by hotrod » Thu Mar 03, 2005 11:36 pm
The old mid 1960's drag racers had problems with broken axles and they would simply paint a straight line down the length of the axle when new. Over time they would see the axle start to "wind up" and the line would clearly show the twist. They learned by experience how much axle twist was too much, and would change out the axles when they got to that point.
I understand cyrotreating works good to increase toughness of axles but have not done it my self, or know anyone that has. Some calls to the cryotreatment places might give you some useful info.
If the axles have sharp machine marks on them some de-burring and polishing could help also. Some axles tend to break right at such a sharp stress riser like the end of the splines. Look for any sharp change in cross section which might focus all the stress in one point. Just like cleaning up connecting rods to remove sharp changes in cross section.
Larry