Ok so I want to make a square driveline, I know the pros and cons. any of you made one? If so How?two pieces of square tube that fit inside one another 1/8 or 3/16 wall? do you weld to orig. tube or just to the yokes? any tips or hints would be helpful.

Im trying to do this by Fri so I can wheel on Sat.


Thanks Ryan

I just built mine tonite, wish i had some pictures. I used 2.5", 1/4" wall square tube, and 2", 1/4" wall tube. In order to get them to slide, you can use seamless tubing but is not as tight as using tube with a seam.

First you need to get the 2" to slide in side the 2.5". This can be done by either milling a grove for the seam, this can also be done with a angle grinder but is more time consuming.

Once you get them to slide nicely inside each other, its is time for yokes. I used 1350 slip yokes from slip yoke t-cases, but u can use sliders from drive shafts, or the other end of the drive shaft. My yokes fit loose inside of the 2.5", so i centered them, plug welded and welded around the end. For the 2" end i sleaved them with a piece of 2.5". If you use sliders, they might fit inside the 2". If you use the other end of a stock drive shaft, u can cut it off, and use a grinder and square off the end so it slides inside the square tube.

Hope this helps.

I made one. you need to get a length of 2.5" square tube flash removed. it will save you a lot of work. I used my stock yoke and CV. slide the yoke into the 2.5" weld it up. I drilled holes in the tube and plug welded it along with around the end. grind the stub hanging off the end of the CV into a square. weld it to the 2" tube. apply lots of grease and install in the truck.

make sure you have the U-joints phased.

I have pics somewhere.

awesome, pics would be great. Sounds simple enough. sounds like with my stock shaft one end will be nice and snug so slide on and weld. The other end is going to be sloppy. I might need a lil clarifying on what to do on that end thanks so much.

Ryan

http://www.runandplaymotorsports.com/working_on_the_little_gray_truck.htm

OK so im on my way. got the yoaks apart, got the tubing. Im going to have 4in exposed, and 10in inside, that is with assuming 7in can slide out and leave me with 3in left when at full droop or flex. What would you guys say is the min amount of shaft contact you would want at full flex?

thanks again Ryan

302188 2" Seamless 1-1/2 seamless You may want to run a bead along the corners of the inner for less movement also drill a hole in the lower end by your 3rd member to drain any water from river crossing.

thanks, I got it done, took it out this weekend worked flawlesly. just needs some zerks.

Happy Wheelin':D

got pics?

2" Seamless 1-1/2 seamless
... also drill a hole in the lower end by your 3rd member to drain any water from river crossing.

Why wouldn't you put the tubes the other way around? (1.5" on the axle side and 2" on the t-case side) Should still let the water and the rest of the crap out.

I would think you would run the big end at the axle for 2 possible reasons:

1. It's bigger so it will take being bashed against rocks better and

2. Gives you more clearance around the transmission and other components.