New Axle

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So after getting advise from you guys, I was planning on modifying a new axle to fit my trailer.  I call a local trailer place to find a 3500lb axle.  He said that he would put on spindles and hubs at the length I wanted for about $75.  I thought, what a great deal, just the hubs run about $35 and spindles around $15 each.  That put me at about $100 just in parts not including labor.  So I go to pick up the axle and new tires and this is what he gives me. Attached Images
Reply:The spindle is 1 and 5/8 inch diameter.  The center of the axle is 2inch square tubing. and the ends that are holding the spindles on are made of 2 and 1/2 inch angle iron welded togather Attached Images
Reply:Here is another shot of the axle. Attached Images
Reply:And I thought I was an amature welder.  I am no longer embarassed to show my welds off.  Here is a close up of some of the welds. Attached Images
Reply:Ok thought I would throw in a pic of myself just so you would know how handsome I am.   LOL
Reply:Forgot to put in the pic. Attached Images
Reply:Ewww... Looks like the welder ate at Taco BellCommon sense in an uncommon degree is what the world calls wisdom.
Reply:I'd say you bought the parts. Myself, I would grind that mess out and reweld what I could. I'd sure find a better way of extending an axle. The porosity and contamination in those welds are terrible. Good luck.
Reply:Did you guys notice how the spindle is welded into the angle iron?  If you look in my second picture, it is only welded on the right side and the bottom.  There is a gap about an inch wide on the top of the spindle and the left side of the spindle.
Reply:I would certainly have...questions about the quality of the welds. If the welds have decent fusion and are of sufficient size, they may just be uglier than a deer after a train hit-ugly welds arn't necessarily bad. Unfortunately, A couple of the welds in those shots look cold-lapped, giving them no strength.If you can cut the angles apart and expose the spindle welds, you may be able to fit reinforcement in and reweld the removed pieces. Otherwise, it's a nice kit you have there. Kinda scary, some of hte 'professional' work on the road, eh?
Reply:I am thinking of just cutting out the parts and getting a new axle and cutting it to length.  What size pipe or square tubing would you guys think I should look for( OD, ID or schedule? not sure of common sizes available?).  I believe that the part of the spindle you insert in the axle is 1 5/8 inches.
Reply:Fat frank,Please show us more pictures of your bbq smoker and tell us about it.  I want to build one this month.
Reply:Sticky, no problem.  I just got it painted up this past weekend and now I need to make the cooking racks and put on the new axle and chrome wheels.  That would have been done tonight, but its looking like more than just bolt the new axle on .  I will get some finished photos by the weekend and start a new thread on it in a few days.
Reply:Originally posted by fatfrank Ok thought I would throw in a pic of myself just so you would know how handsome I am.   LOL
Reply:1 5/8 spindels fit in 2x2x3/16 sguare tube thats what i used to use when i was building trailers for the farn center here.Never had any trouible from them.That guy u got the from should be put in front of a fireing squad
Reply:OOOOOO if u build one find center of the tube run 4 inches of weld with 7018 each side of center 4 places it will give u the right amount of camber.
Reply:FatFrank.  Your a good looking guy, and if it wasn't for me, you'd be the best looking weldor on this site.  Those welds don't look very good.  I'm sure you can repair that axle, and be proud of doing it correctly.  Would like to see a picture or more when you get it done.  Then maybe show the guy you got it from the way it should have been done.
Reply:I'm finding hard to believe that you paid for that.......unless you just wanted the huds & axle stubs so you could build it the right way.
Reply:Originally posted by 7018 OOOOOO if u build one find center of the tube run 4 inches of weld with 7018 each side of center 4 places it will give u the right amount of camber.
Reply:Since Jack is doubtless otherwiuse occupied, NICE use of astrigals on the smoker.Now, I see a lot of bird**** on that iron, but where are the welds?Did that POS come with a complementary can of Bondo?Where the hell are the spring perches?Will you be using Vaselene or KY when you give it back to him?Appreciation Gains You Recognition-
Reply:I’m wondering something… Does the date of them welding the axle coincide with “take your kid to work” day?Common sense in an uncommon degree is what the world calls wisdom.
