is axle shaft to short to be used?
I am completing the '83 CJ7 build my son started. He had a salvaged Dana44 axle which I had shortened and then I ordered a custom length chrome/moly steel axle shaft from AlloyUSA. My measurements were off. It was 3/8" too long for the spindle to mount on the knuckle. I shortened it using a lathe and a hacksaw. That metal is tough to cut, especially the outer layer! It again seemed too short and I cut another 1/4" off, this time spinning it on the lathe but using a grinder with a cut off blade and finishing with a hacksaw. Much faster and still a clean cut. Now I think I didn't push the shaft it all the way past the oil seal when I checked its length, as it is now a bit short. There is only .68" of gear contact, judging from oil marks on the splines. Looking at other axle shafts, there seems to be about 1.2" of contact normally.
My question is whether .68" of gear contact is enough, or if I have to buy another axle shaft. I have written the company, but would like to learn from the experience of others. The CJ7 will go off road, but nothing too radical.