Any tips on how to "truss" a rear axle?

[mr_super-hunky]

[Huck]

My 65 J300 is trussed. My Dana 52 has two triangular sections welded to it. One to the left of the pumkin and one to the right. The trusses were made out of steel ( a little thicker than 1/4") that was cut and bent into a U shape (but instead of being a U, its a box shape). So each truss is a triangle fashioned out a steel that was formed into a box section. They were then welded to the axle tubes and pumkin. The trusses are strong and my axle tubes are super stiff these days. Be forewarned that Dave Gore of Renegade Fabrications was working on some shock mounts and motor mounts for the truck about nine years ago and said welding on the axle tubes weakens them. I'm not sure, but I figure its got something to do with hardening the tubes by heating them. I could be wrong, but I trust what Dave says. I had no problems with the axles tubes, but did snap an axle one time. I hope this helps.
Huck

[jeepin_in_az]

Search for axle truss on Google....

Should get you some good ideas.

[mr_super-hunky]

Woops, deleted my own post!, good one.

Anyway, I'm looking for a way to "strengthen" my dana 35 rear axle. I know your thinking "just toss it and get a real axle!" but I do have some money invested in it via the super 35 axle kit (30 spline shafts) and the detroit locker specific for that kit. Also 4:88 gears.

So, I want to make the flexy tubes not so flexy! I can buy a bolt on kit from superior, but I am able to fab something if I find a good design.

Please let me know if you have any tips or pics of your truss design.
Thx.
S. Hunky

[Huck]

Hey there Super Hunky,
No pics of the truss work, but you're welcome to see how it was done. I live in the North Central Corridor of PHX. Drop me an email or PM and I'll give you more specific directions. The truss work was done over ten years ago to help strengthen up another relativly weak axle, the now extinct Dana 52 (the predecessor to the Dana 60). The design is pretty simple, but difficult to put into words on the forum. Essentially, the sheet metal was cut almost like a coffin tank for a Harley. Then a metal brake was used to put the 90 degree angles into it creating the 'U' shape. It would look like a 'U" looking down the legnth of the truss from one end to the other. Looking at from the side it looks like a stretch out right triangle. The wide end was welded (looking at the side of the right triangle) was welded to the pumkin and the rest was welded down along the axle tube. So, if it made any sense, it looks like a long triangle running the length of the axle. I have always liked the design because the box section of the truss is about an inch and quarter wide. It gives the axle a little skid plate action. Now, it does take away a little clearance from your axle, but certainly no more than strapping on on of those pumkin protector truss devices. Let me know if you want to see it in person or the whatnot.
Huck

[mr_super-hunky]

Huck. sounds pretty trick what you've done. Try to get some pics of it and post it. I'm sure others would like to see it as well.

Lots of flexy-weak axles out there. It's not all in the spline count (although thats a good start).

Am I nuts to think that if someone would build relativelly strong axles around the $1,500 price range that they would sell the heck out of them?

[Huck]

Well, I'd post some pics for you, but I'm in the stone age. no digital photography for me. That's why I offered to let you come by and see it. I actually looked at the the truss work last night after spending the time trying to describe it and the description was pretty accurate. I haven't messed with that axle since I snapped an axle back in '95. Its nice to have something that holds up over time. Anyway, its Patty's Day and I'm off to Flagstaff. We always have a table at Collin's Irish Pub up there. So, I'll check back when I return later tomorrow.
Huck