Had I known how much of a nightmare installing these extended wheel hubs would be, I might have just left the originals. After I was finally able to get the castle nut off, it looks like the tip of the axle is slightly mushroom'd (pic below).



What is the best way to repair this? Will a die shave that off as it cuts new threads? Should I grind that off before running a die over it? Or, should I just hack that 3/8 inch or so off the axle all together, and then run a die over it to clean it up? I was thinking if I circumcised the axle, I would lose the ability to slide in a pin to keep the nut on. However, I may just be able to drench it with lock tight, put a standard nut on, then tighten it down.

How is this normally repaired?

 

Grind down the mangled metal so there is still room for the pin. Then run a die over it or use a thread file starting with the existinf threads. If you start to cutn new threads before it gets to the old ones chances are it will not line up and cross thread. Once you do repair it i recomend locktite and dont over torque it so as to strip out whats left.

 

Honestly I wouldn't do this, but that's me. Reason is you are cutting metal away and making new threads on a smaller diameter, you would need to use a smaller nut after you cut it. The smaller diameter will now not be as strong as the original and could cause the axle to fail at that point. I would buy a new axle for safety reasons. You can try to re-thread it but that's your choice.

 

I didnt say rethread it to a smaller size. Just remeove the trashed metal so you can keep the existing threads and use a die of the same size to chase the threads back to what they used to be.

 

can't really tell but it looks like the threads are almost gone alltogether, which means he needs to go a size smaller. But oblytr8 needs to tell us. Also the threads don't go all the way to the tip so yes if the threads are good just grind down the metal a bit so there is no mushroom.

 

what size is the thread on the rear axle for the castle nut?