I've just finished helping my son get his Comance back on the road..
The BA5/10 started knocking.
Since trannys was in short supply and he wanted a 4x4 anyway,
I chased down an XJ 4x4 with a AX15 and NP231 and we began to work.
So I had the tranny/xfer case in it and all hooked up, but what to do about the rear shaft. With none in he salvage yards, I had pulled the engine from a Licoln Town Car and thought wtf I'm a pack rat so its got to be here someplace.
We found it today and I took the measurements and put a fresh cut off wheel on the 4" grinder and carefully started cutting/welding.
The plus side of the Ford Shaft is it uses the same U-Joints as the Cherokee so there is nothing to remember later...
Cutting a shaft is straight forward,
Use the cut-off wheel and carefully follow the weld around the shaft, when you think your deep enough about 1/8" take your hammer and try knocking the cap out of the shaft. If it doesn't move inspect and cut some more.
GEtting a straight line for your next cut is as simple as using a pieces of paper and wrap it around the shaft and line up the edges and tape it into place. I use a soapstone or pencil to draw the line so I have a perfect line around it.
Once I have it cut i use a square edge and make sure its straight and then knock the cap back in and weld it up.
I called a local place this morning about making a shaft, just to replace the tube with a longer one they wanted $200