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homemade hybrid axle??

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Offline truckasaurus44

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homemade hybrid axle??
« on: March 24, 2005, 04:20:22 AM »
Well, I had a great time wheeling this weekend, especailly with my new regeared t-case.  Only one problem,  I had such a good time that my rear axle looks like someone took a jackhammer to it, especially the wimpy stock axle tubes.

Now, I've got a wrecked tracker with a shiny virgin axle under it and I'm thinking of hybriding my axles using some really thick wall DOM tube.  I figure that working out the width isn't a big deal as I can used the stock shafts with the break mount flanges bolted up to them as my guide.  I've got a nice pipe cutter that should be able to cut the tube square.  the big question is, how to I align the tubes and tracker center so that everything is lined up and straight?  

I figure I can use a second tube thats a tight fit inside the new axle tubes to keep then straight with relation to each other, but how do I make sure they are aligned with the tracker center section????  Has anyone successfully done this mod at home and if so, how did you do it?  

Is there anyone out there that could fab everything up if I shipped everything out to you (at a reasonable price)???  I'm in New Jersey so if anyone knows of a good shop out here that would work too.
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Offline Rhinoman

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Re: homemade hybrid axle??
« Reply #1 on: March 24, 2005, 04:30:53 AM »
Why not just reinforce it, something like this (my 410 axle)



Its just some reasonably thick sheet metal formed into a U channel and welded on. With an extra 'layer' welded on round the diff.
« Last Edit: March 24, 2005, 04:32:12 AM by Rhinoman »
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Offline ed oorklep

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Re: homemade hybrid axle??
« Reply #2 on: March 24, 2005, 04:36:33 AM »
So as I get it right you're going to put a tracker axle under a sammy, right? If not, wouldn't it be easier to just put it under and make some extra protection under it to make it less sensitive?
Lining it up correctly seems very very difficult to me maybe you could make a stellage in wich everything fits in the right place?
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Offline mrfuelish

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Re: homemade hybrid axle??
« Reply #3 on: March 24, 2005, 05:49:39 AM »
Trail tough could do it. I think they qouted me 150.00 for a 3/16 thick wall if I send them my housing. plus shipping.
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mudfkr

Re: homemade hybrid axle??
« Reply #4 on: March 24, 2005, 06:19:15 AM »
If you want to truss the axle like Rhino has done there, you can buy them from Sky manufacturing like these
[EDIT, Can't seem to link the picture ???]
Look here instead.....
http://www.sky-manufacturing.com/

I'm going to make some for my mates Sammy as his rear diff now looks like a banana after he completed the
Nor-west winch  challenge down here in NZ. BTW he got first in class (up to 32" tires) and SECOND overall against the big boys who now have a lot more respect for the humble Sammy  ;D ;D
« Last Edit: March 24, 2005, 06:21:28 AM by mudfkr »
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Offline 1bigtracker

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Re: homemade hybrid axle??
« Reply #5 on: March 24, 2005, 06:58:27 AM »
Quote
Why not just reinforce it, something like this (my 410 axle)



Its just some reasonably thick sheet metal formed into a U channel and welded on. With an extra 'layer' welded on round the diff.

 i put my truss on the top of the axle for ground clearance purpose, how does your truss work?  what i mean by that is does it get hung up and drag alot?

stu
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Offline Rhinoman

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Re: homemade hybrid axle??
« Reply #6 on: March 24, 2005, 08:30:33 AM »
I haven't tried it yet it was previously fitted to another 410 that then had Sammy axles fitted. It didn't seem to cause any real problems on that one. I guess you do loose a little ground clearance but none of it is lower than the diff. If you put it on top the axle tubes would still get a hammering. I think its really just a copy of a Landrover axle they have exactly the same bracing., I think the guy did it to annoy LR owners, he also had LR style graphics on the side. LR owners tend to look down on Zuks in the same way that J**p owners seem to in the US. Thing is his Zuk was one of the Santana built SJs with a LR badge on the VIN plate. The Suzuki is still the best offroader Landrover ever built  ;)
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2000 Vitara 1.6, 3+3 Lift, 33"MTs, 5:83s, LWB brakes, Winch, Snorkel, Safari Rack
1986 SJ413K PickUp, 1.6L conversion.

OBD1 - Full diagnostics on a PC/Laptop: http://www.rhinopower.org
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Offline truckasaurus44

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Re: homemade hybrid axle??
« Reply #7 on: March 24, 2005, 08:59:54 AM »
I may just call trailtough.  I was hoping to use the tracker center to get the 5.13 or 4.62 gears.  otherwise I'd simply truss it as you guys have.  

My buddy will swap the tracker front gears over to my sammy's steel front diff for a case of beer so if I can use the sammy rear diff without much incured cost, thats totally the way to go.  ouit of curiosity, does anyone know how much wider the tracker axles than the sammy units?  Could I just use front spacers to make up the difference?  If so I'd just do that and truss the hell out of the tracker axle.
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Offline chrisvitarasport94

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Re: homemade hybrid axle??
« Reply #8 on: March 24, 2005, 09:29:10 AM »
Rhinoman - Santana.....Spain.....Landrover......Suzuki SJ/Vitara variants......the same production lines;  I'd never made the connection before;  so the LR's are cousin's by marriage then are they ;)
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Offline xontros

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Re: homemade hybrid axle??
« Reply #9 on: March 24, 2005, 07:51:47 PM »
Some (Spanish) Sidekicks here (Greece..) have "Land Rover" in their papers as the production factory  ::)
Even mine is not a Zuki, but a genuine Santana Vitara   ;D
« Last Edit: March 24, 2005, 07:53:25 PM by xontros »
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Offline tracker8wr

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Re: homemade hybrid axle??
« Reply #10 on: March 25, 2005, 02:46:41 AM »
ifu want the gearing that is a different story from what i understood from ur post u just wanted more strength. i u want the gearing u should go with te plans for the swap. good luck. if u r woried about everything being true make a cubed holding jig out of angle iron and squre it up it the center weld it to the jig and take measurments from the jig. i have a 24" cubed jig. i made a mounting bracket to hold tirds and also to hold the tubing in place. i have made several axles of different makes and it hase worked fine.
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Offline truckasaurus44

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Re: homemade hybrid axle??
« Reply #11 on: March 29, 2005, 03:44:55 AM »
THATS NOT A BAD IDEA.  i KINDA GET WHAT YOUR SAYING BUT DO YOU HAVE ANY PICS OF YOUR HOMEMADE JIG?
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Offline azrocktrash

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Re: homemade hybrid axle??
« Reply #12 on: March 30, 2005, 09:55:46 AM »
if you have the sami axels and a track/kick center,call skymanufacturing.his are 225.00 without core charge and they're the thick walled tubes.
      oscar
« Last Edit: March 30, 2005, 09:56:36 AM by azrocktrash »
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Offline mesjr2004

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Re: homemade hybrid axle??
« Reply #13 on: March 31, 2005, 05:27:57 AM »
its ben my experience that the tubes are usually ok the centers take a beating , i have done a tracker center /sammy tube swap and if your not an experienced fabricator its going to be a bitch for you.
if you have a lot of parts and nothing to loose try it , it took me about 5 hours to complete and came out straight, and the measurement to hold is center section center to axel flange. the sammy axel tube will slip inside the track/kick center tube wich makes it a little easier becoues you dont have to worry as much about squair cuts and keeping perfect lengths on cuts. have fun!
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Offline 1bigtracker

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Re: homemade hybrid axle??
« Reply #14 on: March 31, 2005, 09:31:43 AM »
i took all the mesure ments from mt friends hybrid axle, i'll see if i can get them posted.
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