Topic: Square driveshaft - how to determine length?

[Yota Up]

I got square tubing, my driveshaft, grinder, and only a 120V MIG. <- folks say I should be able to pull it off.  I'm a rookie and I suck, but hopefully laying a crapload of metal on it will do the trick...

Anyway - I need to know how long to cut both the outside big square part and how long to cut the smaller inner square part.

I know it's not as simple as measing 3rd to Xcase, jacking up the tire, and taking another measurement.

Is it?

[artistic_gore]

I got square tubing, my driveshaft, grinder, and only a 120V MIG. <- folks say I should be able to pull it off.  I'm a rookie and I suck, but hopefully laying a crapload of metal on it will do the trick...

Anyway - I need to know how long to cut both the outside big square part and how long to cut the smaller inner square part.

I know it's not as simple as measing 3rd to Xcase, jacking up the tire, and taking another measurement.

Is it?

Just take your welding slow and you can't go wrong, remeber to push the pool instead of pull it and you will get better welds (from what I understand)

Also, I don't see why it would be more complicated then taking the two measurements that you mentioned. Get the two extremes and design around them. Just remember to jack somewhere other than the axle so it can free hang and give you an accurate measurement. At least it sounds right to me, I could be wrong.

[Willy Mammoth]

Give yourself at least 6" of compression slip and you should be good.  The longer the better on a square shaft, so long as you don't bottom out.

[Yota Up [OP]]

What about the relationship of the inner and the outer(on the square tubing)?  Should they both be equal lengths, or one shorter than the other?  Sorry for such rookie questions.

[artistic_gore]

I'd say the same length each probably being 1/2" shorter than the compressed distance between the 3rd and the case. Hopefully someone with more experience can chime in though. I'm just going off of what I have been thinking up for myself.

[Duffil]

check out this thread :
http://board.marlincrawler.com/index.php?topic=8233.280

I think about halfway down the page it starts.

[Tallchevy]

I just did this. Sent you a pm

[Willy Mammoth]

Both should be the same length. That will give you the most slip.

The only thing is to make sure it NEVER bottoms out or you will be looking for a new transfer case.

[Siringo]

You need to make sure the driveshaft doesn't bottom out before your flex does. This could have very undesirable mechanical  consequences.

Here's my blueprint. It works pretty well for me ...

[yotatruck]

i did the same thing and have a small mig welder to so cut the tube and took it to a buddys house and used his stick welder and have had no problems

[toywthbdydmge]

did mine about 2 months ago came out pretty good will try to post pictures tomorrow  good luck

[MiniSimp]

This is what I came up with, it worked for mine.