The car I'm rebuilding (Skoda Estelle/120, 70's, RWD, rear-mounted engine), uses half axles for the transmission, that goes inside housing elements (thick "pipes"). These axles uses pin-and-guiding blocks as link to the differential (housed together with the gear box), and a woodruf key in the conical-profile tip where the wheel hub gets secured. The main problem I always have with this design is that the woodruf key/hub/nut assembly gets loose very often, so I want to try a different design.
The half axles I can have are from Ladas. The design is different: the Lada axle is a typical front-mounted engine with rear transmission. However the bearing is the same and its size gives me room for adaptations.
In the inside tip, Lada's has splines, Skoda has pin-and-guide block. I'm aware about precision that this needs, I know it needs to be done in a lathe, welding by hand turning the aligned parts, etc.
- cut both axles and weld together the appropriate sides, reinforcing the joint by welding a sleeve, or
- cut the Lada axle and add a reinforcement ring at the pin side (probably an inner track of an old roller bearing).
The main issue: the diameter in the Lada axle, where the pin hole would be drilled is less than 30 mm; the Skoda's diameter there is 32 mm. So somehow I need to add body or reinforce that tip.
My question is: how should I work the inside tip?
When answering, please keep in mind I don't have access to much more than what I describe.
Engine is 1200cc...See the diagrams I made to support the question:
EDIT: added more pics of what I'm after :)