What it really takes to cut and weld a drive shaft

If you watched our last two updates you saw Davin swap a T5 transmission into our 1946 Ford pickup. Part of that process was getting a new drive shaft to fit the new length of the T5. So, we thought we'd take you behind the scenes with Dan at Valley Truck and see what it takes to make a custom-fit drive shaft.
Check out the T5 Swap here:
Part 1 • T5 Transmission Swappe...
Part 2 • We put a T5 transmissi...
Thanks to our sponsor RockAuto.com. RockAuto.com is an auto parts retailer founded in 1999 by automotive engineers with two goals: Liberate information hidden behind the auto parts store counter (by listing all available parts, not just what one store stocks or one counter-person knows), and make auto parts affordable so vehicles of all ages can be kept reliable and fun to drive. Visit www.rockauto.com/?a=HG-YT-21Q3 to order auto parts online 24 hours a day, 7 days a week, and have them conveniently delivered to your door. Need help finding parts or placing an order? Visit our Help pages for further assistance!
Subscribe to our KZbin channel for new videos every day! bit.ly/HagertyKZbin
Visit our website for daily automotive news, cars stories, reviews, and opinion: www.hagerty.com/media
Stay up to date by signing up for our email newsletters here: www.hagerty.com/media/newslet...
Follow us on social media:
Facebook | / hagerty
Instagram | / hagerty
Twitter | / hagerty
If you love cars, you belong with us. Hagerty Drivers Club is the world’s largest community for automotive enthusiasts. Members enjoy valuable automotive discounts, exclusive events and experiences, roadside service created specifically for collector vehicles, and a subscription to the bimonthly Hagerty Drivers Club magazine. Join Hagerty Drivers Club here: www.hagerty.com/drivers-club
Like what you see? Watch our other series including:
Redline Rebuild | Engine Time-lapse videos from start to finish bit.ly/RedlineRebuild
Barn Find Hunter | Tom Cotter searches the country for abandoned cars bit.ly/BarnFIndHunter
Chip Foose Draws a Car | Reimagining popular cars with new designs bit.ly/HagertyChipFoose
Contact us:
Suggest and feedback - [e-mail]
Press inquiries - [e-mail]
Partnership requests - [e-mail]

[@timmccreery6597]

Nice! Years ago a "mechanic" told me all you had to do was cut the driveshaft tube to length, hammer in the yokes and weld 'em up. No big deal. Of course I was going through u-joints every 3-4 months and no one could tell me why. Much later I put in a new trans in a Ranger pickup and went to a real drive shaft shop where they measured cut and balanced a shaft for me and that truck ran smoother than it ever had. I'm a believer...

[@skvltdmedia]

Really if you do something new, and then something that shouldn't normally fail does fail - start with that new bit.

[@jamesappello386]

Memories! Built thousands of shafts from pto, auto, farm equipment to monster trucks and HD truck shafts. Nothing like putting together a Mack 92n series shaft with 4.5” x .259 wall tubing! Trained on the “Rockwell” (now Meritor) driveline system built by John Nugent. Our balancer was embedded in concrete and would balance any shaft (yes even those Mack driveshafts) at 3000 rpm’s. Loved building and repairing driveshafts!

[@onoyoudidnt100]

Davin looks like he’s had a solid 8 hours of sleep in the past week

[@mechpatt]

Doesn't look or sound like he is feeling 100% Great line though!

[@MrTheHillfolk]

Sleep when you're dead yoe. I'm 48 and probably for the last 10-12yrs I go to sleep anywhere from 12 at the earliest to 2am at the latest, and gotta be up at 6 to be ready and at work by 7. There's not enough hours in the day.

[@UkraineJames2000]

What is this "sleep" you speak of?

[@Jesse-B]

I had a rough idea how they did it, but it's great to see the actual process, thanks Davin.

[@moparedtn]

Some guys have always fussed about the cost of getting a prop shaft made. Now you know why they're wrong. The folks doing it right earn that money, straight up. Thanks as always Davin! - Ed on the Ridge

[@kukko83]

I once bought a '67 Opel Rekord Coupe, that had an engine and trans swap done to it. Sure enough the drive shaft was too short, and the yoke was only about an inch over the trans output shaft. Obviously, it vibrated like crazy. I took out the drive shaft, taped around it, and cut it in half with an angle grinder. I then cut a piece from a scrap drive shaft, centered in between the halves with some loosely fitting sleeves. Made with cutting open the sides of some thin wall tubing, and squeezing them between the parts. Then it was just a matter of MIG-welding all the parts together. Had to weld around the tube in two places with this method. Not a preferred way of doing it by any means, but it got the job done. Surprisingly it didn't vibrate (at least not noticeably) at all, and didn't eat u-joints for breakfast. I wouldn't do it on a more valuable car but that Opel was kinda sketchy anyway, and that was then...

