How do I Cut Down a Trailer Axle?

Trailers come in various sizes with differently spaced axles.

Trailer axles have built-in negative camber on both wheels. Negative camber occurs when the top of the wheel tilts toward the center of the vehicle. Clearly mark a line across the top of the axle tube as a witness mark to help maintain this camber when cutting. When a load is placed on the axle, the tube will flex so that the entire width of the tire tread contacts the road, reducing the negative camber is reduced. Therefore it is important to maintain the proper camber angle when cutting down an axle and re-welding it.

Things You'll Need

• Safety glasses
• Tape measure
• Snap chalk line
• Magnetic angle finder
• 4-foot level
• 4 jack stands
• 4-foot section of angle iron
• 4 C-clamps
• Reciprocating saw
• 2 stainless steel hose clamps
• Permanent marker
• Welder
• Welding helmet
• Welding gloves
• Paint

Instructions

1. Place the axle onto four jack stands, one near each wheel and two spaced evenly in the center of the axle. Be sure the two outside jack stands are on a level surface and set at the same height.

2. Mark clearly the top of the axle tube all the way across with a chalk line. Use a permanent marker to highlight the chalk mark.

3. Stand a 4-foot level upright against the axle wheels. Place an angle finder on the flat edge of the level and determine the exact tilt of the each wheel. Record this measurement and be sure to match it when rejoining the shortened axle.

4. Determine the measurement of the section you'll cut out. Mark the exact center of the top of the axle. Measure half the distance of the section to be removed from the center mark on both sides of the axle and mark them. Tighten a stainless hose clamp so its edge aligns with the cut marks on both sides of the center line.

5. Cut the axle slowly with the reciprocating saw, using the hose clamp guides for a straight cut.

6. Align the center marks of the two remaining axle halves. Place a piece of angle under the two halves and solidly clamp it.

7. Lay the 4-foot level vertically against the wheels on both sides. Place the angle finder against the flat side of the level and check the tilt of the wheel. Match it up to the recorded angle you made before cutting down the axle. Adjust the clamps as needed to get the proper tilt on both wheels.

8. Tack weld the axle in enough places to safely remove the angle. Check the wheel camber again to be sure the weld hasn't changed it. Weld the axle all the way around the cut area in one inch beads in opposing position.

9. Paint the welded area and remove the axle from the jack stands. You're ready install it on a trailer.

Tips & Warnings

• If you are cutting an axle from an old mobile home, cut out the center section crown and set the wheel tilt at 90 degrees to the ground.

• Bevel the splice area so there is an area for weld bead.

• Always wear safety glasses when working around power tools.

• Use a welding helmet to protect your eyes.

• Always wear long-sleeved clothing when welding to prevent radiation burns.

References

• "Metal Fabricters"; Ron & Sue Fournier; 1990
• Circletrack.com: Building a simple race car trailer