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Old 04-20-2017, 09:23 AM   #21
USA1

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Most if not all at closer to 3/16" (.1875). I have some old 9" sections (I'm a hoarder) that measure closer to .190 but it's been a while since I measured them. The last Dana 60 I did, 3" OD and 3/16" wall.

Never in my years of cutting and shortening any housing to include Olds, Poncho, Chevy (10 & 12) and most Ford housings have I ever seen an 1/8" WALL.
The stuff I cut up was from the 60/70s and really thick. I still have some left over ends, what was that 60 out of originally. I have a 1/2 ton ford 60 under my 55 I thought was thin. time to measure the ends I cut off. At least we agree on the 1/8 tube, that would not even make a legal roll bar.

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Old 04-20-2017, 11:49 AM   #22
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The stuff I cut up was from the 60/70s and really thick. I still have some left over ends, what was that 60 out of originally. I have a 1/2 ton ford 60 under my 55 I thought was thin. time to measure the ends I cut off. At least we agree on the 1/8 tube, that would not even make a legal roll bar.
Not sure what to say in response. I know what I've seen in numerous 8.8" Ford tubes. I've narrowed some 9" Ford, and 12 bolt and 8.5" 10 bolt GM axles also, and they are indeed heavier. But the 8.8" just isn't that heavy, and I can easily burn through the tubes with my Millermatic 140 if I'm not careful welding on heavier brackets.
It's well documented all over the internet if you search 8.8 For thin axle tubes. Lots of 4x4 Ford forums talking about it. Here's a link to Hotrod Magazines 9.8" ford axle review. Scroll down to the part on removing brackets and welding on new brackets. "The 8.8" tubes are extremely thin, which means the heat from a cutting torch will easily bend the tubes."
http://www.hotrod.com/articles/ford-8-8-rear-end/

I cut brackets off with a parting wheel, and take a lot of time being careful welding on them to avoid warping the axle. They're a great rearend, and I have a couple installed on vehicles, plus more I've put in other's cars. But the tubes are the weak point.
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Old 04-21-2017, 10:00 AM   #23
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the 8.8 I did was 1/4 wall. I have a chunk in the garage I can measure when it quits storming. Penetration is all in the bevel. Vee it out. multiple passes if needed
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Old 04-21-2017, 12:41 PM   #24
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word of caution i know of 2 people who had the wheel bearings become welded
seems the ground sent current thru them. ground the axle as close to the weld as you can
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Old 04-22-2017, 10:29 AM   #25
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word of caution i know of 2 people who had the wheel bearings become welded
seems the ground sent current thru them. ground the axle as close to the weld as you can
Very sensible and timely advise , I know for a fact this can happen , may
not be actually welded solid but the arc will etch the bearing and guarantee
failure in a very short time , beware !!!!
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