Axle replacement options

[MillWeld]

From all the suggestions I have received, I plan to do:
1. cut the axle about 8" from the brake mounting flange
2. slip/press a larger 16" tube/sleeve over the cut end leaving enough room for a torque wrench to fit over the brake plate nuts and weld
3. slip/press a pipe (~2" sched 80) in the other ends of the sleeve and weld.

The 3" sleeve will rest on the springs so I will change the u-bolts to acommodate them.
I need to locate the steel and the sleeve will need some machining. I'll post pics when the parts are ready to assemble.

Thanks for replies,
Bob

 

[petes]

The answer is simple - Rotate the axle 180 degrees and continue drive over the same roads for another 12 years... that should put it about straight, THEN weld up some reinforcement to keep it from bending further! (kidding of course) ;]

 

[MillWeld]

It's even simpler - I will just drive backwards over the same routes of the last 12 years. Reverse things and you reverse the effect, right?:confused2:
Bob

 

[MillWeld]

I pretty much followed my plan in post #11. Today I got the pipe back from the machine shop where they bored out the OD to receive the old axle (cut off to 6" long). I drilled suitably places holes for plug welding, inserted the axle/spindle assembly into the sch 80 pipe, plug welded and welded around the end of the pipe. Then I placed, leveled and welded the spring seats. Electrodes were E6011 and 7018 both 5/32". Went pretty fast. See pics.
I made pretty careful measurements to assure my torque wrench would still fit over the brake mounting flange nut with the larger diameter pipe.
Tomorrow I fish the brake wires thru the axle, put the brakes and drums on and hang the axle under the sawmill and mount the wheels. :cool2:

 

[Renze]

Thought of needing new U bolts to fit the bigger diameter ?

 

[MillWeld]

Yes. I bought new Ubolts. New axle is on the mill now. Pics to follow when I get the brakes connected.
Bob

 

[PILOON]

Nice work, the rosette welds about 6-8" between shaft ends and spring brackets are the right way to go.

 

[Renze]

Yes. I bought new Ubolts. New axle is on the mill now. Pics to follow when I get the brakes connected.
Bob

I was just wondering if they were available for the new tube size, but apparently you knew they were before setting the saw in the axle

 

[MillWeld]

The axle is installed. The Ubolts are for a 3" axle and the sch 80 pipe I used is 2.9" so I inserted a u shaped shim around the Ubolt to take up the gap. Don't know if that was necessary but it was easy to do. Also the threads on the Ubolt were not long enough so I added a 1/2" bar on top of the plate. See pic. Its torqued down to ~60 ft-lbs and ready for wheels to go back on. All-in-all it was a pretty straightforward project.

 

[George2615]

I missed your original post and as I read I agree with easygo (post 5) as to what caused the bending. It seems you did a great job beefing up your axle at the most reasonable cost. That's what I would have done. Great job.