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post #1 of (permalink) Old 03-05-2001, 12:03 AM
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Axle housing cutting?

I need your thoughts on the best way to shorten axle housings. Either a D60, D44, or 9".

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post #2 of (permalink) Old 03-05-2001, 08:54 AM
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Re: Axle housing cutting?

For the rear to just shorten the tubes the rossetts?(holes on the pumpkin that are filled with weld to hold the tube in) are burned out and the weld around the tube is ground off. The tube in then pulled out, cut to length, reinstalled, a jig like the one in the high pinion page is used to ensure straightness and then rewelded. As for the shaft, custom shafts can be made or the shaft can be cut down and resplined.
Good Luck

76 CJ5 360/T18A/Bronco gear D20/D30 big brake disc, locker/D44 big drum working on disc/ factory slip/4inch lift/33's/6000lb winch/All Fiberglass/electric fan/full cage/ appetite for MUD
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post #3 of (permalink) Old 03-05-2001, 09:26 AM
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Re: Axle housing cutting?

Pigpen is right for D44's and 60's, and I haven't messed with 9" stuff that much. After you have cut the tubes, it is best if the axles are pressed back into the housing. I am not exactly sure what the correct interference is, but I know that it is a fairly tight fit. You will probably need to get the ends turned on a lathe to get the right fit. I would recommend warming the center section in an oven to get the holes a little bigger, and if you can, freeze the axle tubes. The extra expansion and contraction make all the difference in the world. I am not so sure about the welds around the tubes. Everything I have seen warns against welding around the tubes. With a good press fit, and the plug welds in the housing you shouldn't need to weld around the tube. If you do weld around the tubes, it will create a heat affected zone around the axle tube creating what is called a stress concentration. Stress concentrations can lead to premature failure of the housing. If you don't press fit, and you do weld the tubes, I would not run the axle without a truss of some sort. I would not let any of the complications stop you from shortening your housings, just be sure to follow good practices when you are doing it. Unless you always wheel close to home and don't mind getting stranded.

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post #4 of (permalink) Old 03-05-2001, 09:42 AM
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Re: Axle housing cutting?

Thats the high tech way.. then you have my way.. hehehe... i stuck the axle housing in a band saw.. and chopped it in the middle of the tube.. (since it was a semi-floater D60) took out 3".. then for welding it up.. i checked it with a level.. like 100 times.. then welded it back.. i then took a piece of 3" tube.. sliced it length ways.. and put one piece on top.. and one on the bottom.. welded them on..
will be giving it the road test here in a few days..

84 CJ-7 401/T-18/D20/D44/D60w/4.10&Detriots/YJ frame & tub/35x16x15 Boggers
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post #5 of (permalink) Old 03-05-2001, 12:22 PM
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Re: Axle housing cutting?

How has the splice held up? I am always interested in easier ways of doing things. I saw on the other post concerning shortening D60's that they just welded the tube. They used a full penetration groove weld, but they just welded the bearing ends right on. I wonder if they did any post weld heat treat.
Do you have a truss of any sort on your axle. Have you seen any cracking around the sleeve at the welds.
I have a CJ 5 that I plan on using a D44 on the front, and wasn't looking forward to the whole shortening process. If the sleeve works, why mess with a good thing, and it is a whole lot easier than all the pressing, and other crap.
I have access to all the needed tools to do it the hard way, but if the sleeve works?
Cage Up, Wheel Down

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