I'm aware that having a shaft made to size, new by proper engineers is the way to go but I chose to take the path of certain destruction...cut 'n' shut driveshafts

This is what I did:

Set the shaft ends in diff and hub to get finished length:


Description


Marked, cut and weld prepped the shafts:


Description


Placed shafts in interrupted vee-block and mounted in 10T press to maintain some degree of straightness and to correct any 'pull' as I built the weld. I haven't got a picture of the welding and dressing as my camera and sparky grindy stuff don't mix.

Crucial bit was the welding though, Arc welded, slowly built-up, part vertical aspect with 29/9 rods. I've used these rods in industry on difficult steels and high stress rotating shafts and they produce very crack resistant and reliable joints.



Description



Finished shafts completed with can/boot sets from Ford dealer - note two sizes of can available 1058426 (smaller) 1058427 (larger approx. 65mm across i/d of can)



Description

I made shrink fit sleeves when I did mine. Then MIG'ed the whole lot up while it was still all hot.
Been OK for 8 years now, but then I'm only putting about 90 HP through them.

Neil