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Old 05-08-2009, 05:39 PM   #1
35PontiacCoupe
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Default Drilling Ford 9 Axles to change pattern

I've read some of the threads about drilling 9" axle flanges to change the bolt patterns, and I know there are some people out there that think it shouldn't be done, etc. I've got a pretty good idea of a fixture to make sure everything is indexed correctly but I don't know how close I can make the new holes to the old ones.

I'm going from 5x5.5 to 5x4.5 and the biggest problem is the access hole is right in the way- of course. There were some people who had drilled to 5x4.75 and made it work, but my templates put the holes pretty close to each other.

Basically, I'm wondering how much space needs to be left in between the lug holes to keep it stable. If there isn't enough room, how would a plug work? Would it have to be welded in from the backside?
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Old 05-08-2009, 05:47 PM   #2
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Default Re: Drilling Ford 9 Axles to change pattern

i sent some axles over to the local mud bogger machinest here & he welded plugs in & then redrilled a pattern.

i see new currie axles with 2 patterns & the holes are pretty close.
i too would like to hear what others think.
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Old 05-08-2009, 06:00 PM   #3
35PontiacCoupe
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Default Re: Drilling Ford 9 Axles to change pattern

WHen he welded them in, did he take a slice out of the flange to make sure it wasn't warped?
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Old 05-08-2009, 08:28 PM   #4
Old Guy
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Default Re: Drilling Ford 9 Axles to change pattern

Just did a set from 5.5 to 4.5. Plugged the holes, welded both sides, and resurfaced the flange.The only thing that sucks is that the welds get really hard, which makes it a little tough to drill.
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Old 05-08-2009, 08:36 PM   #5
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Default Re: Drilling Ford 9 Axles to change pattern

Did them on my 37...welded...resurfaced...milled new holes...used screw in studs....used to beat the livin' shit out of it...no problems!!!!
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Old 05-08-2009, 08:39 PM   #6
1935Ron
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Default Re: Drilling Ford 9 Axles to change pattern

Been there done that a few times before, I personally had a few issues with balance, after i pluged it.... did not want to spend the bucks to send them to the balancer .... got pretty close (guessing 99%)with a old high speed balancer on the car.
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Old 05-08-2009, 08:41 PM   #7
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Default Re: Drilling Ford 9 Axles to change pattern

When I ordered my axle shafts for my 9 inch rearend from Dutchman, they drilled them with 3 different bolt patterns [ 4.5", 4.75" & 5"]and the extra holes didn't void the warrantee. Must be safe.
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Old 05-08-2009, 08:41 PM   #8
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Default Re: Drilling Ford 9 Axles to change pattern

I would just send them to Moser Eng.

Gary

Redrilling Bolt Patterns
To suit your requirements, we can redrill new bolt patterns on most OEM or M/E axles, most one-piece rotors, hubs, and brake drums. (We do not drill Chevy Luv rotors.) See our price sheet for your application, and feel free to contact us if you have any questions!



Axles - redrilling only

$60 pair



Axles - plug & redrill holes

$80 pair
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Old 05-08-2009, 09:24 PM   #9
35PontiacCoupe
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Default Re: Drilling Ford 9 Axles to change pattern

Is the balance issue sideways or top to bottom balance?

I know moser doesn't cost a ton but shipping both ways is a pig too..

Rocky- did those axles have access holes in them? How much material is there between the holes?
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Old 05-08-2009, 09:31 PM   #10
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Default Re: Drilling Ford 9 Axles to change pattern

I would just send them to Moser Eng.
That's what I did well over 10 years ago, many miles with no problems
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Old 05-08-2009, 09:35 PM   #11
Dolmetsch
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Default Re: Drilling Ford 9 Axles to change pattern

I just redrilled the new pattern in between . Why weld??????? went from 5.5 to 4.75. Took a morning of measuring and work. Measuring and layout is the key.
Don
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Old 05-08-2009, 09:37 PM   #12
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Default Re: Drilling Ford 9 Axles to change pattern

