C90/VL 1500 Drive conversion

Hi all.
By chance today I went onto an american Volusia owners site & saw there threads on the diff drive conversion & read the following info:-

You can use a VS1400, a C90 or a VL1500 diff unit to do the conversion on your Volusia or C50 or any 800 models with a shaft drive.

So I take it that if you cannot find a VS1400 unit you can use the other's as an alternative.
All part numbers etc are exactly the same also for the conversion as we have here from Mr Intruder.

I thought there was at least a different sized axle hole but if your saying the mod is exactly the same I will not disagree.
I am only prepared to advice on something I have done & would not try to advice on another drive in any way.

Yes Peter, You can use a C90/ VL1500 Drive, But there's extra work involved in doing so, The 1500 uses a lager diameter wheel spindle which means having a spacer made with a built in bush to accommodate the 800 spindle, The VS1400 uses the same diameter spindle thus requiring less work.

Hi Peter,
Here is the spacer, it comes from an American site so is in inches.

Well at least thats good to know eh? I must admit I did not dig too deep in the site as I was looking for something completely different & this just stuck out but it's good to know you can use another diff with only a minor additional spacer.    :cmate:

Dave I'm only stating what I saw & that's why I bow to your better knowledge my friend on these things.  

The spacer posted in the above drawing is causing me some confusion? I'm thinking if the use of a 1500 drive is going to be posted on site, we need the measurements clarified and correct before anyone does the mod and breaks their pride and joy.

I'm guessing the external dimension of 0.9880" is the internal dimension of a 1500 axle hole, and the internal dimension of 0.6719 is the external dimension of a 800 axle? and then sliding the 1500 spacer over the sleeve brings all the dimensions together, If so? where does the length of 2.8150" come into play? the spacer between the drive and wheel needs to be 2.7/8", which gives a difference of nearly 3mm, The length of the standard bushing inside the 1500 drive is 0.75" (19mm roughly), That would give a 3mm internal bushing using the 800 axle, That's 16mm short? 

ps. Yes I agree the 1500 drive can be used and has many times, it's the same drive, only with a thicker axle.

Just for clarification if I'm talking gibberish lol This is a 1500 drive and spacer milled to 2.7/8" with the axle spacer/sleeve for using on the 800 axle.

Hello Sim mate,
Bit of a cock up on the computer front,
should have been this one



The next photo down from what you showed, shows the Bushing being push fitted into the spacer,



And here is a segment of a write up on the fitting of the C90 drive,
 
 
MODIFICATIONS

There are three issues to be addressed when mounting a C90 drive to a C50.

1. The C90 drive fits a larger axle than the C50.
2. The spacer between the wheel bearing and the drive casing is different
3. The C90 drive shaft is too long.

1. The axles in these drives are a TIGHT fit in the steel bushings in the drive casings. This is clearly done to maintain the alignment of the drive. The steel bushing in the C90 drive casing (to suit a 20mm axle) needs to be sleeved so that the 17mm (nominal – more like 16.9mm) C50 axle is a tight fit here.

The spacer appears to be an intentionally loose fit on the axle. Because of the length of the axle there would obviously be a problem with the axle seizing if it fit as tightly as it does in the housing bushing.

Under no circumstances should the spacer and bushing be machined as one piece – that would be asking for trouble for the reasons given above.

Mike the axle and the inside of the steel bushing. Turn the bushing to about 2 to 3 thou over on the exterior and an exact fit on the internal diameter and the same length as the steel bushing in the C90 drive at 20mm. The dimensions of the bushing are approximately 20mm long, 20mm OD, 16.9mm ID.
Press the bushing into place with a little red locktite. I made a small shouldered shaft to fit the new bushing to aid in pressing it into place. Ream the bushing for the axle as necessary. Mine was a perfect fit and did not need reaming. If the fit is close you could hone and save the cost of a reamer.

The axle will need a larger and thicker washer under the axle bolt head at the drive. This is because the casing of the C90 drive is recessed but the C50 casing is not, so the axle bolt is now slightly long. It is also necessary to be sure that the axle shoulder is tightening against the C90 steel bushing and not the new bushing. Turn a washer to suit.

Good call mate, my bad.

Good Morning John, Thanks for the clarification mate, My confusion is resolved    So in addition to the axle bushing, A larger washer is needed on the axle bolt due to the recess in the 1500 drive  

As I stated I only had a brief look at the info but it seems others like John have been there before me so that I did not know obviously.   
I can only apologise if I opened a can of worms but if it means you can use another drive when 1400's are few n far between then it ought to be made known to the forum members & if it means a little more work making a bush or such then so be it.   
I know Dave only knows about the 1400 diff & accept what he say's 100%, but we have to look at all possibilities don't we, after all if the American's use the 1500 diff in basically the same way but with minor differences ought we not use their knowledge to boost our own? :what1:

peardrop3 wrote:

I can only apologise if I opened a can of worms but if it means you can use another drive when 1400's are few n far between then it ought to be made known to the forum members & if it means a little more work making a bush or such then so be it.  

No need for apologies Peter, You're only trying to help    Although there are various options of fitting these drives, The VS1400 drive mod is featured on the forum because it's the easiest and least expensive way due to having parts machined by a 3rd party for the 1500 drive which adds to the cost of the mod.