Welding Axle Trusses

MBDIAGMAN · Jun 6, 2025

It seems to me that the the relatively thin axle tubes on the DANA 30 (and maybe a 44 also) would indeed benefit by the addition of the welded on trusses. Curries have much heavier tubes, but many late model a lesser to hVe relatively thin.

Although I can run a pretty good bead if everything is set up correctly, I don’t consider myself a real weldor. That, said, I have done enough welding to know that welding on one side of a tube whether square, round or whatever, will cause dimensional distortion. So with THAT said, it seems that welding a truss in place on these standard tube size axles is a common practice, so it would seem that the heat presents no problem. Has anyone ever seen a problem from it or not?

Thanks for sharing your experience.

jjvw · Jun 6, 2025

If you are bending the factory axle tubes, you already need a bigger axle for other reasons beyond the tubes.

astjp2 · Jun 6, 2025

jjvw said:
If you are bending the factory axle tubes, you already need a bigger axle for other reasons beyond the tubes.

You can get a 70’s 44 that is 1/2” thick tubes from the factory, so they went thinner to save money, not because they had a better design.

jjvw · Jun 6, 2025

astjp2 said:
You can get a 70’s 44 that is 1/2” thick tubes from the factory, so they went thinner to save money, not because they had a better design.

That does not change my response.

macleanflood · Jun 6, 2025

Woodrow · Jun 6, 2025

macleanflood said:

He said the C is cast. I thought it was forged.

Astala3 · Jun 6, 2025

Bro I just spent an hour on an in depth reply just to have it taken by a pop-up somehow. I'm not doing that again!

I just finished these last week. I weld for a living. The truth of the matter is this. It's not an easy job, not for the weekend warrior. Welder/fabricators exist because not everybody can do it. That's ok.

It's like this, it's probably not the job for you. I say that because you looked at the job and commented on weld bead quality. The difficulty of a truss kit is the proper layout and placement of all the brackets these things have. If you are qualifying yourself for the task by weld bead without considering how complicated the layout is then I advise you to stop immediately.

Maybe you aren't considering the attempt but just wanted to chat about it. The heat is never a problem when done correctly. Heat is only a problem for the guys I mentioned above. Please don't take me for some sort of arrogant jerk. I'm being blunt. We learn from mistakes, especially us professionals. This is not the job to be learning those mistakes!!!!

If you or anyone else who is not a fabricator wants to try it, get a spare axle!

Rickyd · Jun 7, 2025

macleanflood said:

Imagine the bump stops you'd need to keep that crap out of your oil pan when jumping your tj

MBDIAGMAN · Jun 7, 2025

Astala3 said:
View attachment 621789 View attachment 621788

Bro I just spent an hour on an in depth reply just to have it taken by a pop-up somehow. I'm not doing that again!

I just finished these last week. I weld for a living. The truth of the matter is this. It's not an easy job, not for the weekend warrior. Welder/fabricators exist because not everybody can do it. That's ok.

It's like this, it's probably not the job for you. I say that because you looked at the job and commented on weld bead quality. The difficulty of a truss kit is the proper layout and placement of all the brackets these things have. If you are qualifying yourself for the task by weld bead without considering how complicated the layout is then I advise you to stop immediately.

Maybe you aren't considering the attempt but just wanted to chat about it. The heat is never a problem when done correctly. Heat is only a problem for the guys I mentioned above. Please don't take me for some sort of arrogant jerk. I'm being blunt. We learn from mistakes, especially us professionals. This is not the job to be learning those mistakes!!!!

If you or anyone else who is not a fabricator wants to try it, get a spare axle!

I’m sorry that you wrote a lengthy reply and lost it. It’s happened to me and is very frustrating. I’m also sorry that I was not clear in my post.

I am not considering welding axle trusses myself. I was only describing my limited welding skills to explain that I have seen welding done on one side of a member cause distortion, or bending in that member, which seems to me if it occurred would make for an axle that is not straight.

My question is simply, is there a chance of warping the axle, even a small amount, from welding these trusses in place? I admire your welding skills, and there’s no worry of me EVER welding good enough to take your job.

Again, I am sorry for not being clear. I simply want to know if it is a good idea or not. No insult, or implication that it is simple was meant.

cmoore · Jun 7, 2025

MBDIAGMAN said:
I’m sorry that you wrote a lengthy reply and lost it. It’s happened to me and is very frustrating. I’m also sorry that I was not clear in my post.

