Trailer axle repair/replacement question

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Ok I think the cotter pin/ castle nut failed on my way back from CA to CO a couple weeks ago sending my wheel and tire somewhere off into the bushes on I 40 somewhere and I couldn't find it. anyway I use a chain and the winch to pull the axle on that side up to the frame and made the rest of the trip on 3 wheels   did unload the wife's car and she had to drive the rest of the way home.. Anyway I am planning to buy a new spindle like This Picture.  I have cut the old one off and have a question for the trailer experts.   the end obviously will be welded all the way around.   however I am wondering if I should put some holes in the existing axle and plug weld the existing axle to the new spindle further back    and yes the hub is in the drum backwards. but its just to keep it all together..Tiger Sales:  AHP Distributor    www.tigersalesco.comAHP200x; AHP 160ST; MM350P,  Spoolmatic 30A; Everlast PowerTig 185; Thermal Dynamics 60i plasma.  For Sale:  Cobra Mig 250 w/ Push-pull gun.  Lincoln Wirematic 250
Reply:My point of view is why did you cut the whole thing off when you could have just bought a new spindle and backing plate and bolted it back on?  ...zap!I am not completely insane..Some parts are missing Professional Driver on a closed course....Do not attempt.Just because I'm a  dumbass don't mean that you can be too.So DON'T try any of this **** l do at home.
Reply:Oh I get it now that I re read your post..I don't know if you can pull this off without removing the whole axle..Gotta be straight and true...You might need to just replace the axle with a used one or find a shop that can put it in a lathe and do it right but that may not be cost effective.....zap!I am not completely insane..Some parts are missing Professional Driver on a closed course....Do not attempt.Just because I'm a  dumbass don't mean that you can be too.So DON'T try any of this **** l do at home.
Reply:the inside diameter of the tube is 2" which is also the outside diameter of the replacement spindles.   the orignal spindle only sat about 1/2 inch inside the axle tube and was welded on.  the replacements go in 4-6 inches into the tube so that will make it straight and true to the axle.  going to try and find one with the brake mounting flange already installed.  I think the brake assembly is usable with a cleaning and new pads and a couple of misc. parts so will just need a brake drum, seals and bearings, castle nut etc.     I did an axle before on a trailer I got on trade and that one some idiot had cut the axle to lengthen it and joined it with a piece of 2" angle.    i cut that all off and slid the round tubes inside a 3" 1/4" wall square tubes but on that I cut a 1 ft notch lengthwise and welded the old axle to the square tube along that 12" section.   Just trying to see if there is any benefit to doing that or the plug welds further in on the new spindle as its say 4 to 6" inside the old axle tube?   obviously the OEM design felt just welding the 1/2"  spindle stub into the tube is sufficientTiger Sales:  AHP Distributor    www.tigersalesco.comAHP200x; AHP 160ST; MM350P,  Spoolmatic 30A; Everlast PowerTig 185; Thermal Dynamics 60i plasma.  For Sale:  Cobra Mig 250 w/ Push-pull gun.  Lincoln Wirematic 250
Reply:Originally Posted by zapsterMy point of view is why did you cut the whole thing off when you could have just bought a new spindle and backing plate and bolted it back on?  ...zap!
Reply:Go buy a new axle.....200 bucks at best. I just bought one last year for my trailer, i think it was 130, 200 ish with hubs n bearings. They will make the the exact length of your original axle.I forgot how to change this.
Reply:Originally Posted by LawsonWeldingLLCGo buy a new axle.....200 bucks at best. I just bought one last year for my trailer, i think it was 130, 200 ish with hubs n bearings. They will make the the exact length of your original axle.
Reply:Tractor supply sells Carryon axles of various lengths as well as Orschelen's might try and see if you got those places local, I found my axle at Tractor supply. But i bet you could find somewhere that can make one . if it were mine, id just replace it but to each their own. I forgot how to change this.
