want to cut an axle!

[minibajaman]

Originally Posted by K-fab

Take them to a drive shaft shop. They'll have all the stuff needed and can make sure everything is nice and straight.

If you overlap the tube 3" like I did and make it a tight fit, there is almost no way it will not be straight.

Originally Posted by Bugpac

Be carefull when boring, dont leave a square edge inside, I broke my first set like that, I chose after to Use a piece of 4130 bar and drill the ends in... I prefer to turn the axle to fit the dom myself, each has there own way tho...

I agree. Actually I drilled out the tube for mine, it worked out that the shafts were about .879" so using a .875" drill bit made a perfect press fit and I didn't have to do any cutting to the hardened axle shafts.

[Philabuster]

Originally Posted by minibajaman

If you overlap the tube 3" like I did and make it a tight fit, there is almost no way it will not be straight.

It will be straight before welding. After welding, it may need to be straightened back up.

[deviant_illusion]

I did this with my Rhino Axles. 3.5" over stock very thick wall DOM and a press fit. We put them In an oven @400 deg for about an hour pulled them out welded them placed them back in the oven and turned it off allowing them to cool slowly. I really have no clue if this step helped or not. I never had a problem with them but after I sold it I ran into the guy that bought it and he broke one rear the first weekend he had it out. So I may try it again some time on my Teryx.

[buggito]

I weld my first set and they hold, just drill a pin hole to release gas when welding and pressing in, then plug it when done, we put booth end on the lathe to check how straight it was and we got a 1/2 thousand , no wobble, I pres3" both side .250 wall tig well around plug four "pin" hole ( around .250)

[LiveWire]

These were welded at the ends along with the rosette welds