I know I can't be the only who has had to have banjo axle shafts narrowed. I have already narrowed the housing but I can't figure out how/who would narrow the shaft. I called moser and they said they can cut and respline the axles, but banjo axles shafts arn't splined, the spider gear is part of the axle and the other end is tappered and they don't have a fixture to narrow it. The other problem I have is that I have another carrier (no axle shafts) that has the spider gear sepreat from the axle with the inside splined so that it can take a splined axle. Is there is a axle that I can use with the other carrier/spider gear and still use a early ford hub and backing plate? This can't be the first time this has been done.
A good machine shop that has a lath with a taper attachment would be able to shorten those stock tooth pick axles. You need to find a shop that has an older lath like a Southbend with taper attachment its an easy job on a lath.
This is going on memory, But I remember an article using merc axles. Same spider gears but splined. 49 and up axles.
Just take the axle to a good old style machine shop, it'd be a pretty simple job to turn the taper further back, rethread, and cut a keyway no welding required If my lathe wasn't****s up, id offer to do it myself
Most narrowed Banjo rears back in the day I doubt had the axles shortened properly, most were cut and arc welded with added collar over the welded area...If they broke another was made just as easy..With modern weld materials it maybe feasible but the best would be the machining way..I can do them but I am in CT..How hard are you going to beat on them?
That sounds like the best plan. No explaining to the local machine shop worker about how you need it done either. Just give the exact measurements that you shortened each tube and put the axles in a box and take the box down to the brown truck. Turn around will probably be faster than waiting for the local job shop machine shop to get to it too.
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