Once I had the original axles apart I spent some (unnecessary) time cleaning them up and giving them a new coat of paint. Now for assembly.
STAGE 2
1 - These are the parts for the hub side of the shaft. The original RX7 hub spline and bearing cage. Also the DSS bearing core.
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2 - There are no instructions with these kits so you kind of have to guess/assume how things go together This is the orientation of the parts (I hope). Notice the bearing cage has a slightly larger radiused recess which points away from the spline.
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Drop the cage into the housing. You need to keep the gaps on the sides (as pictured) otherwise it won't go in.
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3 - Now put the core into the cage. To do this you need to hook one of the points into one of the holes in the cage.
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Take note of the core orientation. The flat surface (I assumed) was the clip side and the other side is tapered at the opening so the c-clip slides in.
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4 - Next you need to twist the core and cage so that you can start pushing the bearings in from the outside. The first three go in pretty easy.
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To get the last few in I had to use a screwdriver to lever the cage up to make room.
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5 - Now you can slide the rubber boot on the shaft and push it into the core. When I did this one went in easily and the other took me several evenings. No matter how hard I tried, the c-clip simply wouldn't pass through. Then, after a forehead slapping moment I realised that the shaft had been supplied with the c-clip and circlip on the wrong ends. One of the grooves these sit in is deeper than the other. I swapped the clips and bingo, it went in nicely.
6 - Slide the boot over the housing, put a clip on and tighten. Job done (partly). I resented buying a proper tool for the clips so I made a botch-job version myself. Worked great
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