Dana 60-2 Cutting Down 3"

Well I have finally had some time to get to the rear axle of mine and address its problems. First off it is 3 inches wider than my front axle and with that the differential was also offset to the passenger side. This axle came out of a 1973 Jeep J-10, that had a 3/4 ton upgrade from the factory, so what they did was put a dana 60, semi-floater with 5 on 5 and half bolt pattern, in place of the rear d44. They offset the differential so they could use different transmission and transfer case options in the same chassis. With the truck being as long as it was they could get away with this with no significant problems.

Unfortunately, with me installing this into a much shorter CJ-7, I ran into the problem of blowing through u-joints like it was cool. Just to many angles on it. So, I sent the shaft off to Moser Engineering and for $65 they cut it down 3" and re-splined it (that is with shipping and handling). They did an excellent job! Now all I had to do was cut down the housing 3", so it was off to the hobby shop. There I put the axle housing in the band saw and cut it towards the middle of the axle tube. I decided to cut it in the middle and then cut a piece of round 3" tube steel in half (down the length of the tube) and put a piece on top and bottom of each tube for reinforcement. I did it to both tubes so they would be the same thickness, thus being able to utilize the same u-bolts for each side.

Here is the tube after I welded it together and ground it smooth. This is where I cut out the 3 inches, about in the center of the tube.
This is a shot of the axle tube before I ground off the welds. Like I said I took a piece of 3" tube steel and cut it length ways, then put one piece on top and one on the bottom and welded them on to the axle tube housing.
And here is the final tube after grinding the weld smooth.

I now have the axle together, and am waiting on some 3 1/2" u-bolts and I also have to make some spring plates for the u-bolts to bolt to. Also have to weld on the spring pads, so hopefully next week I will have the axle in and this write up done.