Update...
Today I hit up the JY to grab a front drive shaft from an explorer to shorten for the rear. I pulled a shaft and yoke and started to walk through the yard, then I noticed a Mid-90's sport. So I went and checked it out, and notice its a 5-speed, and the shaft was still there, BINGO! So I found the sought after explorer cardan shaft! Also picked up a couple of other small things.
I installed the airbox and then proceded to shorten the drive shaft...
Here is the diffference between the stock B2 CV garbage and the explorer sport Cardan shaft:
NUFF SAID-
So the process begins... I marked a line with permanent marker about 8 inches down the length of the shaft on the Cardan end and proceded to grind the weld down flush with the tube.
Then I wrapped masking tape around the tube in about where the center of the weld was and drew a line around the edge of the tape.
Then I took the shaft to the bandsaw and followed the line around about an 1/8" deep. Next I took a Deadblow and knocked the flange off and out of the end of the tube.
Next I took and Marked the tube 6" in from the end just cut off (the difference of the two shafts to make the length I need) and again masked it off at the line and drew a line around it, and took it back to the band saw and cut it off just shy of the line...
Then I took a grinder and ground the rest down right to the edge of the line so that the end was perpendicular to the tube and checked with a square. I also ground the surface of the end so I could get a good weld on it.
I lined up the lines and installed the end in the tube all the way up to where I sawed...its a very very snug fit.
Then I threw a tig weld down on it just because I can
Done!
Thats as far as I got today, but im sure ill get some decent progress tomorrow...
Stay tuned.