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Improving Your Mokai

Shop Talk => Jet Pump Discussion => Topic started by: Painlesstom on October 15, 2012, 08:45:58 PM

Title: More shaft repair from factory coupler stripping splines
Post by: Painlesstom on October 15, 2012, 08:45:58 PM
These three hardened shafts came off of three different 2011 Mokai that aren't even a year old yet. Just goes to show that hardening the shaft does not stop the binding and grinding going on with the factory solid coupling system in a bouncing and flexing drivetrain. Follow the pictures to see the before, during and after of the repair. My splines aren't any better or stronger than what Mokai does, my coupling system is what makes sure they won't wear out again.

(http://s10.postimage.org/5eeb7lt4l/HSb1.jpg) (http://postimage.org/image/5eeb7lt4l/)

(http://s10.postimage.org/52wuuucol/HSb2.jpg) (http://postimage.org/image/52wuuucol/)

(http://s10.postimage.org/yjcgx9j1x/HSb3.jpg) (http://postimage.org/image/yjcgx9j1x/)

(http://s10.postimage.org/3qf5syf91/HSb4.jpg) (http://postimage.org/image/3qf5syf91/)

(http://s10.postimage.org/pqvi9kxx1/HSb5.jpg) (http://postimage.org/image/pqvi9kxx1/)

(http://s10.postimage.org/k3z5c3ved/HSb6.jpg) (http://postimage.org/image/k3z5c3ved/)

(http://s10.postimage.org/o1mf1ii7p/HSb7.jpg) (http://postimage.org/image/o1mf1ii7p/)

(http://s10.postimage.org/eicq81uph/HSb8.jpg) (http://postimage.org/image/eicq81uph/)

(http://s10.postimage.org/ejr9f7lx1/HSb9.jpg) (http://postimage.org/image/ejr9f7lx1/)

(http://s10.postimage.org/ov3m7vdmd/HSb10.jpg) (http://postimage.org/image/ov3m7vdmd/)

(http://s10.postimage.org/4c8q2szp1/HSb11.jpg) (http://postimage.org/image/4c8q2szp1/)

(http://s10.postimage.org/77lt9o3p1/HSb12.jpg) (http://postimage.org/image/77lt9o3p1/)

(http://s10.postimage.org/mhloguz79/HSb13.jpg) (http://postimage.org/image/mhloguz79/)

(http://s10.postimage.org/qs0ccg4ad/HSb14.jpg) (http://postimage.org/image/qs0ccg4ad/)

(http://s10.postimage.org/ca354gcz9/HSb15.jpg) (http://postimage.org/image/ca354gcz9/)

(http://s10.postimage.org/f5g8bbgz9/HSb16.jpg) (http://postimage.org/image/f5g8bbgz9/)
Title: Re: More shaft repair from factory coupler stripping splines
Post by: Fly Mokai on October 16, 2012, 11:05:49 AM
Very impressive!
Title: Re: More shaft repair from factory coupler stripping splines
Post by: Hillbilly on October 17, 2012, 08:31:34 AM
Looks great, Tom.  No more wasted shafts.  What does it cost to rehab a shaft ?
Title: Re: More shaft repair from factory coupler stripping splines
Post by: Painlesstom on October 17, 2012, 09:04:51 AM
Thanks  :) Cost is $50 + shipping.
Title: Re: More shaft repair from factory coupler stripping splines
Post by: Peter on November 05, 2012, 07:29:03 AM
Том, а обработку вала высокочастотным током  проводил?
Title: Re: More shaft repair from factory coupler stripping splines
Post by: Painlesstom on November 05, 2012, 09:07:27 AM
Том, а обработку вала высокочастотным током  проводил?

You will need to try that again Peter. I tried translating myself but couldn't understand what you were trying to ask.  :(
Title: Re: More shaft repair from factory coupler stripping splines
Post by: BarnieM on November 05, 2012, 04:42:06 PM
Tom, the coupling system you have?  Does it needs to done by you or can we order one and we can put it in? These shafts look like they have seen better days.............Barnie
Title: Re: More shaft repair from factory coupler stripping splines
Post by: Painlesstom on November 05, 2012, 05:17:58 PM
The coupler is pre-assembled by me, it is my design. Nobody else sells it. You, the customer, only has to install it in place of the factory coupling. Very quick and simple process that will stop this stripping shaft syndrome in it's tracks.

