chain drive 930CV rear end with reverse.
    #7
    Millenium Member plkracer's Avatar
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    I used HH pads and I had no problem locking up with the single rotor on pavement. I had poly e pads on the new buggy and went to metallic. The coefficient must be double for the metallic pads.

    Also, if you strip out the threads, use a helicoil to strengthen it significantly. I believe 2 times the diameter in thread depth will break the shcs before it strips out.

    Also, you might want to run the numbers to make sure your cv cups can take the torque. If I remember correctly, the stock design was right at 100% utilization for my 750 in 1st gear with the power split between the two sides. It never broke, and I doubt the tires would hold that kind of torque, but shock loading could get it close, and removing more meat around the counterbore could push it over the limit.
    Proud owner of a two seat pucker-mobile. Funco inspired mini buggy powered by a Busa. Giving out free rides to anyone brave enough.
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    Re: The next generation chain drive 930CV rear end with reverse.
    #8
    Senior Member Lance-W's Avatar
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    Quote Originally Posted by plkracer View Post
    I used HH pads and I had no problem locking up with the single rotor on pavement. I had poly e pads on the new buggy and went to metallic. The coefficient must be double for the metallic pads.

    Also, if you strip out the threads, use a helicoil to strengthen it significantly. I believe 2 times the diameter in thread depth will break the shcs before it strips out.

    Also, you might want to run the numbers to make sure your cv cups can take the torque. If I remember correctly, the stock design was right at 100% utilization for my 750 in 1st gear with the power split between the two sides. It never broke, and I doubt the tires would hold that kind of torque, but shock loading could get it close, and removing more meat around the counterbore could push it over the limit.

    There's no room for a Helicoil. It was on the list. Edge distance gets crazy small. It has more to do with the CV both pattern than the adapter. Plus everyone has an opinion and I personally think Helicoils suck. If I was going to use an insert I'd do everything in my power to use a Keensert.

    The counter-bores on the on the center tie fasteners are shallower than they were on the original and the thru hole thru the center is smaller so there's more meat than on the originals. I actually considered just taking the thru hole out all together but really didn't think it would add any strength that close to the center of rotation There's only so much that can be done within the envelope defined by the CV.
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    Re: The next generation chain drive 930CV rear end with reverse.
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    There's a whole lot of metal flying around our skies with a few million Helicoils in, so they can't suck that much...
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    Re: The next generation chain drive 930CV rear end with reverse.
    #10
    Senior Member Lance-W's Avatar
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    Quote Originally Posted by PhillipM View Post
    There's a whole lot of metal flying around our skies with a few million Helicoils in, so they can't suck that much...
    Yup you're right. You'll notice I didn't say they didn't work they're just most definitely not my first choice. They have their inherent problems, but they do work. Keenserts are better but you pay the price for the "better" with them being larger package too. Life is a trade my friend and design isn't any different. We all make choices.
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