[@arfreak1979]

As a Michigan resident, I would like to let all of you know that "yeah, no" is completely normal in West Michigan/Up North

[@andrewetherington9828]

I would not have thought making a drive shaft was interesting, but it really was. Thanks for that. 🙂

[@FourDollaRacing]

Davin, we are so proud of you for not saying " relative to... " once in the whole video! 😆 Dan did a great job. Definitely, show more of him and his shop in future videos... 👍

[@markjames9205]

I usually do a shot every time he says that , and I’m drunk by the end of the show. Now what do I do?

[@Subarubruce]

Coming from an owner operator of a driveline repair shop, this is the first video I have watched that did everything right 👍. I swear people think it takes 10 minutes to make a shaft and they are the only person in the world waiting for one. Great job and I wish my shop was that clean

[@bhumiriady]

Not gonna lie, this video is very fascinating! Now I know the process of cutting and welding a driveshaft for a transmission swap.^^

[@miketeeveedub5779]

Great video! I had a driveshaft shortened by a local truck repair shop (Fort Garry Industries) on my 81 Olds Cutlass when I swapped in a TH-700R in place of the factory TH-350c. Now I know what steps were necessary to service or create a new driveshaft. BTW - FGI did a great job! It looked brand new when it was returned to me. There was no vibration issues at all, and best of all, they only charged $125 for the procedure. Mind you that was 25 years ago. I imagine they're charging more now! 😆

[@stevefaltis8989]

I shortened at least three driveshafts in my day. Never had a problem. Ya just gotta pay attention. A mig welder and a straight bandsaw will make it perfect

[@nsbhagwat]

Such a technical video, loved it. Thanks Davin and Hagerty.

[@showtimesrh]

This brought back some memories. I worked in a driveshaft shop for a few years during the 90s. It looks like things haven't changed much.

[@MrTheHillfolk]

Basics are basics I'd think. Maybe some new tools or materials came along in the meantime. What I know is it's not something that's easily done in a backyard, so other than maybe cutting up a spare one at home to fit for measuring(and take that to the shop for them to duplicate) ,it's best to let the pros do it.

[@bozodog428]

Had it done when I swapped in an FE with a C6 into a 55 Ford but didn't get to watch. Now I know. Great video.

[@chucka53]

My Dad and I put a 1960 372 Olds motor in a 1949 F 3/4 ton. The Olds driveshaft slid right inside the Ford truck's driveshaft. We welded it at the joint. No wobble no vibration. Couldn't have gotten any luckier.

[@CanadaBud23]

I shortened my own and I spent a good 2-3 hours doing it to make sure it was straight and good. Smoother than what the factory had so good enough for me. I only did it because people around here were asking nearly a grand to do it and it wasn't even everything brand new either. But I had a lathe to use for myself and built a jig for measuring runout and to balance. I always hear people getting them done for like pocket change, I wish I knew who those people are lol.

[@giancarlopbranco]

Thanks for share knowledge, Mr Davin! 👏🏻👏🏻👏🏻👏🏻👍🏻👍🏻

[@RestorationObsession]

Fascinating process!

[@brainlost686]

Good work bro..I Cut my one in my Opal over 10 years ago running a stroked 350 with a t400 with a hose clamp for the whites on the tail shaft and is still doing skids 👌👌

[@joeschlotthauer840]

Really enjoy these machine shop visits...

[@frediefarmer]

Nice video. Always wondered how they were balanced..👍🏽👍🏽

[@williamhumberhawk8187]

Good to see the process. And measuring tip.

[@DustinSeiger]

That was a cool behind the scenes. Thank you!

[@michaelesplin529]

Thanks Dave, that was so cool!

[@hdbikerdave5835]

Great informative video. Thank you for sharing.

[@GalleryBones]

Love those in depth videos

[@cayman9873]

I had a custom drive shaft made for my 84 formula 455 firebird. Engine was rebuilt and new cam and pistons and new carb and new dist advance. Was making 425 hp at the rear wheels... and the new driveshaft did not explode. Rear axle seals were still wear item every few months. Liked the car. Ate tires every few thousand miles. Did not handle well.. but was fun

[@THROTTLEPOWER]

Great vid!!!

