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Thundair... Please feel free to talk about what-ever... Now I'm interested in hearing about an experimental aircraft... harmonics... heat treat and the usage of variable materials etc...

Thanks TVP... I'll do as you said.. Swall... why not have the splines nitrided?... Will it make them too brittle?

I have no 4340... I had a piece of 8620 which was already used... and 4140 was what I had left or remaining.. I guess I can go yank a pinion out of a 14 bolt rear and full-anneal it and turn the teeth off of it... and then spline it for the output shaft... On the old shaft and and gear they both...

If I wanted to heat treat a shaft made from 4140 with the major O.D. @ 2.5"... what would be the ideal temp/amount of time and proper quenching method be?... My gears that I tested have a Rockwell of 62 on the "C" scale... So if anything I'd like to match the hardness or be a little under that...

This is what figured for the Fellows Stub tooth (It seems like Some of Involute Spline formulas and Stub Fellows coinside)... The only problem I have is the OD matching... If I use the Involute method I get the desired O.D. If I use the Fellows Stub method I get an O.D. that is way too small...

Thanks for the sites... I'll be sure to read-up on them... I found a cutter that matched the tooth radius and I counted the offset,height and rotations.. I know this isn't the proper method but... It worked... (on the test piece)... I'll tweak it a little more...

Well, I just started measuring the Splines and so far nothing (Mathmatically) is correct. It must be stub splines right?

Here are some links to see what I'm talking about...

Sorry to double post but.. I was also wondering about pressure angles...

I have a few questions about cutting splines. I'm not sure what splines these are... and what type of cutter to use... I'm making a HD Rear Output shaft for my Dana 20 Transfercase... The only thing stopping me from finishing this project is the splines that go into the T-case and into a...