Where to get custom axle shafts made?

K45

K45

Active Member
Joined
Feb 21, 2007
Location
Statesville
I have contacted a few vendors about getting some front inner dana 44 axle shafts with 31 spline. I was curious who else makes axle shafts locally or who has good experience with different vendors? Thanks
 
Currie, Mark Williams, Strange. All Good. Insist on getting rolled splines instead of cut splines. MUCH better. Cryo treating is worth the money if you are really going to hammer on it. Jeepspeed guys that run Baja flock to Currie.
 
I have heard a lot of bad reviews for Moser Engineering, but I have had them do several shafts for me. I have been pleased with everything they've done. Both in price and quality. What exactly are you looking for?
 
I am building a hybrid axle using a mitsubishi pumpkin and third member. The mitsubishi uses a 31 spline axle shafts that I think might be the same as the ford 9". I will need to figure out my axle shaft length, but if I can iron out a place to get them made I can get all the dimension and specs. Thanks yall.
 
The problem is that you can't add a u joint yoke to a 9" shaft. The only thing that comes to mind is to take a dana 60 35 spline shaft and have it turned down. The problem is that the dana 60 joint wont clear a dana 44 knuckle. If you could find someone selling dana 44 35 spline shafts then most if your problem would be solved.
 
That's pretty much what Moser has done for me. You will need to send them the side gear. You can buy Dana 44 blanks from several places, or Moser has their own hardened shafts they can spline.
 
nctom said:
Currie, Mark Williams, Strange. All Good. Insist on getting rolled splines instead of cut splines. MUCH better. Cryo treating is worth the money if you are really going to hammer on it. Jeepspeed guys that run Baja flock to Currie.
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insist on rolled splines....right.... they will do it for sure if you insist :rolleyes:

cut splines are fine, i have never seen a failure that was because the splines were cut instead of rolled in any motorsports application.

any shop that has the ability to spline regular D44 or D60 shafts can do what you are asking given a side gear or an axle shaft to take measurements from. if you are going through the work to build a custom axle, build it to use D60 style knuckles from the get go. building it with D44 sized parts is a waste of time unless they are all free
 
You can't take a blank 30 spline shaft and make it 31 spline. It would be easy to make it 29 spline, but you can't add material to it.
 
Metto said:
cut splines are fine, i have never seen a failure that was because the splines were cut instead of rolled in any motorsports application.
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I'd say that really depends on how the splines are cut and is a pretty funny thing to say as I'd imagine you've seen plenty of sheared spline transitions. It may not be the shaft's weak point but there is no argument that cold rolling a spline isn't quite a bit stronger...

My question is why the mitsubishi 3rd in the first place? As has been said, you're probably going to have to go with 60 sized knuckles unless you want to pay for a double splined shaft and yoke or cv.
 
There are a few reasons for this project:
1. it has never been done
2. the SR has a 9.5 ring gear
3. the Sr has factory air locker
4. I already have the same rear axle and it would be cool to have match front and rear axles.
5. There is not alot of options for a driverside drop

I have thought about the combining my axle with a dana 60 but at the time cost was a huge factory and I got my SR and dana 44 axle for very good prices. if this works out well I will look at upgrading to a dana 60 outters down the road. the big thing is I am not planning on going any bigger than 36" tires. I am trying to find someone with a ford 9" axle shafts. I am thinking they might be the same and if so currie makes inner dana44 axle shafts spline for a 9" third member. Thanks all for the advice and help.
 
GubNi said:
You can't take a blank 30 spline shaft and make it 31 spline. It would be easy to make it 29 spline, but you can't add material to it.
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I had 1.31 33 spline end cut on the UN-necked down portion of a factory Dana 44 shaft. I had to use two long sides, but it was done.
 
According to what I can find if your axle has the 9.5" ring gear, the shafts are 1.40" 31 or 33 spline. Which doesn't match any Ford I know of. And will be too large for a Dana 44 shaft. Might as well start out using 60 outers.
 
braxton357 said:
I'd say that really depends on how the splines are cut and is a pretty funny thing to say as I'd imagine you've seen plenty of sheared spline transitions. It may not be the shaft's weak point but there is no argument that cold rolling a spline isn't quite a bit stronger...
My question is why the mitsubishi 3rd in the first place? As has been said, you're probably going to have to go with 60 sized knuckles unless you want to pay for a double splined shaft and yoke or cv.
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you are correct in saying that i have witnessed breakage at the spline transition on cut splines, however it was because the shaft was not necked down to the spine minor diameter/root diameter after the splines ended. cutting splines without necking down is asking for trouble as it creates a lot of spots for potential crack propagation. necking does not eliminate the possibility, but if the shaft diameter is the same as the spline minor diameter instead of the major diameter then you have reduced the number of potential sites by however many splines you are talking about, 62 in this case as a crack could propagate from the backside/unloaded side of a spline just as easily.

the bottom line is that a splined joint in general is not a great idea, but because of how easy they make everything else its worth it. all you can do is minimize potential problems as much as possible. my point with the cut vs rolled splines is that with the materials and heat treat methods we encounter the most in the 4x4 industry, a "properly" cut spline is not going to be the failure point on the shaft (i.e. you wont "strip" the splines off before the shaft breaks, which seems to be the allegation here).

my 2 cents
 
what he said

Metto said:
you are correct in saying that i have witnessed breakage at the spline transition on cut splines, however it was because the shaft was not necked down to the spine minor diameter/root diameter after the splines ended. cutting splines without necking down is asking for trouble as it creates a lot of spots for potential crack propagation. necking does not eliminate the possibility, but if the shaft diameter is the same as the spline minor diameter instead of the major diameter then you have reduced the number of potential sites by however many splines you are talking about, 62 in this case as a crack could propagate from the backside/unloaded side of a spline just as easily.
the bottom line is that a splined joint in general is not a great idea, but because of how easy they make everything else its worth it. all you can do is minimize potential problems as much as possible. my point with the cut vs rolled splines is that with the materials and heat treat methods we encounter the most in the 4x4 industry, a "properly" cut spline is not going to be the failure point on the shaft (i.e. you wont "strip" the splines off before the shaft breaks, which seems to be the allegation here).
my 2 cents
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you are learning something at school I know Chase is proud of you........lol
 
That's my boy gettin all educated in rittin and rithmetic.

First off you can cut a 31 spline shaft out of a D44 blank OD of blank is 1.345 and a 9 inch from my notes requires 1.340 material to spline. you basically just polish it and then cut the splines.

Secondly any custom shaft is going to be cut spline not rolled, one would have to have a spline roller machine there is like 2 in america and when they run they roll minimum 200 shafts at a time not 2. most Oe rolled shafts are made in mexico (spicer) and china india for other manu's

We can make these shaft but would require a side gear as anybody would as we ar enot familiar with whats mits Major and minor diameter is or what pressure angle they are cut.

Unfortunately we were told we are to expensive though we are well within what the market charges for custom shafts.
 
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