|
Working on the little gray truck, Tuffy II.
Square Shaft Build
After spending almost $400 on a custom long slip yoke, and have it pull apart
4-5 times on the trail and finally bend on the last obstacle at Outer Limits, it
was time for a Front
Square Shaft build. Parts cost maybe $20 for square tubing from the local scrap steel
yard.
High dollar long slip yoke proves worthless on Sledge Hammer.
Home again after the Outer Limits run.
 With
a dual transfer-case installed, a long
slip yoke was in order. Here it is, slightly bent from abuse on Outer Limits...square tube at
bottom.
I took the high dollar long slip yoke and with my Harbor Freight cut-off saw,
chopped the splined section off, leaving a good u-joint and flange.
Here I have started squaring up the step to push into 2" square tubing.
After checking it for square and welding it, this
part's done.
 Next
it was time to prep the transfer case end of the driveshaft. Started by using
a sawzall to chop it off at the nub. Than started squaring up with the grinder.
 
 Trying
to take care to square it up before welding.
 Nice
fit, as square as I'm getting it, ready for welding.
 2
1/2 " tubing welded to old stock '85 u-joint flange.
 Notice I used u-joints at both ends.
I also had to groove the inside tubing because I used square tubing instead of
receiver tubing. Each tube measures 23" long. With a 5" suspension lift,
dual transfer-case and the
front axle relocated 1 1/2 " forward, there is about 4" of the 2"
tube showing, so I figure I have about 18" of reliable slip. I
don't think this one will ever come apart.
 The
stock front driveshaft has a CV joint at the output flange of the transfercase.
I swapped it out for a flange drilled for a u-joint. I saved the CV joint
for future use at the rear shaft.
 Improvising
a special tool needed to remove the output flange. The C-clamp secures the bar,
the bar is wedged between two bolts on the flange at the transfercase. (See
above) This facilitates removal of the nut without the flange turning.
Testing the new square shaft on my Costco retaining wall index ramp!
(Outer Limits body damage)
The brake line is limiting droop, and the new square shaft still has plenty
of slip.
Back to build ups
|
