Hey guys help this newbie out.

I try to figure out how axleshafts are made. Obviously (I guess) the shaft themselves are probably extruded or rolled, but how are the flanges and u-joint yokes attached. My mind says that these have to start out life as seperate pieces, how are the joined, some sort of resistance welding or something? Are they pressed together and then welded. I know the old amc model 20 had problems with two piece shafts, so I guess there is something obviously different in the construction of a 1-piece shaft.

I'm not quite ready to start making my own, but I'm curious. I guess one reason I'm asking is most of the front axle breakage I see is the yokes on the u-joints, it would seem to me if someone could make a strong 2 piece front shaft, we could just replace the yokes, or the shaft depending on what went. without having to shell out the money for a complete shaft. I'm sure there is a good reason this isn't done, but I don't know it...

Chad

Just to clarify you are asking about axle shafts correct?

Do a search on CTM joints or warn shafts. There is a mountain of info on here about all of those components.

Oh yeah :flipoff2:

Yes axle shaft, the part that goes from the diff to the wheel flange or u-joint yoke... I've read the tons of articles on CTM's and alloy shafts, including many breakage pictures which is why I asked the question. How is the flange (or u-joint yoke) attached to the shaft (the round part). They are often called "one piece", but I doubt they are really carved out of one huge chunk of steel,
there must be someway that the ends are attached to the shafts.... really more curiosity than anything...

chad

Ok sorry didn't mean to be a smart a$$, I accidently put driveshaft in the title, I might be an idiot, but I do know how those are made

They really start as one piece, it is a bar about the diameter of the axle part, and then it is forged to make the yoke for a front axle or the flange for a rear axle shaft. After that it is machined, heat treated and straightened.

First off...welcome...axle shafts a machined on a lathe or forged...when you here a two piece shaft it usually refers to the outer section(spud shaft) could either have a flange(1 piece) or splines needing a flange thus resulting in 2 piece's....most are cold roll steel or Chromoly....refer to the www.spicer.com or dutchman.com, or look at www.dynatrac.com....the list goes on but I'm tired of typing.....

The yoke seperate from the shaft is a good idea this is how Currie is building there front 9" with 60 ujoints now, and Sandy Cone is building Camo's axle this way too. The dificulty is that there is not much room there for a good method of holding the shaft into the yoke, so Curie is just cutting the splines so they are a press fit and tack welding the yoke to the shaft. I bet Sandy will do this too but I don't know for sure.

Thanks for the info guys, I never thought about forging. I looked at my yokes on my junk yard 44, and it looked like they were cast, then machine to make the ears, then some how joined to the shaft. But forging would give some what of the same finish as casting, and makes more sense.

I still think two piece shafts are an interesting (if not entirely feasible) idea. seems like such a waste to have to replace the entire inner shaft (especially some fancy alloy) for one broken u-joint ear.

Chad