retubing an axle

[Bigbike]

SO I want to retube my d60, because it is VERY narrow, and I cant get the coil mounts on easily or comfertably. Whats the deal with retubing? Paging Justin W!

[Zullock Holmes]

take them out, put new ones in.

You can either pull them out of the housing or make sleeves and just add new, longer pieces of axle tube to each side. Measure a lot, press fit and plug weld the sleeves if you go that route, put the c's on, get yo pinion angle where you want it, set your caster, weld your c's and you're in business.

I have some pictures from when I did my front axle, nothings online, so i'll show ya next time I see ya.

None of it is really all that complicated, use a welder capable of welding thick shit and you'll be fine. Measure a lot and make sure your tubes are straight.

Also search on pirate, lots of pics and write-ups

[customcreationsllc]

rear or front axle?

I have axle tube 3-1/8X5/16wall
And tube to sleeve inside of D60 but you need to machine those because everyone is a little different.

Front axle is a lot more forgiving than the rear. The rear you will need an alignment bar and pucks.

Google and Pirate4x4 are good places to start.

[DizzDizz]

he has to do his front.

[customcreationsllc]

are you going to try to mach it up to any stock length axle shaft? You might want to find out what dimension that is.
Not that it is hard to get custom length axles just one more hassle.

I was thinking you already had a short axle, but do you have a newer D60 with the really short short end and trying to fit coils?

My suggestion would be to make it fit people do it.
and then shorten the long side until the axle is centered.
Shortening the long side is very easy as long as you are going more than the width of the C maybe 2 hours.
You just cut the C off and press it back on.

are you going to shorten one and lengthen the other. just cut to length sleeve the inside. not hard but you need a latch to make the sleeve a press fit. or you can do it with an alignment bar or just wing it with an exhaust expander to align it.

Just watch the diff/drive shaft clearance to the engine and stuff.


Before I go on let me know a little more details.

[Bigbike]

It's a 80s king pin 60. Before I got it it was narrowed to 61 wms-wms with a custom inner long side shaft. I want to make the long side longer. prolly 65" wide total.

[customcreationsllc]

why not just buy a non modified axle and sell that one?

I would cut just inside the C then cutoff the weld, then take a sawzall lengthwise inside the tube in the C, usually takes 2 cuts apposing then the tube falls out.

Then find some tube to extend the housing. make a sleeve for the inside.
Hone out the C if it wasn't already because that is a very tight press fit, I just use sand paper on a 1/4" die grinder.
Buy a long 1/4" bolt cut the head off and put a slit down the middle about 1".
Take 1" wide sand paper stick it in the slot just a little longer than the hole.
20,000rpm will fling the paper out and hold the grinder centered, it doesn't take too long and it comes out perfect.

two ways to align it. Just go with the assumption the tube is straight and make a press in sleeve for both sides. or get an alignment bar and go through the spindle, but they usually have some camber so you loose that.
Actually they usually have positive camber so when you load it up it is straight.
In that case just use the alignment bar in the end of the tube.

Or do it the dirty way, just install the axle and center the tube it the best you can.

I have housing tube, tube to sleeve, a lathe, an alignment bar etc. etc.
And stock D60 shafts if you want to match it up.

I may know someone that wants that shorter inner shaft depending on the length.

Let me know if you need a hand your not that far away.
~Justin

[customcreationsllc]

$300 you can have a complete stock axle.

1988
Front Axle Assy.
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$300.43
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[Bigbike]

For 300 I might just buy a new axle and cut it down to length. Ill just have to pay for a new gear set up.