 :)

More Shafts I've rebuilt in the past week.


(http://s13.postimage.org/gbit64ndv/IMG_20121031_202929_706.jpg) (http://postimage.org/image/gbit64ndv/)
Title: Re: More shaft repair from factory coupler stripping splines
Post by: Hillbilly on November 07, 2012, 02:17:32 PM
Tom,
Thank you for splining my old shafts.  They are a thing of beauty.  I didn't want to waste my worn out shafts in the garbage.  Now they are re-splined and good as new.  Recycling at its best!
Title: Re: More shaft repair from factory coupler stripping splines
Post by: Painlesstom on November 07, 2012, 02:35:02 PM
You are very welcome George, I'm glad you like them.  :)

Title: Re: More shaft repair from factory coupler stripping splines
Post by: Painlesstom on December 25, 2012, 10:55:24 PM
Some more shafts I fixed this week.
Title: Re: More shaft repair from factory coupler stripping splines
Post by: Painlesstom on June 10, 2013, 02:25:34 PM
Here are a couple Hex shafts I rebuilt today.
Title: Re: More shaft repair from factory coupler stripping splines
Post by: BarnieM on June 10, 2013, 07:01:35 PM
Here are a couple Hex shafts I rebuilt today.
Okay Tom, what is the diffences  from these to the one I have???
Title: Re: More shaft repair from factory coupler stripping splines
Post by: Painlesstom on June 10, 2013, 07:17:45 PM
They are the version before spline, no better or worse. 2005-2008 used the hex, everything newer is splined. I just repair the damage from the solid factory coupling, and add a relief area past the area where the hex terminates. I updated your shaft when I went through your pump, so you are ready for a clutch when you feel the need.
Title: Re: More shaft repair from factory coupler stripping splines
Post by: BarnieM on June 10, 2013, 10:26:26 PM
I know you have a lot of customers....but I have already have a clutch......bought it way before I bought my Mokai......Barnie
Title: Re: More shaft repair from factory coupler stripping splines
Post by: Painlesstom on June 10, 2013, 10:35:28 PM
Ahhh, right you sure did.. And it is set up for a splined pump shaft, which you do not have. You'll need to send it back so I can swap it over to hex. I remember now you got a few things from me in anticipation of buying a new Mokai, then found a used one instead.

No charge, just cover shipping.  ;)
Title: Re: More shaft repair from factory coupler stripping splines
Post by: bravodelta on June 13, 2013, 09:02:31 PM
This is why I installed the Painless Clutch BEFORE my Mokai even saw water... Did my homework with the purchase of the Painless Clutch Unit. I don't anticipate  a blown shaft........... The first investment for my Mokai and worth it!!!
Title: Re: More shaft repair from factory coupler stripping splines
Post by: Painlesstom on July 11, 2013, 04:32:31 PM
More shafts from the past week.
Title: Re: More shaft repair from factory coupler stripping splines
Post by: bravodelta on July 11, 2013, 07:38:30 PM
More shafts from the past week.

