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I am in the process of having a new 1 piece driveline built to replace the 2 piece. I want it to be bullet proof and was wondering what tubing size people are using. From talking to the driveline shop I have a few options. 3. 5 and 4 inch in . 085 and . 093 wall thickness. In 3. 5 . 085 I am a bit to long for this to work so that is probably out.



I have gone to all 1480 series joints and yokes but had to order a slip yoke from Haisley for the 241 transfercase to a 1480 joint as nobody else builds them that I could find. They said they build there shafts from . 093 tubing but I forgot to ask what diameter they use 3. 5 or 4 inch.



Any input on the subject is welcome as I have a few days before the slipyoke shows up.



I don't want it to get to heavy either. driveline shop said 4 inch by . 085 tubing would be close to same weight as factory shaft.
 
A buddy of mine had a one piece driveline made for his Ford, they made it out of 4'' tubing:-laf I don't know the thickness. It looks cool, because the pickup has 8'' lift with 37''s. He says there is no more driveline vibration under full throttle, pulling a trailer. :)
 
I would stick with the 2 piece shaft set-up especially if it is a daily driver. I have heard of too many stories of serious vibrations with one-piece shafts. There is a reason these trucks were designed with 2 piece rear driveshafts.

I am surprised you actually found a shop that would make you a one piece that is long enough. Most shops will not make a one piece over 70", or at least that is the consensous out here. I had a nice 2 piece made up for my 1480 conversion and it has held up well so far. I think I only paid $700 for the whole thing, even with a new carrier bearing as well.



Joe
 
From talking to them with their driveline tubing spec book in hand the only tubing that isn't recommended for more than 66 inches is the 3. 5 inch . 085 tubing.



The 4 inch . 085 and 4 inch . 093 tubing are good in longer lengths. I used to work for this company and they have a newer state of the art dynamic balancing machine. They can spin them up to what ever it needs to be balanced at.
 
I see some new Dodges and Chevys have 1 piece 6" diameter . 085 aluminum shafts up to 82" long with 1485 AAM joints.

Found a shop here locally that can build 5" aluminum . 120 wall with 1410 spicer joints.
 
Just came back from driveline shop, dropped off the Haisley slip yoke and am going with a 4 inch by . 095 tubing driveline. The old suburbans have 82 inch driveshafts so our 70 inchers are nothing special according to them.
 
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