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Old 03-30-2020, 06:18 AM   #6
Mart
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Join Date: May 2010
Location: Solihull, England.
Posts: 8,732
Default Re: Cutting down 42 to 48 ford axles for a 40 ford

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I traded for one that had been modified. It was not quite right as far as the positioning of the drum so i set it up and skimmed a few thou off the taper. I then had to contend with a keyway that was not quite deep enough.

So it is possible to do the job. Things to note are:
The material is very tough. It needs a good insert tool to turn it.
You don't shorten it enough to lose the keyway. There will be remnants of keyway where the threads are.
The diameter of the taper at a specific distance from the gear is very important as it effects the position of the drum.
Milling the keyway can be tricky to set up as it is at an angle.

If doing one you might consider doing a batch all the same if the "prototype" checks out.

My series of videos from when I broke the shaft in my truck shows the shaft and the problems I had to overcome.

I think this is one that shows the axle.
https://youtu.be/8ToEl7O01P0

Mart.
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