Anyone ever fixed the caster in their front axle by cutting the tube, sleaving it on the inside with a slightly smaller tube that will still clear the axleshaft. Then sliding the out part of the tube on and welding them back together both at the seam and with maybe a few plug welds at the correct caster. Seems easier than grinding and turning the knuckles. Plus it would strengthen it. I think 3/16th wall would be enough, without add too much weight.

(Not to mention that when it's cut apart it would be much easier to machine the spring perch to correct the pinion angle.)

Any input?

IMO, it would be much easier to cut/ grind the welds, than to do all that press/ machine work. Prolly take an hour or so to grind, turn and weld.

I find that heat and penetrating oil helps tremendously

Seek out the articles by Mike Knorr on this exact subject......
BC4x4.com has the links.

it would be easier to just chop the tubes and put the sleeves on the outside, sure youd have to put new perches but it seems a hell of a lot easier than doing it the way your saying

Just had this done to a Scout 44 for the front of my cj5. Needed the obligatory 5* change (plus additiopnal 5* resulting from SOA)so buddy did cut the tubes a few inches shy of the welds at the knuckles. Tubed the inside, welded up the seam and rosetted a bunch of holes that were drilled in the original tube before sleeving once the castor was set. A lot of heat into the tubes but he is also able to true up the tube (great fab'er) so warpage was not an item. Clean up the welds and ya can't tell anyone was there. Plus you end up with a verrry strong tube to "hopefully" guard against future damage.

He says that sleeving is the way to go for him but I would think that if yer soing it at home without the aid of jigs etc to true it up, you'd be safer with the grind and turn the knuckles routine.

To each their own and what works, works.... but it only took about an hour to cut and turn the yokes. I don't think I could have cut the tube, cut the sleeves, deburred, fitted, set up the jig, trued, welded and ground down the beads in an hour.