I would suggest you direct these questions to the supplier of the Nitro axles and housings.
If I hadn't had some many issues with the supplier already I would definitely make that my first call, because of all those problems I do not have confidence in the vendor at this point. Trying to get them to correct this would only delay my project more. Unfortunately, I want it done right and feel I can do a better job than they have so far.
I unbolted one hub axle flange, with the 1/8 inch gap the I can turn the hub by hand. It is still tight but doable. I can also turn it easily at the pinion flange.
The axle shafts are 35" long not including the flange. The center of the pinion shaft to the outer hub surface is 35 3/8 inches. That would only leave 3/4 inches in between the axle shafts. Is that enough room?
Take the shafts out and use a large diameter dowel to measure the distance to the hub flange. Then cut 1/8 short of that length.
What length are the current axles? 35.0625 - .125 does not equal 34.5625 so im skeptical about your math. Did both sides measure the same with the dowel?I measure using the dowel, and got a fraction over 35 1/16th inches, less 1/8th would bring the desired length to 34 9/16th inches. According to this the axles is 1/16th inch too long. Which would explain the 1/8th inch gap I am getting. The opposite side does not have the tension when the other flange is unbolted.
Looks like I will be trimming 1/8th of an inch off of each axle. Any other thoughts before I do that?
I appreciate the help.