Reply:Modern light duty trailer axles are a strange bird. A new axle is the way we would recommend to fix that. Unless we had an exact duplicate length axle on the shelf, a new one would be ordered to match the original. Those axles are jig welded by computer and robot. That is why they figure they can just run a bead all the way around with a half inch inside. The machine is programmed to put the right amount of camber into the tube also. Once you lose that camber, the tube is junk. Tire wear becomes an issue. Check the tube very carefully, it should have a distinct crown in the center.City of L.A. Structural; Manual & Semi-Automatic;"Surely there is a mine for silver, and a place where gold is refined. Iron is taken from the earth, and copper is smelted from ore."Job 28:1,2Lincoln, Miller, Victor & ISV BibleDanny
Reply:I had a similar axle problem and spoke with the engineering dept at Dexter, their axles are only in 1/2" but they are spin/friction welded and hard to get out. With 4 or 5 inch imbedment I think you would be fine if it was properly welded. What spindles are you thinking of using. Dexter doesn't sell just spindles for this reason?"Si Vis Pacem Para Bellum"Lincoln Idealarc 250 AC/DCMillermatic 251   Syncrowave 300   30A spoolgunLincoln MP210Hypertherm 45(2) LN 25(2) Lincoln Weldanpower 225 CV(4) SA200   1 short hood    SA250    SAM 400
Reply:If it were me I'd weld it all around, a couple of plug welds couldn't hurt if you want them.With the extended stub and good welds, it should be as strong or stronger than the original spindleI think the manufacturers use friction welding and don't use the long stubs as their process has been designed to produce axles at the lowest possible cost, with the least skilled labor.  Doesn't mean a skilled welder cannot do this job just as well with ordinary welding methods."The reason we are here is that we are not all there"SA 200Idealarc TM 300 300MM 200MM 25130a SpoolgunPrecision Tig 375Invertec V350 ProSC-32 CS 12 Wire FeederOxweld/Purox O/AArcAirHypertherm Powermax 85LN25
Reply:these were not friction welded as there is mig like ripple is the weld.Tiger Sales:  AHP Distributor    www.tigersalesco.comAHP200x; AHP 160ST; MM350P,  Spoolmatic 30A; Everlast PowerTig 185; Thermal Dynamics 60i plasma.  For Sale:  Cobra Mig 250 w/ Push-pull gun.  Lincoln Wirematic 250
Reply:If me I'd use at least 7018  (I have some 110-18  ).I'd make sure its aligned right and maybe even warm it up a little.I'd try to put on a good strong weld.It should be fine anyway with a 4-6" sleeve fit.  It will not be in complete sheer.Good luck Last edited by slowhand; 08-14-2011 at 07:50 PM.
Reply:My buddy has a busniess called Axle Surgeons and this type of repair is what he does day in day out, except normally on big rigs.  He cuts two holes in the axle housing for plug welds, bevels the end of the housing, uses 11018, preheats to 250ish, welds all the way around, and plugs the holes, covers the finished repair in a heat blanket to cool slowly. The spindles he deals with have a higher chromium and molybdenum content, hence the 11018.JayJay DavisAWS-CWIC-60 Specialty Welding ContractorLoving husband, and father of two boys (
Reply:Is his axle surgeons franchise in northern California?Vantage 500's LN-25's, VI-400's, cobramatics, Miller migs, synch 350 LX, Powcon inverters, XMT's, 250 Ton Acurrpress 12' brake, 1/4" 10' Atlantic shear,Koikie plasma table W/ esab plasmas. marvel & hyd-mech saws, pirrana & metal muncher punches.
Reply:Originally Posted by DualieIs his axle surgeons franchise in northern California?
Reply:I am driving up to redneck trailer parts store in longmont, CO this morning to get all the parts I need.   They are a huge distributor of all trailer parts and also found that their online catalog is chock full of useful info and calculations for buildin trailers such as axle placement, spring pad location etc....Tiger Sales:  AHP Distributor    www.tigersalesco.comAHP200x; AHP 160ST; MM350P,  Spoolmatic 30A; Everlast PowerTig 185; Thermal Dynamics 60i plasma.  For Sale:  Cobra Mig 250 w/ Push-pull gun.  Lincoln Wirematic 250
Reply:Would you post the web address for trailer parts place.  My son lives in Longmont xnd I might have to visit the store sometime.Thanks,  John M
Reply:Originally Posted by iffida20Would you post the web address for trailer parts place.  My son lives in Longmont xnd I might have to visit the store sometime.Thanks,  John M
Reply:Originally Posted by jbyrdIt sure is.  His name is Robbie and we're neighbors.  Do you know him?