I just double checked it and I'm still seeing 3.8125 for a 382S which I am 99% sure is a d60 carrier bearing race.
In case you aren't aware of this tool, take the blue pill and follow me down the rabbit hole:
Go to www.timken.com . Click on "online services" in the upper right hand corner. Then click on "bearings online services" on the left. At this point, you will have to register, if you have not done so. It's not difficult.
Once registered, go to "Timken Bearing Product Dimensional Data By Part Number" and punch in a 382-S race.
... 3.8125 and it even references the 387A bearing cone for a d60 carrier.
I'd hate to "ruin" a prefectly good set of d60 side gears. Plus, the only d60 carrier I have lying around is a 35 spline spool.
True, two 1" donuts will work and that's probably what I'll end up doing tomorrow morning ... if I can get to work before the boss man gets there. However, I think one long tube would better support and align the alignment bar. Although the amount of alignment that is realistically necessary is debateable.
I think you are waisting your time with the tube idea. If you wanted to be fancy then make 2 donuts and a tube between then and slide it all onto the bar and bolt them together so that they become 1 unit but still a waist of time IMO. When you weld it all together it will move quite a bit so worrying about a few thou won't make it wheel any better.
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