Alright, I think I have my Driver side axle issue resolved, For Now......
After talking with many people about DSM/CSM axles I came to the conclusion I had already concluded. I needed something totally different! Im not sure why. Maybe its because there are three Bodies/generations to these Excels. As Follows:
X1 1986-1989
X2 1990-1991
X3 1992-1994
Mine is a 1991 so I have an X2. Most swaps I have seen out there have all been X3 Excels, all have expressed no issues using CSM axles, and elantra xmembers. Did I mention I could not use the early elantra Xmember? It wouldnt line up. I used my original Excel xmember and welded mounts onto it.
Someone earlier quoted me that My excel is a Modified C10 chassis,
In conclusion I beleive my problem all along was a combo of having an X2 Excel and the engine placement in the car, also possibly a wheelbase difference between CSM and Hyundai.
This is what I have tried:
92 DSM Intermediate shaft with CSM axle: Too Long
90 Galant FWD Long Axle: Way Too Long
Original unmodified Excel axle: Perfect Length but does not lock into trans, Pops out!
Now, I finally have an axle that is the right length and does not pop out of the trans, in my last post I mentioned that I was going to try to build a hybrid Axle, and I have done it with the help of Archi at PSI (Performance Specialties Innovations) Tucson AZ.
What I did was use my original Excel axle with a 1990 Hyundai Sonata Trans side cup. The Sonata Cup is a larger diameter at the bearing area but it is a perfect fit where it slides into the trans, Locks in Nicely!
In order to have this cup work on the thinner excel axle, Archie welded the larger sonata interior part/Cog? Onto my Excel axle.
Normally this piece slides over some Splines and is locked into place with a C-Clip. This is a part that never moves, so I figured welding it into place was the best solution. Since it was a larger spline diameter it slipped right over the Excel Axle. Archie centered it using some wire shims and tacked it into place A full weld on both sides will keep it in place for good. Be sure to have the boot and bearing holder ring already around the axle before you weld or you will never get them on again!
Enjoy the Pics!!!
Excel 1.5 Sonata 2.0 90 Galant FWD
Excel 1.5 on the right Sonata 2.0 on the left.
This is the Sonata Centerpiece over the Excel Axle
This is the same piece welded in place by Archie
This is the bearing holding ring over the center piece
This is where everything slides into. Dont forget to shoot some C/V axle grease in there. There is also a large Clip that keeps the combo from sliding back out. Dont forget that, Sorry No pics,
Here is the finished Product