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Old 08-24-2011, 01:48 AM   #1 (permalink)
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Extending the Toyota Front Axle

Anyone done this? I searched, and didn't see anything offhand. Trail Gear makes their dirty 30 plus 3s, that is, the short side bird is extended 3 inches, designed to work with their axle housing. Makes it IFS width, without wheel spacers (duh, I know).

But, has anybody just spliced 3 inches into their stock Toyota front housing? Seems like something pretty easy to do if you're already doing an SAS. I don't have an axle here in front of me, and this might be totally retarded, but seems like you could just cut, weld in 3 inches of correct sized tube, then probably weld a sleeve over the outside of it for extra strength (I'm guessing this would be better than sleeving inside, to make sure the axle shaft has plenty of clearance on the inside, but I could be wrong?), and then you'd have to relocate your spring perches and steering stops - not too big a deal, especially if say you upgraded to something like the Ruff Stuff elongated perches... Then you could mod as usual - shave, truss, armor, whatever... Am I missing anything? Is this totally dumb? I know I'm a newb, but I've searched, and I don't think this is totally dumb... Would mean IFS width with no wheel spacers.

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Old 08-24-2011, 02:01 AM   #2 (permalink)
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If the goal is just to be IFS width without wheel spacers you could go the simple route and install the IFS hubs, rotors, etc. on the solid axle. There is good info on it in the FAQ 2.0 Front Axle-IFS Hub section.

Last edited by jersummers; 08-24-2011 at 02:32 AM.
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Old 08-24-2011, 05:57 AM   #3 (permalink)
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start reading

/forum/toyota-truck-4runner/854674-another-home-brew-front-axle-build.html
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Old 08-24-2011, 08:31 AM   #4 (permalink)
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Do you have access to a "jig bar" to keep it all straight when welding it back together?
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Old 08-24-2011, 10:11 AM   #5 (permalink)
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jersumers - It seems to me that even with the IFS hubs and all, you're still using a spacer, which wouldn't be as strong as having a longer axle.

Jake - I've read that - super cool, but a ton of work, and quite expensive. If you already have a front axle, making it a little longer, rather than fabbing an almost completely new one seems easier and cheaper.

OOP'S - I don't have a jig, but could have one machined up, or could weld up a half assed jig. Or, I think you would have decent success with tacking, installing your birf/eyeballing with a straight edge, pull the birf and weld a bit, repeat, massage with BFH as necessary. You would definitely stand a chance of warping your axle, but with a bit of patience, I would think you could do it. Definitely the best way to go though would be to have somebody machine up a 'jig bar'.

I'm getting ready to order all of my goodies, so now would be the time, if ever, to try this...

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Old 08-24-2011, 10:32 AM   #6 (permalink)
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I would just make a jig out of square tube and old perches, flip perchs and weld them on to the square tube and drill holes so you can run a u-bolt through it and clamp down the axle housing. make some feet for the square tube and connect the two together with more square tube. If you take your time and make this right is will hold the axle tubes and prevent it from warping. It still is a good idea to have a alignment bar in it too
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Old 08-24-2011, 11:09 AM   #7 (permalink)
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Sparticus - I was thinking the same thing. After reading a bunch, it definitely seems like a 'jig bar' would be worthwhile - I wonder if there's anything out there which would work, which didn't have to be custom machined?

After searching, I wasn't able to find anything other than the link above which shows an axle housing being almost completely fabled - but apparently I didn't include all the right search terms - kept using the word 'extend' instead of 'widen' - plug that one in and you come up with this thread:

http://pirate4x4.com/forum/showthrea...t=gettin+wider

which shows a guy doing almost exactly what I was thinking, except way higher quality then what I was envisioning. Way cool. I'm only 7 out of the 11 pages through it.

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Old 08-24-2011, 11:16 AM   #8 (permalink)
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or... even easier, put a dana 60 in it
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Old 08-24-2011, 12:01 PM   #9 (permalink)
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i will have to draw up the jig plans i think it would make the axle houseing easier to make by far
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Old 08-24-2011, 12:15 PM   #10 (permalink)
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or... even easier, put a dana 60 in it
There is always one bad apple in the bunch.
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Old 08-24-2011, 12:42 PM   #11 (permalink)
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/forum/axles-tires-wheels/997804-fj80-high-steer-way-you-need.html
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Old 08-24-2011, 01:44 PM   #12 (permalink)
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http://www.diamondaxle.com/index.htm

http://www.ruffstuffspecialties.com/...eHousings.html
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Old 08-24-2011, 01:47 PM   #13 (permalink)
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Old 08-24-2011, 02:22 PM   #14 (permalink)
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widening toy axles is common in the cruiser world when they put fj-60 axles under fj-40's cause it puts the pumpkin where the spring perch should be:

/forum/toyota-land-cruiser/694646-fj60-axle-sleeve-widening-front.html

the guys name is Dave Gore, real nice guy and easy to do business with. i bought two spacers from him and the long side inner longfield shaft (he was out of the short sides at the time) to build my axle.

I was planning on grinding the weld for the knuckle balls, and making two identicaly beams out of some smaller I beams that would mount to the top and bottom knuckle studs which would not only ensure they were welded back on strait and hold it strait but make sure each had exactly the same caster.

I am still planning exaclty how this will work but i think it it should keep it strait enough.
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Old 08-24-2011, 04:13 PM   #15 (permalink)
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jersumers - It seems to me that even with the IFS hubs and all, you're still using a spacer, which wouldn't be as strong as having a longer axle.
Spruce
I was mainly referring to the last line on your original post where you mentioned "IFS Width with no spacers" which is what the IFS hub swap offers. It puts you almost exactly at the same width of the IFS rear axle. I agree it probably isn't as strong as extending the axle itself, but many guys on here have been running it with big tires, lockers, etc. even as daily drivers with no issues at all for years.

Anyway, good luck with the axle build.
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Old 08-24-2011, 05:04 PM   #16 (permalink)
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Huh, nice links fellas. Overall I doubt I'll go to the trouble at this point - gotta learn to crawl, before you can walk, and at this point I have enough other things to learn how to build, so that this should be the least of my worries. But, I get sidetracked...

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Old 08-24-2011, 05:11 PM   #17 (permalink)
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Do the ifs hub mod, my current truck has it as do the last 4 trucks I have done SAS on.
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Old 08-24-2011, 06:30 PM   #18 (permalink)
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Jake posted the link to my thread already

but i think what your looking to do is more like what Pat did in his "getting wider" thread
http://pirate4x4.com/forum/showthrea...=654231&page=3

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Old 08-24-2011, 07:30 PM   #19 (permalink)
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Nope...

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Old 08-25-2011, 03:18 AM   #20 (permalink)
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Wasn't there a picture in one of the FAIL threads where someone made a centered toy front with two long side shafts? It was was pretty, um, special.

IFS hub mod, and if you want to go baller do the taco rotor swap at the same time.

Or buy a Dana 60.
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Old 08-25-2011, 10:01 AM   #21 (permalink)
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Jake posted the link to my thread already

but i think what your looking to do is more like what Pat did in his "getting wider" thread
http://pirate4x4.com/forum/showthrea...=654231&page=3

this^^^^^^^^^^^ I owned that axle awhile
& you better have a good jig, these axles bend even tacking on a weld on truss.!
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