Hey Tom did you recondition these shafts????
Title: Re: More shaft repair from factory coupler stripping splines
Post by: Painlesstom on July 11, 2013, 07:53:51 PM
Yes, that's why I started this topic. ;)
Title: Re: More shaft repair from factory coupler stripping splines
Post by: Painlesstom on September 04, 2013, 09:00:15 AM
More shafts I've re-splined.  :)
Title: Re: More shaft repair from factory coupler stripping splines
Post by: Painlesstom on October 01, 2013, 12:19:59 AM
Worn Hex shaft converted to spline today.  :)
Title: Re: More shaft repair from factory coupler stripping splines
Post by: bizler on October 01, 2013, 04:15:09 PM
Just curious, do you build up the shafts with weld and then machine them to size?  Or do you machine new stock to make new shafts?
Title: Re: More shaft repair from factory coupler stripping splines
Post by: Painlesstom on October 01, 2013, 05:29:23 PM
I media blast the shaft end, weld material to build it back up, machine it to a blank, then cut the splines. Takes about 45 minutes all together. Making a shaft from scratch takes a couple hours, so there is no sense making new ones when I can repair any of the old ones easier, and for less. Mokai charges $90 for a new shaft, I will fix an old one for $50.
Title: Re: More shaft repair from factory coupler stripping splines
Post by: bizler on October 02, 2013, 11:49:04 AM
Nice work! The look fantastic when finished.
Title: Re: More shaft repair from factory coupler stripping splines
Post by: Painlesstom on October 02, 2013, 02:24:38 PM
Thanks!  :)
Title: Re: More shaft repair from factory coupler stripping splines
Post by: Peter on October 19, 2013, 12:13:36 AM
Tom
What kind of tap for the thread on the shaft - 5/8 "G18 (18 turns per inch?)?
and what the angle between the turns - 50 degrees?
Title: Re: More shaft repair from factory coupler stripping splines
Post by: Painlesstom on October 19, 2013, 12:20:56 AM
That is correct, Peter, 5/8-18.  \./8
Title: Re: More shaft repair from factory coupler stripping splines
Post by: Peter on October 19, 2013, 12:22:38 AM
Tom!
Thank you!
Start my turbine project :)
Title: Re: More shaft repair from factory coupler stripping splines
Post by: Peter on October 19, 2013, 12:23:26 AM
what the angle between the turns - 50 degrees?
Title: Re: More shaft repair from factory coupler stripping splines
Post by: Painlesstom on October 19, 2013, 12:26:02 AM
That, I do not know. I've always used a tap, or die, to do any threading. I never got involved in cutting threads with a lathe where that information would be necessary.
Title: Re: More shaft repair from factory coupler stripping splines
Post by: Painlesstom on August 05, 2014, 01:16:13 PM
Latest pump in was just rebuilt by Mokai on 9/13, it had the newest version hardened shaft.
Title: Re: More shaft repair from factory coupler stripping splines
Post by: bizler on August 05, 2014, 04:10:28 PM
Having at least a flexible coupling in this application seems like a no-brainer to me.  Alignment is never going to be perfect.  An even better coupler incorporates the clutch.  I wouldnt want to run my Mokai without one!

BTW, I am extremely pleased with my new one.  Thanks!
Title: Re: More shaft repair from factory coupler stripping splines
Post by: Painlesstom on February 10, 2015, 01:08:08 PM
I love rebuilding these pumps and shafts. Here is pump 76 & 77 with their fresh oil rebuilds and converted shafts, along with wear rings and clutches. Two more Mokais on the road to becoming "Painless"!  \./8
Title: Re: More shaft repair from factory coupler stripping splines
Post by: Painlesstom on February 10, 2015, 01:10:44 PM
Having at least a flexible coupling in this application seems like a no-brainer to me.  Alignment is never going to be perfect.  An even better coupler incorporates the clutch.  I wouldnt want to run my Mokai without one!

BTW, I am extremely pleased with my new one.  Thanks!

Wow, I missed this one somehow! Glad you like it Bill, I wouldn't run mine without one either!!  :)
Title: Re: More shaft repair from factory coupler stripping splines
Post by: lagolag on October 31, 2018, 03:23:11 PM
My 2007 Mokai has a newly redone spline and that is bigger then the 5/8 (15,875mm) that's mentioned here, when I measure it I get 17mm (inner diameter) and 19mm (outer diameter) and there is 17 splines, are there different pump shaft dimensions? ???
Where can I find a additional coupler? I need one for expremental use.  \./8
Title: Re: More shaft repair from factory coupler stripping splines
Post by: Painlesstom on October 31, 2018, 04:34:25 PM
All the splined shafts have the same spline profile. The only measurement 5/8th had to do with pump shafts was with the old hex version that could vary between 5/8 or 16mm socket.

What are you trying to do with an extra coupler?
Title: Re: More shaft repair from factory coupler stripping splines
Post by: lagolag on October 31, 2018, 06:14:55 PM
My plan is to install a electric motor and I don't want to use the std coupler.
Title: Re: More shaft repair from factory coupler stripping splines
Post by: Painlesstom on October 31, 2018, 07:34:51 PM
As long as shaft alignment is accurate, the standard coupler would be fine with an electric motor. There is no low rpm pounding from the combustion cycle that the gas engine produces, that is one of the reasons my clutch prevents shaft wear since it engages at an rpm when things smooth out.