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Old June 21st, 2011, 08:14 PM   #1
broke33
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Default what is the minimum tube ID for a dana 60 front axle

Im building a Ford HP60 and re-tubing it for a Bronco coil spring application. I want to run a 3.5 inch diamter DOM tube with 0.75 wall thickness. Does this make sense or is there a better option?
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Old June 22nd, 2011, 08:34 PM   #2
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The stock axle tubes are 3.125 inches OD with 0.5 wall thickness. This leaves 2.125 in for the inside diameter. If I go 3.5 inch OD with 0.75 wall thickness this will leave exactly 2.000 for an inside diameter. I know that 35 spline axle shafts are typically 1.5 inch diameter so there is 0.25 inch from the shaft to the inside walls of my application at room temperature AND assuming that tubes and axle shafts are perfectly straight. Im I missing anything else or does this seem like it should work?
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Old June 22nd, 2011, 08:35 PM   #3
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Also does DOM make sense for tube material?
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Old June 22nd, 2011, 10:19 PM   #4
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sounds way to expensive and heavy

how about thinner wall thickness and a truss
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Old June 22nd, 2011, 10:50 PM   #5
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DOM is the proper material to use. I think that a 3.25 OD - 2.0 ID (.625 Wall) would be a better choice though. With the 3.5 OD stuff you will have to turn the OD to get the tube to slide into the cast Dana pieces, which will sacrifice strength and add cost to the project. The 3.25 will be quite a bit stronger than the stock tubes and will allow you to retain as much of the tubes strength as possible. If you feel that isn't strong enough the go with a full width truss.

Unless you plan on treating this like a monster truck though the stock tubes with a well designed and fabricated truss will be plenty strong. That will save you some money which in turn will allow you to purchase the parts to fix the Dana 60's other weak area - the inner C's and knuckles. (which would be a bigger concern than the tubes for me)
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Old June 22nd, 2011, 10:51 PM   #6
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Available DOM from Alro Steel

http://www.alro.com/dataCatalog/007-...pe.pdf#page=11
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Old June 23rd, 2011, 05:57 AM   #7
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Thanks for the info. I already have dedenbear C's and knuckles. Since I am already commiting to these pieces I wanted to maximize the tubes strength. Sounds like the 3.25 is the right way to go.

Thanks again
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Old June 23rd, 2011, 08:16 AM   #8
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FYI, the later super duty HP60 has 3.5" axle tubes from the factory. If you were worried about tube strength specifically, I'd go with that pumpkin and see if the dedenbear knuckles can be bored to accept the 3.5" tube.

What has you worried that the factory size tubes are too weak?

Anyway, if you are going to that trouble, gusset the C's where they go onto the tube, and truss it over the pumpkin, since you will still need those areas turned down to 3.125. Don't forget to turn the ID to accept an axle seal.

Check with speedymetals.com, you can buy DOM buy the inch. I use them for when I retube axles.
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Old June 23rd, 2011, 08:23 AM   #9
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Moments of Inertia:

3.125 x 0.500" = 3.674
3.250 x 0.625" = 4.683
3.500 x 0.500" = 5.439
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Old June 23rd, 2011, 09:02 AM   #10
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I don't see the need for a thicker tube. When I bent my front axle (.50" wall) I did not bend the tube. I broke the rosette welds in the dif housing and the tube moved in the bore. Going to a larger axle tube diameter will make this problem worse, not better. The housing would be bored out and therefore would reduce the hoop stress that helps hold the tube in place.
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Old June 23rd, 2011, 09:06 AM   #11
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don't listen to these guys, .75 is not thick enough, go with .95 at the least. Also truss it with half inch plate, make sure that all said and done it weighs in well over 2,500 lbs, otherwise it will not be strong enough.
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Old June 23rd, 2011, 09:15 AM   #12
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Quote:
Originally Posted by whiterhino View Post
I don't see the need for a thicker tube. When I bent my front axle (.50" wall) I did not bend the tube. I broke the rosette welds in the dif housing and the tube moved in the bore. Going to a larger axle tube diameter will make this problem worse, not better. The housing would be bored out and therefore would reduce the hoop stress that helps hold the tube in place.
That is the standard place that I have seen D60 failures as well.

I would start with a 3.5" bore casting like the super duty units, or properly truss it (which you need to be good at, to not warp).
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