The T-100 axles will NOT work with the 2" kit. You have to run the Porshe 930 CV's. We have some in stock at Baja Concepts. Give me a call on Monday if you want. They are like $1000 though!
they have a torsion bar like load, but i do not think they flex like one. maybe a little, but not like a spring. are they made from spring steel, or some type of alloy. it would seem that because the load on them is not that great, and not constant like a rear end, it could be done if it was done carefully.
just my idea.
They don't wind up like a t-bar does, they're designed so as to minimize that. That wind-up is part of what is called "Torque Steer" in a front driver.
They do, however, see reversing torsional loads which are far, far more destructive than the loads a t-bar sees. Reversing torsion is a shaft design worst case scenario.
Give up on welding them and move on to something more productive.
"if i remember right, a tacoma has about 200 ft/lbs.
transfer case gearing 2.72
differential gearing 4.11:1
first gear (manual) approx. 4:1
200*2.72*4.11*4= 8943 ft/lbs of torque."
8943 ft'lbs of torque / 4 wheels = 2235.75 ft/lbs. per wheel in 4 wheel drive.
that would be at 100 % efficiency, and that would never ever, ever happen. and plus the wheels would have to be locked down solid. i am not saying that they would not break, but most drive shafts are welded. don't be mad because i have different views, but i think they could be extended if the proper metal and welding process was used.
I don't know if this is relavent but the front axles on my Ford TTB system on my Exploder have been cut, machined down, and welded an extra length of tubing into them. I've got 2 HARD years of use on them with no cracks and no "visable" twist on them. I drew a straight edge line down them to keep an eye on. I've done prerunning and rock crawling with this rig... And it's got a 4.0 V6, 33" tires and 4.56 gears so I'm sure in Low it see's some decent torque...
whos mad? im just saying i know a thing of 2 about tempered steel, and in my expert opinion, i would say it should never be welded. axles do actually twist up, much more than is realized. put enough stress through there and it will shatter.
and your numbers ignore that differentials and tires slip and all the torque can go into one tire.
They are also before the gear reduction in the rear end..... Welding will work for set up, but they're not going to be striaght and will prematurly wear your CV's/ u-joints. Be prepiared to spend the money for good parts.
I was talking to Mike Kkenig (Locos Mocos) a couple years back about his mid 90's Toyota truck. At the time he had the Total Chaos Cadillac kit but he had just upgraded from the 2" wider Total Chaos kit. He used his stock axles with the 2" kit, cut them in half, sleeved them, and welded them 2" longer. Not sure about the actual details since he had already gotten rid of the kit, but I know it's been done and apparently they held up.
Here's a picture of the truck, apparently he drove it pretty hard and pretty often:
I think I still have a set of 2" extended axles laying around from the truck I sold. I used them with the first TC kit I had then I got T100 axles when I put the Caddy kit on that truck. When I extended the axles we cut them in half then machined the ends down and made some thick chromolly sleves then TIG welded them. Then we used a lathe, gauge and a press to make them almost perfectly straight again. But I only put the truck in 4wd if I was worried about getting stuck, or if I got stuck somewhere because I never knew how strong they were. By the time you buy a set of 930 CV's for it you could probably sell what you have and get a Caddy kit and T100 axles for not much more money.