Reply:TheFrenchCanadian, when you weld on one side of a piece of flatbar, it tends to camber twards the weld side.Common sense in an uncommon degree is what the world calls wisdom.
Reply:Well i guess Brainfarth told u what u needed to know,tubing does the same thing, the welding causes it to arch alittle u would put the arch up this giving u the needed camber,or off set to ur wheels.also dont drill the spring locating wholes in the axle.drill them in a peace of 1/4 inch flatbar and weld them to the tube!!
Reply:The only reason I went ahead and bought it was they were charging me less than what I could buy the parst for and also I was buying some wheels and tires from them.  I figured it wasn't that big of a deal because I can fix it and I was in a good mood and not wanting to ruin it by being an a-hole.  So anyway, I went last night sorted through my neighbors junk pile and found a some sections of oil field pipe that I may use for a new axle.  The pipe is O.D. of 2 3/8 and looks to be about 1 7/8 for the I.D.  I found some spindles that are 1 3/4 for $15.  I think it may be easier to just cut a section of pipe and insert new spindles and reuse the hubs rather than cutting out the poorly welded ones.  I want to have this road worthy by friday and only have 2-3 hours in the evening to work on it.  Do you think this pipe will be ok for an axle?  Franz, nice use of the work astragals.  I had to look it up to see what it meant   I thought I was just covering up my crooked kerf so no one could notice. LOL
Reply:Oh yeah, 7018Now when putting the camber in can you elaborate on the weld postions.  I understand that it needs 4 welds on each side of center, each being 4 inches long.  Are the welds side by side or end to end?  I kinda assume side by side, if so how do you space between the welds?  Does each stringer touch the next, or do you space them apart 1/8-1/4 inch.  Also how close to the center line would you place them, just a couple of inches off the center line?  Does the same hold for round tube as square.  I realize that I am asking you to be real specific, but I want to get this on the first try and not have to keep messing with this.  I appreciate your help.  I know it must suck having to teach a rookie over the internet.I agree fatfrank, I'm a little confused too. I realise welding beads will force your material to camber. But where? How much? Does the length of the axle, thickness & shape of material play into it as well??
Reply:Ok Find center mark 4 inches each side of it. run 8 inches of welf i used 7018 4 passes i always ran 1 pass on the edges thrn split the other 2 in between if u dont want to do that u acon split 3 sides and weld it back togather it will work on round to but run ur welds closer togather. I hope this clears it up for u!!!
Reply:damn i need some spelling lessons or typeing lessons or something
Reply:Originally posted by 7018 Ok Find center mark 4 inches each side of it. run 8 inches of welf i used 7018 4 passes i always ran 1 pass on the edges thrn split the other 2 in between if u dont want to do that u acon split 3 sides and weld it back togather it will work on round to but run ur welds closer togather. I hope this clears it up for u!!!
Reply:well maybe u can't understand hillbilly talk,being as how u is up north,hay just kidding
Reply:You could also put the axle tube in a Harbor Freight type pipe bender and add camber with that. For the spring perches, I would buy them from a trailer supply store, especially of you are using round tube/pipe instead of square tube.
Reply:Why not just make the perches out of 2x2 tubing?  That what alot of the jeepers are doing for a spring over axle lifts.Mike 93 YJwww.moabjeeper.com
Reply:Faftrank...did you build the grill also ? If so any suggestions / things youd do differant on the next one ? Im collecting parts now to build  a trailer mounted grill so I can take my ribs on the road !
Reply:7018, thanks for the details.  Thats pretty much how I figured I would try it, but didn't want to screw things up.  YJ, I am going to make a 1" lift only on one side because of the way the weight is arranged on the cooker.  John, yes I built it.  I am pretty happy with the design of this one.  I stayed home this morning and did some more touchup work like installing spring handles, making the grill racks, grinding down the welds on the racks etc.  I was going to take some pics but ran out of time.  I will try and get some pics tonight or in the a.m. and post.  If you have any questions I would be happy to answer.