This summer, the McMaster EcoCAR Propulsion System Integration (PSI) team has been working hard on several different projects. One significant project was the design and manufacturing of the rear half-shafts for the team built electric driveline. Previously, we had integrated temporary shafts by welding a collar onto the existing Blazer and Camaro shafts. The new shafts were optimized for length and weight.

To determine the required length of the new shaft, we took measurements between full droop (wheels hanging at their lowest point) and full compression (suspension at full compression). We then created a CAD model and preformed finite elemental analysis to validate the design and material selection. Once finalized, we worked with one of our sponsors, Berkel Tooling Solution, to be machined. Finally, the shafts were reassembled and put back in the car for further testing.