Attempting to Strengthen Front Axle For 40's?

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You ever modify a 80 series full float rear axle housing adapted for late 80’s-90’s yota pick ups? Always thought that would be the shizz. I’m not a fan of semi float designs.

Nope. Mostly Dana 44, 60 and Ford 9 inch housings.

Start your own thread on it if you want and I'll do my best to explain the process.
 
I'm more of a burn it in hot and straighten it later type of fabricator.

I'm a better at machining and bending stuff than welding.
Well that’s a different approach.
I haven’t heard that one 🤣
 
You ever modify a 80 series full float rear axle housing adapted for late 80’s-90’s yota pick ups? Always thought that would be the shizz. I’m not a fan of semi float designs.
The main problem is it’s off set. Mini truck stuff is centered.
By the time you deal with all that may as well go custom housing 🤷‍♂️
 
Where are you all sourcing best knuckle gussets? Or DIY?
Marlin crawler makes a a set for the mini truck housing that easily modified to fit a 80 axle
I’m running them 😎
 
The last Toyota axle I will ever make for 40s+. It's a hybrid axle 91 semi float rear axle cut down for a frnt axle. Best of all worlds 9.5 ring gear with the larger Birfs . Even with all this work still needed to be mindful with the skinny pedal . Once I got everything dialed in I ran 43 stikckies for a few years problem free (on a buggy)

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Well that’s a different approach.
I haven’t heard that one 🤣

Im not saying I throw caution to the wind and weld hot from one end to the other, but rather that I tend to plan out my welds, burn them in good then measure and correct any distortion at the end. Usually not very much.

If I am for zero distortion I'll take much longer, welds will be weak and ugly. and it'll probably have distortion anyway lol.

In my teens/20's I was a good welder. In my 40's not so much anymore. I don't see as good under a hood. Probably why I don't enjoy it like I used to.
 
How does one bend/straighten a warped axle?

I use a rosebud on an acetylene torch and a heavy t-slotted table with clamps and jacks. The torch usually does a good job, but the table is necessary for real bad stuff. I've straightened out excavator booms, truck frames, bent hydraulic cylinder rods and tubes, big weldments.

I used to do alot of heavy repair work for the PNW logging industry. My shop is the closest big machine shop to a concentration of logging companies and a few of my friends are field mechanics for them. So I did the stuff that was too big or time consuming for the mobile guys to handle. Mostly large lathe and HBM jobs (Horizontal Boring Mill is a huge milling machine that can do anything if you're crazy enough). Most of the welding I did was bore out, build up with weld and re-bore.

Just a couple days ago I put a new center and bushings in an old 1980's Cat220 excavator track nose wheel. I still do some of that stuff for locals, but mostly got out of it for it's feast/famine nature. Fun work. I love doing repair machining and emergency breakdown work. Just not consistent enough to support the cost of living around here.
 
Im not saying I throw caution to the wind and weld hot from one end to the other, but rather that I tend to plan out my welds, burn them in good then measure and correct any distortion at the end. Usually not very much.

If I am for zero distortion I'll take much longer, welds will be weak and ugly. and it'll probably have distortion anyway lol.

In my teens/20's I was a good welder. In my 40's not so much anymore. I don't see as good under a hood. Probably why I don't enjoy it like I used to.
40 just a puppy, I'm 67 and ya I don't see as good as I used to !
I did that truss about 8 years ago and it's held up well. I'm sure there's better.
There's puck's in there and the tube I did short hot welds jumping from side to side and front to back and spinning the the tube to make sure it was not binding.
I wish you where closer, I would hire you to help me straighten my front bumper on that table of yours 😎
 
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Marlin crawler makes a a set for the mini truck housing that easily modified to fit a 80 axle
I’m running them 😎
If only they would stock them. They’ve been out of stock for months now.
 
The last Toyota axle I will ever make for 40s+. It's a hybrid axle 91 semi float rear axle cut down for a frnt axle. Best of all worlds 9.5 ring gear with the larger Birfs . Even with all this work still needed to be mindful with the skinny pedal . Once I got everything dialed in I ran 43 stikckies for a few years problem free (on a buggy)

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That was a sweet front housing Randy
 
If only they would stock them. They’ve been out of stock for months now.
These guy make the best one IMO runs all the way to the control arm mount. Very nice
 
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