Axle Housing Upgrade - Page 2

The new 3.25 OD. DOM tube was a little wider than the stock center section so we had to cut some notches front and back to allow the new axle tube to engage the center section as far in as possible.

Next the cleaned up center sections and knuckles were placed in the jig.  We could now measure for our axle tubes.

Mark cut the tubes.  Once that was done I drilled four holes in the knuckle end of each tube to allow us to place some additional  plug welds at 90 degree increments.

The knuckles could then be pressed into the new axle tubes.

The axle jig was loaded up one last time and we set the caster for the knuckles.   I went a little more than last time to eliminate a slight bit of front driveshaft bind that occurs on full droop. Mark then went to work welding up the housings.  He did small sections at a time to avoid building up a lot of heat in one spot.

Once my housing was done we let it cool for a while then removed the axle jig.  Marks housing was then setup and welded.  I am in the process of installing spring perches, shock mounts and eliminating the passenger side inner u-bolt on my housing. 

Update1-31-04 - Here's what the assembled and installed housing looks like.

These pictures show the blocks I welded on the passenger side of the axle so I could eliminate the inner u-bolt.

Top view of the passenger side spring plate.