Topic: Square driveshaft complete - step by step pics "for dummies".

[Yota Up]

This has got to be the millionth one out there, but just as I appreciated every picture when brainstorming, I'm sure someone can appreciate these, too.  Hopefully.

The beginning:  Driveshaft, reciever square tubing, inner and outer.

PS:  Take note of the size of the wheel on the grinder in the background...

[Yota Up [OP]]

I decided to cut my lengths according to a theory:  Stay safe with the factory "short" possiblity.  This means that the shortest my new driveshaft can get is just as short as the stock one.  Even though my lifted truck will not get the third as close to the transfer case as the stock, incase I happen to bust a spring hanger or somehow jam that axle all the way to the frame - I'm still good.

Despite keeping the shortest part as short, you got more than enough room to add plenty of inches that the factory line does not utlitze efficiently with the space "allotted".  <- I know it's misspelled, blah.

I cut both drivelines to within an inch or so of the "knuckle".

[Yota Up [OP]]

As you see, both sides are equal length.  Put together, they are the exact same length as the stock.  Pulled apart they go much further before dropping out.  Sweet.  If you notice the "ring" on the thick part of the driveline at top of pic - I ended up taking that ring off.  99% has to go anyway to fit the inside of the larger square tubing.

Here's the pic and the general idea.

[Yota Up [OP]]

Be careful on this part to take away metal equally from all four sides.  You'll notice I kept the balance weight on and used it as a corner.  This provides a tiny bit of balance and a considerable amount of additional sturdiness.

Do the same thing to the larger tubing(one that one, cut to just before it rounds out).

Clean off nearby metal to prep for weld.

[Yota Up [OP]]

Good fit.  Ready to make sparks fly.  Notice how it's not perfectly centered with the square.  That's ok.  It matters zero.

[Yota Up [OP]]

Weld them up, paint them, and set them out to dry.

[Yota Up [OP]]

New driveshaft all ready.  BEEFCAKE.

[Yota Up [OP]]

Remember that wheel on the grinder?
I'm really pushing my luck here...

[Gewehr43]

Awesome!  Looks like I will have to build one for my project!

[MiniSimp]

Nice job!
Here is the writeup on how i did mine: http://board.marlincrawler.com/index.php?topic=14915.0

[Yota Up [OP]]

Sweet, bro.

Yours is like the responsible way to do it.  Right on.

[_HOIST_]

Did you weld the tubing on there in a particular way so that the U-joints are going to be lined up a certain way when installed?

[MiniSimp]

Did you weld the tubing on there in a particular way so that the U-joints are going to be lined up a certain way when installed?

you can rotate the tubing to put the joints in phase.

[Willy Mammoth]

Good fit.  Ready to make sparks fly.  Notice how it's not perfectly centered with the square.  That's ok.  It matters zero.

The joint should be square to the tubing so it will line up with the other end. The ujoints must be in phase or it will viberate.

[Yota Up [OP]]

This truck is not going to be doing any speeds of consequence(snow, etc.)  The 4x4 will only be engaged for slow crawling.  I don't think the vibration becomes an issue unless I plan on driving on snow or somthing.

Here's a shot, mounted.

[kneedownnate]

Beefcake

[89toy]

Beefcake

X2   

[Yoat Goat]

Love the beef cake man!

[sinbob]

X2  

x3