Quote Originally Posted by DVA View Post
That weld is not all that bad. I notice some plug welds on the drive shaft. How far does the spline extend into the drive shaft?
the farthest set of plug welds holds a thin bushing I had my brother make up for me. i had him clean up the inside of the tube with a lathe, tap in a light press fit piece of tubing then turn the id of that to be a press fit with the od of the splined piece. Doing it that way assured I would keep the spline concentric and straight. the closer set of plug welds (and another set 90 degrees off in between the two you see) holds the splined coupler in place.

in the "old days" back when this type of driveshaft was shortened often these types of precautions werent taken. you would be lucky if they used some shim stock to fill the slight gap between the spline and the tube!


unfortunately as you can see, for anything over 24" square (the size of my welding table) I'm working on an old particle board ping pong table, using a couple of jack stands as V-blocks lol.