With so many questions appearing about "how to do it", I decided to show you all how I will be making and fitting up the axles for my next project, a slightly modified LLM. As I started to design the axle structure, I thought I would design an asssembly that could be made without a lathe.
The drawings will, I hope, explain everything involved. The design is based on the use of a 20mm dia. axle. The length is shown as a nominal size and made need to be ajusted to suit your own needs. The 20mm thread can be cut with a threading die. but will require a bit more expense. