Straightening a rear end housing
From Crankshaft Coalition Wiki
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==Introduction== | ==Introduction== | ||
Here's how to make a fixture and rack for straightening a rear end housing. | Here's how to make a fixture and rack for straightening a rear end housing. | ||
==Building a straightening table== | ==Building a straightening table== | ||
| − | The straightening fixture pictured below is an old compressed gas cylinder cart, | + | The straightening fixture pictured below is an old garage sale compressed gas cylinder cart, with its top cut off. A 6" X 6" I-beam was then welded to the cart. You don't need a cart, any table with sturdy legs will do. This cart just happened to be handy and had nice wheels so we could wheel it around the shop. |
[[Image:Axle_straightening_table.jpg|frame|none|A gas cylinder cart, converted for straightening rear end housings.]] | [[Image:Axle_straightening_table.jpg|frame|none|A gas cylinder cart, converted for straightening rear end housings.]] | ||
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Then, make some inserts. These are about 2" long, as to provide some load bearing area to lessen wear caused by repeated use. For this application (10-bolt Chevrolet), the ID is 1.504", and the OD is 2.894". These same size inserts will work in an 8" and 9" ford center sections as well. | Then, make some inserts. These are about 2" long, as to provide some load bearing area to lessen wear caused by repeated use. For this application (10-bolt Chevrolet), the ID is 1.504", and the OD is 2.894". These same size inserts will work in an 8" and 9" ford center sections as well. | ||
| − | [[Image:Making_inserts_in_lathe.jpg|frame|none|Making the inserts in a lathe | + | [[Image:Making_inserts_in_lathe.jpg|frame|none|Making the inserts in a lathe]] |
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The inserts are then clamped in the bearing saddles and the bar slides through them. The fit should be snug; the bar should slide through easily, but with no noticeable play. | The inserts are then clamped in the bearing saddles and the bar slides through them. The fit should be snug; the bar should slide through easily, but with no noticeable play. | ||
| − | [[Image:Straight_bar_in_inserts.jpg|frame|none|The straight bar, in the inserts | + | [[Image:Straight_bar_in_inserts.jpg|frame|none|The straight bar, in the inserts]] |
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==Measuring== | ==Measuring== | ||
The housing end insert slides over the bar and indicates how much the end of the housing is bent out of alignment. | The housing end insert slides over the bar and indicates how much the end of the housing is bent out of alignment. | ||
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[[Image:Housing_end_insert_slid_over_bar.jpg|frame|none|The housing end insert is used to indicate the alignment of the housing.]] | [[Image:Housing_end_insert_slid_over_bar.jpg|frame|none|The housing end insert is used to indicate the alignment of the housing.]] | ||
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Hold a ruler on the tube to see where it's bent. In this case, it's bent at the areas that were welded by the previous "builder". | Hold a ruler on the tube to see where it's bent. In this case, it's bent at the areas that were welded by the previous "builder". | ||
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[[Image:Finding_housing_bend.jpg|frame|none|A ruler is used to see where the tube is bent.]] | [[Image:Finding_housing_bend.jpg|frame|none|A ruler is used to see where the tube is bent.]] | ||
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==Heating and bending== | ==Heating and bending== | ||
| − | Next, rig a chain at the point of bend and put a 12-ton bottle jack under the end of the axle. To prevent bending the center casing, attach the rear cover. You can try to bend the axle tube at this point, without heat. If you want to bend the tube in this way, push the tube approximately 5 times the amount you want it bent. In other words, if your alignment is off by .030" , you need to push the end of the tube about .150" or more to overcome spring-back. If your axle housing end is off by more than .100" from the alignment jig, you will probably need | + | Next, rig a chain at the point of bend and put a 12-ton bottle jack under the end of the axle. To prevent bending the center casing, attach the rear cover or a fabricated piece of thicker steel flat stock drilled with the bolt pattern of the cover to provide better support. |
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| + | You can try to bend the axle tube at this point, without heat. If you want to bend the tube in this way, push the tube approximately 5 times the amount you want it bent. In other words, if your alignment is off by 0.030", you need to push the end of the tube about 0.150" or more to overcome spring-back. If your axle housing end is off by more than 0.100" from the alignment jig, you will probably need to use heat. | ||
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[[Image:Bottle_jack_and_chain.jpg|frame|none|A bottle jack and chain are used for bending.]] | [[Image:Bottle_jack_and_chain.jpg|frame|none|A bottle jack and chain are used for bending.]] | ||
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If you find that you need to heat the axle tube, jack up the housing into perfect alignment with the housing end insert and heat a band all the way around the tube until it's red-hot. Let the tube cool while it's still supported by the jack. | If you find that you need to heat the axle tube, jack up the housing into perfect alignment with the housing end insert and heat a band all the way around the tube until it's red-hot. Let the tube cool while it's still supported by the jack. | ||
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In this case, when the tube cooled, the housing end was only a few thousandths of an inch off, and was easily bent into alignment cold, using only the bottle jack. This housing was initially out by almost 1/4" on one side, and 3/16" on the other. Now, the housing end slips on with minimal effort. | In this case, when the tube cooled, the housing end was only a few thousandths of an inch off, and was easily bent into alignment cold, using only the bottle jack. This housing was initially out by almost 1/4" on one side, and 3/16" on the other. Now, the housing end slips on with minimal effort. | ||
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[[Image:Insert_fits_properly.jpg|frame|none|The housing end slips on with minimal effort.]] | [[Image:Insert_fits_properly.jpg|frame|none|The housing end slips on with minimal effort.]] | ||
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| + | [[Category:Tools]] | ||
[[Category:Rearend]] | [[Category:Rearend]] | ||
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