checked the size of the LSD hole by lathing a tube diameter down till it fits.
found the inside is 60mm while the outside of the tapered hole is exactly 60.1mm
[ATTACH=full]50233[/ATTACH]
lets dismantle the inner joint so I can use the inner shaft as reference for lathing the new piece. cut off the one-piece boot clip
[ATTACH=full]50235[/ATTACH]
ew it's filled with this brown runny goo. wonder if I'll be alright using that dark grey CV grease I got from halfords
[ATTACH=full]50239[/ATTACH]
the inner shaft has a nicely machined lip, gr8 for clamping on the lathe
[ATTACH=full]50237[/ATTACH]
other than some little heat discolouration, ain't too bad inside
[ATTACH=full]50236[/ATTACH]
machined a tube upto 59.92mm inner dia
[ATTACH=full]50234[/ATTACH]
and it slips nicely over the 59.91mm shaft.
mount the assembly onto lathe, center it, then lathe the outer dia to precisely match the LSD bore 
[ATTACH=full]50238[/ATTACH]
