methodical wrote:
wyeeoddy,
The axle I used on my set up is from a 2013 Polaris 800 EFI Midsize, 4X4.( this may be the same as other models) I purchased a set of axles new on ebay. They are like $125, not to bad at all. The mod was easy. Disassemble the CV assemblies, cut the splines off, cut the inner ujoint spline adapter, align the items and weld. I then had them re-hardened and then reassembled. Interesting things that occurred. The original Honda steel that the ujoint adapter is made of, was very difficult to ID. I actually had them metallurgically examined and no 100% definitive answer came back as to alloy content. I moved forward with the assumption they are a form of 4340. The new cv/ujoint spline adapter needed slight massaging when it was returned as the heat treating distorted the metal just a little. Nothing that can't be gently smoothed and sanded.
If you do the outer side, just do the same thing. For the axle length, well I did a hole suspension so I worked with the length of the axle I bought. Others have just cut the axle in the center and used a sleeve with plug welds. To hold together.
Now, I'm pretty sure I'm about to build an oddy with a simple CV upgrade and additional link, using the factory rear suspension. I am going to use a different axle for that build. I will be using 2013 POLARIS RANGER 500 MIDSIZE FRONT AXLES. These are a little smaller in over size and are a good candidate. They will be more then strong enough to do the job. Good luck! If I start that build soon, I will do a build post.
Awesome I still need to make mine for stockshock measurement for the fl670