[@jeffplant3]

Very cool cool episode! I learn something everytime.

[@ellieprice363]

Nice to see how that’s done. I wish Dan would have explained how the balancing machine works. I know there’s a sort of “cradle” that’s free to rock back and forth but how does the operator know where to weld the weights to stop the rocking?

[@brunocorrea6010]

The machine tells him the location and weight needed. It has sensors, same thing as tire balancing.

[@Squintanditsmint]

Good information, nice to see the progress.... cheers

[@DOCTRJ]

You guys at hagerty, and the power nation guys are the best on here

[@ekscalybur]

If machine shops (of all types) were open to the public, I'd probably hang out in one at least once a week. Working metals just fascinates me. Thanks Davin!

[@LightGesture]

Great video

[@sonyhk3824]

Pretty nice done guys 👍. Cheers

[@coolbreeze5561]

I once had to lengthen a drive shaft. Did it with a roll of duct tape and a Lincoln 220. Never had a problem with it.

[@ronlynch7744]

Great video, done tight & right. 😎👍🇨🇦

[@gy4246]

Impressive!!

[@vettekid3326]

The last driveshaft I had made was for a Ford Explorer Sport trac tha has a two piece shaft with a carrier bearing in the middle. The OEM shaft comes with a non replicable carrier bearing so to replace it you have to buy a whole new shaft and I think Ford wanted $900 for one so instead I had a shop that specializes in these make a new one with fully replaceable U joints for less than half that shipping included.

[@MrTheHillfolk]

Heehee nice side effect is supporting a local shop,too.

[@sparkplug0000]

A guy who thinks a driveshaft is pretty is truly the kind of guy worth hanging out with.

[@bbrown5887]

Great episode. Late 70’s, early 80’s I worked on some old school mopar muscle including helping cut a few for beater cars. We did send the good car shafts out to a machine shop but I never actually saw the process. I’ll soon be needing to do the same for my 68 Coronet R/T for some powertrain upgrades. I won’t be doing any homeschool hacking and balancing for that though.

[@09mxrider]

Its pretty easy to do a man knows the pain when your working on ford Broncos the smaller ones there is about 4 different transmission and driveline combos and you never have the right length. so you end up cutting one down to size. Just mark the tube and dont cut the end with the ballance weight off put it back in and weld

[@scootosan]

I had a 65 Impala with a Powerglide and I had the drive shaft balanced.... worth every penny.... and nickel.

[@Dukat35131]

Nice Peterbilt backside of the shop

[@jamesmisener3006]

Davin where is the road test? Ahhh❗ Would be interesting to hear your thoughts on how the clutch and shifts work together with the new T5. Is the old clutch linkage feel normal on shifts? Next time. Cheers 🇨🇦

[@jimclarke1108]

Yep been watchin

[@norherman]

Have a happy Thanksgiving!

[@h2woda]

Any chances for music name/artists used in Redline Rebuild series? Is it recorded especially for this series? Would love to see "OST" playlist or link to buy individual songs ;)

[@faduhfade77]

If u check the final stage of balance at 1k rpm could it still be off at 8k rpm when it’s on the car ??

[@PhillyDee215]

💥That's cool😎

[@tihspidtherekciltilc5469]

That 67 Bug doesn't need a driveshaft. It needs me and my living room.

[@vintagedashboard6810]

My spline slip joint on my 78 K5 rear drive shaft is worn out and when I’m driving and let off and on the accelerator I have slop and I think that is pretty tough on the transmission and rear gears.

[@bielie84]

What RPM do you run the Lathe when welding the shaft?

[@jayemlov]

Wait.. what does the truck on the ground have to do with the length of the shaft? I understand the slip yoke but thats not what he measured right? Is it not center to center of each u joint?

[@ronaldhunter1560]

needs to be end of output to center of ujoint on diff

[@ianeyolfson6525]

Cool beans 👍

[@johnds6621]

Half Ass Customs always cuts down his own drive shafts and he does okay.

[@tihspidtherekciltilc5469]

When you only have half an ass it's harder to feel the vibration as there's only half the seat of the pants feeling. The more you know. 🌠

[@1959BB]

The worst article I've ever seen about home modded props was in an issue of Custom Car magazine where they pretty much just chopped the tube in the middle, and then inserted a tube inside, slid the two parts together and then welded it up. All that extra mass in the middle of the prop would have been like some kids skipping (jump rope). The following issue the magazine published a retraction saying not to do it, and had a visit to a prop place showing how they are done correctly !

