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Sanity Check, D44 Full Floater

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Slowtwitch View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Slowtwitch Quote  Post ReplyReply Direct Link To This Post Posted: 02 Feb. 2023 at 2:38pm
I got my situation figured out.. new to the axle thing and was thinking in terms of flangeless axles that require a 'drive lug' to be bolted to the hub.

Anyways, axles have been ordered through Dutchman. According to TJ @ Dutchman, they will NOT turn down one piece axles, and they strongly discourage doing so as it greatly increases likelihood of breakage. He also mentioned that it would be a couple hour process.

He said a two piece axle could be turned down safely.. a difference in the castings evidently.

The two axles for a Narrow track D44 are 22.25 and 30.5 inches. This was taken from the face of an installed hub on Brennan's spindles to the center pin then - .25" (as per Brennan) with an ARB diff.

These guys are crazy busy.. lead times are increasing.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Slowtwitch Quote  Post ReplyReply Direct Link To This Post Posted: 01 Mar. 2023 at 3:33pm
I got the axles. Length is perfect. The diameter towards the middle was too large. Looks like they post machine the diff ends after heat treatment (shaft is a darker color than turned ends). To transition the difference in diameter (stress relief) they grind a radius at the transition. The main shaft then tapers down towards the flanges. I was able to maintain the ground in transition, and the cut then just tappers off as the axle tapers in towards the flange. Doesn't strike me as stress inducing... at least not to an extent that will matter with 'normal' use. The axles showed obvious turning marks as received, so....Setup in the lathe took all of a minute.. the spline end is nicely center drilled and even greased!

So I don't know..my gut tells me taking a small cut off these is no issue whatsoever. Someone at Dutchman told me otherwise. Seems like it would be no problem for them to turn it to desired dia at Dutchman. Only the shadow knows... YMMV.

I am using  two rock assault seals 144020 at each end. They do not seat firm on the OD... close, so I sealed them in with some RTV... time will tell.
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Metcalf View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Metcalf Quote  Post ReplyReply Direct Link To This Post Posted: 02 Mar. 2023 at 4:08pm
Originally posted by Slowtwitch Slowtwitch wrote:

I got my situation figured out.. new to the axle thing and was thinking in terms of flangeless axles that require a 'drive lug' to be bolted to the hub.

Anyways, axles have been ordered through Dutchman. According to TJ @ Dutchman, they will NOT turn down one piece axles, and they strongly discourage doing so as it greatly increases likelihood of breakage. He also mentioned that it would be a couple hour process.

He said a two piece axle could be turned down safely.. a difference in the castings evidently.

The two axles for a Narrow track D44 are 22.25 and 30.5 inches. This was taken from the face of an installed hub on Brennan's spindles to the center pin then - .25" (as per Brennan) with an ARB diff.

These guys are crazy busy.. lead times are increasing.

I should call Dutchman and remind them that they turned down the OD on my full float one piece1541 axle shafts a decade ago.....and that they have functioned flawlessly for that time. They are NOT weak. 

My gut feeling is that they just don't want to do the work anymore, not that there is any engineering behind it really. They turn down the section for the splines and seal......it doesn't break there. They up-charged me to do it all those years ago, but at least they did it. 

Technically speaking, turning down the shaft all the way to spline minor would actually give even better shaft performance because of the increased torsion capacity. There would also be less root cracking where the splines end. Carl Jantz did a lot of experimenting with this on OEM spicer shafts years back with excellent results. 




Edited by Metcalf - 02 Mar. 2023 at 4:09pm
42 MB that had a one night stand with a much younger 69 CJ5 and a 50s GM truck.



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Post Options Post Options   Thanks (0) Thanks(0)   Quote Slowtwitch Quote  Post ReplyReply Direct Link To This Post Posted: 02 Mar. 2023 at 7:41pm
It very well could be luck of the draw who shepherds the order through. It is odd they don't do it the way you suggest... seems it would be easier.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Metcalf Quote  Post ReplyReply Direct Link To This Post Posted: 02 Mar. 2023 at 10:53pm
I think it would be better, yes. Is it easier, no. Turning down the shaft is extra work, I don't mind paying for that. The 1pc shaft system is still simplier and cheaper than double spline shafts ( in addition to having to purchase a locking hub or drive flange ). I just don't really understand why they wouldn't offer the service since it would be an issue for many applications with a shaft like this. In most floaters, the spindle bore does not have a lot of extra space. If the forging is large enough to turn for the splines....it probably have to be turned to pass through the spindle. 


42 MB that had a one night stand with a much younger 69 CJ5 and a 50s GM truck.



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Post Options Post Options   Thanks (0) Thanks(0)   Quote Slowtwitch Quote  Post ReplyReply Direct Link To This Post Posted: 05 Mar. 2023 at 11:42am
I was thinking they could just continue the lathe cut all the way to the tapper at the flange and not need the grinding op at the diameter/cut transition that they currently perform.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Metcalf Quote  Post ReplyReply Direct Link To This Post Posted: 08 Mar. 2023 at 4:25pm
Originally posted by Slowtwitch Slowtwitch wrote:

I was thinking they could just continue the lathe cut all the way to the tapper at the flange and not need the grinding op at the diameter/cut transition that they currently perform.

Yup, it is not much extra work in my opinion to turn the shaft to spline major diameter. There are probably pics of my shafts floating around in the Rango build thread, I think the shaft necked down under spline major about 8" away from the flange. I'm pretty sure they didn't have to turn the entire shaft. 


42 MB that had a one night stand with a much younger 69 CJ5 and a 50s GM truck.



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