want to cut an axle!

[TEO]

Can you cut and lengthen an axle? I have a pair of axles from a pontiac G6, they measure 13-3/4" spline to spline. Can I add say 4"?

[bdkw1]

Are they a nice consistent diameter? If so, cut a piece of tubing about 6" longer than you want to extend them. bore the ID to make them the axle pieces a press fit. Cut axle in two and press into tube to desired length. Check for straitness. Weld. Recheck straitness. If your running a lot of power through them fish mouth the ends of the tube for more weld surface area.

[TEO]

So shove them up each end 3" and weld (straighten if needed). How thick wall should the tube be? Can it be like 1018?

[bdkw1]

I would use 4130, 1018 is a little on the weak side. .120 wall minimum.

[sodman]

TIO
I used 1.50 inch DOm .25 wall for my jetta axles I shortened not lenghtened mine but I've had no issues so far got the idea off of plkracers thread worked for me I'm on the lower HP band though than most here around 35 HP. I'll quote plkracer "cheaper than custom axels"
Later Sodman

[sodman]

Sorry should have TEO to TIO memory good just short
Latter Sodman

[minibajaman]

I did what bdkw1 said to my axles. Took a piece of 1.25" OD x 0.25" wall 4130 tube, drilled out the ends to match the axles (.875") about 3" deep, put a slight fishmouth on each end, and also drilled two holes thru each end for a rosette weld. Then I pressed the axle halves into the tube and welded it up. I have had no problems so far. I think it would hold up just fine for a lot more than the 70hp I am putting through it.

[TEO]

Those look sweet! Thats were I'm headed, Thanks for all the feedback.

[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.

[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...