I am not considering welding axle trusses myself. I was only describing my limited welding skills to explain that I have seen welding done on one side of a member cause distortion, or bending in that member, which seems to me if it occurred would make for an axle that is not straight.

My question is simply, is there a chance of warping the axle, even a small amount, from welding these trusses in place? I admire your welding skills, and there’s no worry of me EVER welding good enough to take your job.

Again, I am sorry for not being clear. I simply want to know if it is a good idea or not. No insult, or implication that it is simple was meant.

You concerns about weakness are valid but adding a truss to a Dana30 will not improve real world durability as the tubes are not what fails on a trail ride. You’ll generally break almost everything else first.

jjvw · Jun 7, 2025

Rickyd said:
Imagine the bump stops you'd need to keep that crap out of your oil pan when jumping your tj

Imagine all that work to add a bunch of useless weight and the real problem of stretching the ball joint yokes is still there.

macleanflood · Jun 7, 2025

Rickyd said:
Imagine the bump stops you'd need to keep that crap out of your oil pan when jumping your tj

NashvilleTJ · Jun 7, 2025

Astala3 said:
View attachment 621789 View attachment 621788

Bro I just spent an hour on an in depth reply just to have it taken by a pop-up somehow. I'm not doing that again!

I just finished these last week. I weld for a living. The truth of the matter is this. It's not an easy job, not for the weekend warrior. Welder/fabricators exist because not everybody can do it. That's ok.

It's like this, it's probably not the job for you. I say that because you looked at the job and commented on weld bead quality. The difficulty of a truss kit is the proper layout and placement of all the brackets these things have. If you are qualifying yourself for the task by weld bead without considering how complicated the layout is then I advise you to stop immediately.

Maybe you aren't considering the attempt but just wanted to chat about it. The heat is never a problem when done correctly. Heat is only a problem for the guys I mentioned above. Please don't take me for some sort of arrogant jerk. I'm being blunt. We learn from mistakes, especially us professionals. This is not the job to be learning those mistakes!!!!

If you or anyone else who is not a fabricator wants to try it, get a spare axle!

How did you verify that you did not bend the axles after the truss install?

mrblaine · Jun 7, 2025

Woodrow said:
He said the C is cast. I thought it was forged.

The TJ inner C is a forging.

astjp2 · Jun 7, 2025

jjvw said:
That does not change my response.

Depends on what is failing, an hp44 in the front from a 78 snow fighter would be stout enough to handle a 3/4 ton truck and plow, without breaking it. The size of the 60 or some special aftermarket may not be what the op wants.

mrblaine · Jun 7, 2025

astjp2 said:
Depends on what is failing, an hp44 in the front from a 78 snow fighter would be stout enough to handle a 3/4 ton truck and plow, without breaking it. The size of the 60 or some special aftermarket may not be what the op wants.

Same still applies though. You would have to be a complete moron to truss that axle. If you feel the need to truss an axle, you don't have enough axle.

mrblaine · Jun 7, 2025

NashvilleTJ said:
How did you verify that you did not bend the axles after the truss install?

I stand back about 30 feet and squint. If it looks straight, good enough.

astjp2 · Jun 7, 2025

NashvilleTJ said:
How did you verify that you did not bend the axles after the truss install?

mrblaine said:
Same still applies though. You would have to be a complete moron to truss that axle. If you feel the need to truss an axle, you don't have enough axle.

I wasn’t saying to truss the 44, but there are factory options that were factory that are more stout than the newer ones, just a comparison

alittleoff · Jun 7, 2025

mrblaine said:
I stand back about 30 feet and squint. If it looks straight, good enough.

This sounds reasonably accurate.
Since my ethnicity dictates that I'm always doing it.

Astala3 · Jun 7, 2025

NashvilleTJ said:
How did you verify that you did not bend the axles after the truss install?

All you need to check for warping is a straight edge and a digital angle finder. I did not do that however. The countless hours in years of experience as a professional in structural welding is what I used. That is confirmed when it is mounted back into position.

Again, not trying to be arrogant. I want people to learn to weld and fabricate and create. Its awesome! If you can weld and fabricate then you can create nearly anything you can imagine!!!! I want that for everyone.

Welding Axle Trusses

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