[@JeromeBill7718]

How much room do you leave for spli drive shafts? does it change if you raise your truck? My step dad said that the frame and bodies on tucks sway and chnge pitch whie driving on hills etc.

[@Dan-kb9dr]

As far in as the slip will go. Pull out about an inch to allow for collapse and measure center of cap on slip to center of cap on rear diff

[@jimburns9674]

Put a dedicated mic on him. Y'all can afford it. LOL This is also an issue on Barn Find Hunter.

[@FourDollaRacing]

Davin ridicules "Barn Find Hunter"... too many armchair mechanics in their adult diapers and rocking chairs.... 👎

[@jameseastwood4984]

I think the shortening yourself could be done if the shaft wasn't too long and you were only doing one end. The key is that 0.001" run-out he achieved on the tube before welding. I wonder also if you could do the shaft then just have it balanced. But you know that a lot of places would probably protect themselves and say if it wasn't shortened at their shop, they won't balance it. I'm a big do it yourself-er with no major mishaps in the last 30 years.

[@khalid749]

Always state the units!

[@max.racing]

6:00 how can i learn this job? Is it an mechanic or an lathe operator job?

[@georgegrierson]

Every man needs to know the length of his drive shaft

[@FourDollaRacing]

Yeah, in your case, for over-compensating...

[@vettepicking]

How does a yoke center to center distance move on a welded one piece driveshaft??

[@FourDollaRacing]

Watch the previous video, yo...

[@tihspidtherekciltilc5469]

Slip yoke.

[@asromiasromi6653]

Sangat bagus cara kerjanya....🍴🍴🍴

[@thundermite1241]

I kinda want to see a explorer 5.0 swap in one of these trucks

[@Hoaxer51]

Or a Chevy small block!! ☺️

[@asarand]

Was there a noticeable difference in the way the vehicle operated as a result of the new drive shaft?

[@Hoaxer51]

He can probably drink coffee instead of wearing it while he’s driving down the road now! Lol

[@Hoaxer51]

Hey Davin, where did you have that driveshaft made? I’m thinking it’s probably made in Michigan but where specifically, like city and the company name. I know every one is different but what would be a ballpark price for a driveshaft like the one you just had made? Thanks, great show, I really like this series with the ‘46 Ford!

[@stephenholland5930]

Check out the sticker at 10:43

[@CanadaBud23]

@@stephenholland5930 True true. But I think we are all more interested in the bill he's holding instead lol.

[@Dan-kb9dr]

Valley truck parts in Traverse City. Typical 1 piece shaft brand new are around 4-600 depending on size and series.

[@SpatialDragon]

What does it take? I have done it with a lot less than this video. I have seen it done with even less than I had in third world countries and they worked just fine... I saw a man with a hacksaw, an oxy-acetylene torch and some baling wire shorten a drive shaft. It worked fine on the patched up Pakistan bus... Topped out at 35 mph down the mountain which was good since the brakes were hand made by another man with a coal burning oven.

[@ks_1111]

The bus likely ate u-joints and bearings every 10,000 miles or less......

[@woof3598]

can we ask how much some thing like costs ?

[@Hoaxer51]

I just asked also, but I don’t really expect an answer.

[@ronusa1976]

Driveshaft Labor and Part Costs . Front driveshafts are commonly between $150 and $250; the larger rear shafts start around $250 and can reach $400 and above, possibly more for a two-piece.

[@joppejoppsson9604]

But how do you balance a 2 part drive shaft?

[@zephyracer4082]

You need to balance them together with the carrier bearing. They should be marked so they are put back together in phase

[@zd302gt]

Now, time for some nicer exhaust.

[@km6832]

2021 and this guy wearing a silly band

[@Pikulev_Evgeniy]

Какой креативный карданщик.В носу пирсинг,в ушах заклепы.Про Ивана Дулина видео им посмотреть надо

[@autka_me]

I'm quite surprised that after all that hard work on the shaft it was rattle can painted. Maybe I'm just too sensitive about it living in part of the world where they salt roads like crazy.

[@bradmaas6875]

And it explains why the question about the damper removal wasn't answered.

[@DumbCarGuy]

Nothing funner than having a needle bearing fall sideways and you don't realize it until its too late.

