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Mike
997.1 C4S RWD conversion
The hole in the center of the guibo is the diameter of the bearing on the driveshaft. The little pin goes inside of the bearing and is approximately the hight of the guibo’ a depth. Here are additional pictures.
If we create a dome for the shaft like your original design I believe that would work?
Mike
If we create a dome for the shaft like your original design I believe that would work?
Mike
High Temp Brembo Caliper Rebuild Kits & Pistons
www.ohioperformancesolutions.com "CARPOKES" discount code
2007 C4S F77 Aerokit / 2004 E46 M3 / 2018 M3 comp
www.ohioperformancesolutions.com "CARPOKES" discount code
2007 C4S F77 Aerokit / 2004 E46 M3 / 2018 M3 comp
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Tom
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Willing to give it a shot. Worst case, we may need to iterate a bit if the first try isn't just right. Shoot me an email or PM to get it going. 
No indications where these failing CV boots were sourced. I went thru this problem a while back on an '04 BMW XiT wagon's front CV boots. They kept failing after a 1000 miles or so. These were remanufactured from a reputable supplier ($) but kept failing. The problem was eliminated by buying brand new OEM CV axels from BMW ($$$$). My supplier covered the replacements on the remans but the labor replacing the units over and over got old. Just my experience.
They were bought from FCP Euro and were Porsche brand. Im almost sure its going to be the chip and seal aggregate…
High Temp Brembo Caliper Rebuild Kits & Pistons
www.ohioperformancesolutions.com "CARPOKES" discount code
2007 C4S F77 Aerokit / 2004 E46 M3 / 2018 M3 comp
www.ohioperformancesolutions.com "CARPOKES" discount code
2007 C4S F77 Aerokit / 2004 E46 M3 / 2018 M3 comp
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Tom
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Sorry it's been a while but working on your cap/cover now.
Hey no rush! Just took out my car for the first drive after hibernation and she has a random tick I now have to source! Stuck lifter or gravel on the heat shield are my initial thoughts.
High Temp Brembo Caliper Rebuild Kits & Pistons
www.ohioperformancesolutions.com "CARPOKES" discount code
2007 C4S F77 Aerokit / 2004 E46 M3 / 2018 M3 comp
www.ohioperformancesolutions.com "CARPOKES" discount code
2007 C4S F77 Aerokit / 2004 E46 M3 / 2018 M3 comp
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Tom
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Here's a quick print of a cover that fits the flex disk. I designed it to use steel inserts, much like the flex disk, so that the bolts can be torqued to spec. While you can torque on the plastic, there's a risk of breaking it, and an even bigger risk of them coming loose as the plastic compresses over time. The inserts are about $2.50 at McMaster so will add them to my next order if this looks like a go.
I had to guestimate is how tall to make it so it clears the shaft stub sticking out. I hopefully erred on the tall side.
One thing I noticed while doing this is the shaft will not be entirely sealed off from the elements, since there is a gap between the flange and the flex plate. Same must be true of the factory configuration. But this will protect it from road debris/rocks, etc. to the same extent it was protected from the factory.
Let me know if you see any issues, otherwise I'll get the inserts so you can give it a whirl...
I had to guestimate is how tall to make it so it clears the shaft stub sticking out. I hopefully erred on the tall side.
One thing I noticed while doing this is the shaft will not be entirely sealed off from the elements, since there is a gap between the flange and the flex plate. Same must be true of the factory configuration. But this will protect it from road debris/rocks, etc. to the same extent it was protected from the factory.
Let me know if you see any issues, otherwise I'll get the inserts so you can give it a whirl...
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Hell of a job! I agree with the metal inserts as I will torque the bolts to an extent with the added security of locktite like it cane from the factory. That dome will be plenty to cover that little shaft also! I say full send!
Attachment point.
Mike
Attachment point.
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High Temp Brembo Caliper Rebuild Kits & Pistons
www.ohioperformancesolutions.com "CARPOKES" discount code
2007 C4S F77 Aerokit / 2004 E46 M3 / 2018 M3 comp
www.ohioperformancesolutions.com "CARPOKES" discount code
2007 C4S F77 Aerokit / 2004 E46 M3 / 2018 M3 comp
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Tom
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Finally made one with the inserts. Looking at that picture above, you may need to put washers in the recesses above the holes, so that the inserts on the cover can be torqued against metal.
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