tip of my shaft

[hughmungas]

I want to cut the end of my NP208 transfer case shaft off at the output side so I can drill a hole and then cut threads in it to secure a SYE. The reason I want to cut the end off is that it is hardened steel and you can't drill through it without pulling it out and putting a torch to it to change the properties. I don't have a torch and don't really want to pull it all apart and reassemble it and so was thinking I could just cut the tip off to get past the hardened part and drill and thread a hole.

The question is, how much would I need to cut off of the shaft to get past the hardened part?

 

[rgorsuch87]

Hmm I'm not really sure. I almost want to say that the hole shaft is hardened steel, but thats just me.

 

[hughmungas]

I think it only is hardened in towards the middle by about 1 cm from the end but I am not sure. On my other np208, I took it apart, had a machine shop heat upthe shaft and drill and tap a hole for me. I was hoping I could just cut off the end and drill and tap it without having to take the hole thing apart, carry it to a machine shop and then bring it back and reassemble it. Less chance for screwing something up.

 

[4X4HIGH]

You should be able to drill and tap the shaft with a GOOD Cobalt drill bit and a quality tap.

 

[sweetk30]

and lots of work

 

[hughmungas]

You should be able to drill and tap the shaft with a GOOD Cobalt drill bit and a quality tap.

tried it. The shaft laughed at my drill bits.

 

[4X4HIGH]

tried it. The shaft laughed at my drill bits.

COBALT drill bits and not just Cobalt coated.

 

[K85 Octane]

gunna add to or hijack the thread, whichever u want to call it

is it worth the cash (approx $550) for a 241 and SYE kit? Meaning, having the SYE and driveshaft upgrade, plus a slightly lower 4L gear?