Any machine shop that has a indexing head can machine them in a few minutes for any bolt pattern you want, thou it will require machining and welding in a plug for the "access" hole. You can send them to me and I'll do it for you right, PM me if you need my help.
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Old 05-08-2009, 09:49 PM   #13
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Default Re: Drilling Ford 9 Axles to change pattern

I send everything to Moser. I have them shorten and respline when necessary, change bolt pattern and install new studs and wheel bearings. I have then send their retainer plates as they are slip on not the captured stock type. When they change bolt pattern they weld up the old pattern
remachine the flange true to the axle centerline and redrill the new pattern and press in new studs. They can put new bearings on for less than 1/2 what it costs to replace them here.
Nice thing about them is they have a 24 hour turnaround. When I send them a pair of axles UPS I have them back in less then a week ready to install. Best service of any aftermarket company I've dealt with.

Frank
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Old 05-08-2009, 09:49 PM   #14
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Default Re: Drilling Ford 9 Axles to change pattern

Ford made a LOT MORE different axles with the 5 on 4.5 pattern than with the 5 on 5.5 pattern.

The 57 to 67 F-100 axle shaft measures 30 inches ( both the right side and the left side ) ... I helped a friend with his project and we used 64/65 Full size Ford axle ... It is 29.5 inches long ... and it has been trouble free for many, many miles. We even used the drums, backing plates and all.

He runs a 460 Ford with a 125 shot of NOS ...
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Old 05-08-2009, 10:06 PM   #15
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Default Re: Drilling Ford 9 Axles to change pattern

Quote:
Originally Posted by Dolmetsch View Post
I just redrilled the new pattern in between . Why weld??????? went from 5.5 to 4.75. Took a morning of measuring and work. Measuring and layout is the key.
Don
This is what I want to do. How close were the holes to the access hole/existing holes? I'd rather drill without welding if I can.

Moser is still an option but I'd rather do this myself if possible because I'm cheap and like doing things myself..
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Old 05-08-2009, 10:30 PM   #16
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Default Re: Drilling Ford 9 Axles to change pattern

Quote:
Originally Posted by 35PontiacCoupe View Post
WHen he welded them in, did he take a slice out of the flange to make sure it wasn't warped?
yep he surfaced them. -- he is a very good machinest but he cant get off the mud bog 4x4 shit.
he charged me 70.00 for the pair new studs included.
i wanted mine surfaced. he does alot of 4x4s with the big tires they wouldnt know if the axles were warped or not.
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Old 05-09-2009, 10:43 AM   #17
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Default Re: Drilling Ford 9 Axles to change pattern

i'm think of drilling my axle from 4.5 to 4.75, i would start by placeing them in my lathe and take a little cut/sctarch to give me the correct DIA. then print out the pattern on my office printer and center punch the locations, or i may mill my wheels to except uni-lug washers as they are aluminum.
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Old 05-09-2009, 10:52 AM   #18
35PontiacCoupe
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Default Re: Drilling Ford 9 Axles to change pattern

How much space between the old holes/access hole and the new lugs is acceptable though? I'm looking at the template that I made with both patterns and it looks like about 1/8" of material in between. I don't know if that's enough- that's really what I'm looking for...
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Old 05-09-2009, 11:15 AM   #19
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Default Re: Drilling Ford 9 Axles to change pattern

"How much space between the old holes/access hole and the new lugs is acceptable though? I'm looking at the template that I made with both patterns and it looks like about 1/8" of material in between. I don't know if that's enough- that's really what I'm looking for... "

Ain't it Hell trying to get a straight answer on the H.A.M.B.? Regards, Ron
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Old 05-09-2009, 11:50 AM   #20
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Default Re: Drilling Ford 9 Axles to change pattern

Yes. Yes it is! I appreciate all the other ideas though!
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