’28 Tudor update #7: Peaking the I-beam and adding a grill insert

Peaking the dropped ‘33-‘36 axle was a labor-intensive process. It was my first attempt and took ~80 hours, but I learned as I went. A second one would probably take “only” half that. Also, I didn’t actually remove much of Henry’s forged steel. Instead, I added a peak, filled in low spots and leveled everything out. Here’s how:

1. It started out like this- with a forging seam the entire width, top and bottom.




2. First, I welded a long bead on top of the raised forging seam, then long beads on either side of it, the entire width of the axle. I also filled in some gouges. I used a Lincoln 140C mig, 0.025” EZ-grind wire & 75/25 gas.




3. With a 4 ½” grinder and a dremel, I ground two flat surfaces to gradually form a center “ridge”. The dremel worked best in the concave curves between the spindle and spring perch holes. I tried to avoid the beam’s outer edges to keep from making them thinner & weaker.




4. I hand-filed flat sides on either side of the ridge… using a wide file for big flat areas and a round or semi-circle one on the concave curves. A “diagonal cross-hatch” motion (like block sanding) worked best. This took forever…






5. Hand-filing revealed more gouges. I went back and filled them with weld, then ground them flush and continued filing. I also smoothed the front and back sides of the axle (like where the spring perches are).




6. I tried to file the entire surface (NOT localized areas, which would create ripples in the final product). The goal was to make the whole thing flat.

 

7. Finally came block-sanding with #60, then finer grits, then rounding the edges slightly to get rid of the “angular billet” look and restore the “old Ford parts” look. 




8. Voila! Top and bottom, front & back, kingpin to kingpin. Ready for a trip to the plater.




9. The grill insert started life as an office building’s ventilation duct screen. I plucked it from a dumpster during a coffee break, took it home and trimmed it to fit.


10. I welded four machine screws to the back of the grill shell to attach the screen.


11. …and washers to the screen to reinforce it. Locknuts hold it in place and a coat of black rustoleum makes it look good.


12. I’m pretty happy so far- what do you think?

 

Axle looks great its amazing how much time we can spend just trying to get the right look.
I need to fab up a grill insert for my 29 A just haven't done it yet.

 

A lot of work but the results sure look good,time well spent. HRP

 

wow ive never seen a peaked axle before , good job its pretty cool looking

 

Hey Gary, The axle looks killer, great job