Custom Spring Perches

[Tom Mandera <tsm1@domain.elided>]

OK.. time for some Mandera-engineering again...

Though I admit to stealing this idea from one of the 4x4 rags...

I bought some 5"x3/8" strap to fab some U-bolt plates from today.. while
I was measuring the axle U-bolts, I noticed (and finally measured to
compare).. the Travelall rear axle I'm using has 2.25" wide perches,
while the stock Scout perches are only 2" wide.  This means I need to
grind off some excess perch so the U-bolts snug up properly... or.. just
put new perches in.

Well, if I put new perches on, I can put 'em in the righ location (about
2" closer to the diff) *and* make 'em the right size.. sounds like a
plan I guess..

So here's the idea.  I didn't measure it yet, but the T'all Dana 44 rear
axle housing should be less than 3" diameter tube.  

Buy a hole saw of the appropriate size to match the tube.

Get some 2x2 or 2x2.5" steel tube.  Say maybe 6" lengths.  Use the
holesaw to cut a semi-circle in the tube.  Fit the tube down over the
housing, drill the top for the centering pin, and weld.

I'd like to make the semicircle such that the top of the square tube is
resting on, or nearly resting on, the top of the axle tube for more
strength.

Anyone care to comment on what wall thickness I want?  1/4" sound
right?  3/8? ..

-Tom (who just ordered the 727 overhaul and shift-kit for the racer...
and the steel for new U-bolt plates)