Re: Retubing axles
I have built several axles over the years with custom tubes, shafts, perches etc etc. Its not overly difficult with the proper equipment, a good welder (a harbor freight special is not appropriate here), jigs, accurate measuring and angle devices (a tape measurer and a carpenter's square don't count) etc. But... The long and veiny of it is, it's a completely pointless waste of time and effort to do this type of work simply to restore the rear to oem condition.
You're talking about a extremely common, still in production rear end that can be bought from any junkyard for usually less than a couple hundred bucks. And in many cases you can even upgrade to say a rear disc axle, different ratio, with a limited slip etc.
So really, unless your building a trophy truck or rock crawler and need to build a custom rear, your not saving any money or doing yourself any favors in taking on this type of endeavour. The chances for mistakes are high and mistakes on this type of work often land in the catastrophic category on a daily driver. Cost savings are nothing since new tubes, mounts, and perches will end up the same as a good complete used rear so the wallet isn't a factor. Again, availability is not a problem since there are millions upon millions of ford 7.5" and 8 .8" rears all over the world.
If you have some reason for wanting to do this I missed I can definitely give you better, more in depth info though. However my advice, start searching for a 8.8" rear from an explorer with rear disc and a limited slip. Set it up in your garage or wherever and clean it up over the winter. Fresh paint, new seals, new brakes, etc. Then in the spring you can swap rears and be back on the road in a couple hours.
Last edited by Dirtman; 10-21-2018 at 10:34 PM.
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