[@cesarconh895]

How to cut and make your driveshaft: About 600 dollars, that's all

[@brennerheavy]

Video starts at 4:12. You're welcome.

[@mustangdemon87]

Except In Southern California places what over 500 just to rebalance a two piece ram driveshaft!!!!!

[@travisweller1754]

Am I the only 1 that noticed he said his solid already built driveshaft grew 1/2"when he measured from center of each u joint? Not physically possible. You are demonstrating with a complete driveshaft but explaining how to measure if there is not a shaft. Yes it is correct that the mounting surface on the rear end will change the distance in relation to where the proper yoke position is at ride hight.

[@TheMeanestGuy]

What is the longest driveshaft ever made in a production vehicle

[@whosurdaddy8907]

Do you count multiple piece driveshafts?

[@Dan-kb9dr]

Consumer vehicles for steel shafts we cap at 68" anything longer is aluminum or a 2-3pc

[@LTVoyager]

I was impressed until the rattle can came out and ruined it. 😂

[@sevenknot7244]

Pipe code please

[@dangerdavefreestyle]

The building and the balancing was spot on, but the assembly wasnt. axial play needs to be set and various thicknesses of snap rings utilized appropriately. as you can see, the ujoints are not tested for operation. if they are bound up it will cause a vibration in the vehicle. this is because in the vehicle the ujoints are in motion with it at an angle. on a straight balancing machine the ujoints could be filled with super glue and no-one would be the wiser.

[@Jessersadler]

measured wrong. It is yoke to yoke, but with no shaft installed. Keeping the shaft installed, keeps the length, exactly the same. . . its physics.

[@ODGColornChrome]

If you are measuring center yoke to center yoke, there is no way the length changes. The change in length would be measuring to the slip in and out of the transmission. The drive shaft length can't change. Not sure how you got different measurements?

[@ronosga5072]

When a leaf spring is compressed it lengthens, that's why one end of the spring mount swings. Also the reason you need a slip yoke at the trans.

[@Bob-Sacamano]

@@ronosga5072 You're explaining how leaf springs work, which does not answer @DarrenCannell 's question. His comment is correct. On a slip-yoke style driveshaft, the difference in length between a truck on a lift and when on the ground happens at the slip yoke. The driveshaft length itself (center yoke to center yoke) does not change since it's a solid shaft. If this truck had a CV-style driveshaft, then yes the length changes depending on suspension compression/droop. The correct driveshaft length measurement should have been taken from the lip of the transmission tail housing seal to the center of the pinion yoke.

[@CanadaBud23]

@@ronosga5072 These two comments are good examples of how people just don't understand and shouldn't touch things at all.

[@CanadaBud23]

It's simple when there is load on the suspension the wheelbase changes which changes the distance from the output to the differential. On leaf sprung vehicles you can make the drive shaft short and have less slip yoke engagement into the output shaft if you measure it wrong. 4x4's would have much more difference in length and have seen many where driveshafts fall out while driving from major wheelbase changes during suspension articulation.

[@Bob-Sacamano]

@@CanadaBud23 lmao, no, just no. YOU are wrong. Have you even watched the video? Skip to 1:20 and watch how he measures the driveshaft. He measures from center yoke to center yoke on a slip yoke driveshaft. That is absolutely 100% not the correct method. Fucking noob telling me i dont understand lmao.

[@kiddwebb9588]

Looks like an overly complicated process of pressing the tube yokes in the tube.. true each tube yoke, check runout and weld. Then balance

[@daisoreanulaurentiu3943]

What are some great drift engines for europeans viewers?

[@FourDollaRacing]

Send me your engine and it will "drift" to the bottom of the ocean... 😋

[@Hoaxer51]

@@FourDollaRacing, that wouldn’t be a drift engine, I think they call that an anchor! Lol

[@Lilpowderfoothillvilla]

I had to get a new one made at a drive shaft shop they charged me 650$ Jesus it cost more then a new one 😅 I just don’t get it my poor Tacoma

[@boostkash2640]

Yea no cool.

[@doublecheeseburger1712]

Why that dudes ears taped up

[@jamesrogers6376]

You could of done a better job. Tolerance stacking. Check the process

[@domesticcat5069]

🗨️😽

[@the4armedmonk]

pls readd the dislikes

[@domenickpace3450]

Nice but why no price included?

[@rexruggless9671]

no work on old ford race car. very upset.

[@salami99]

Balanceing a drive shaft is real, just drive a poor built jeep you will know it all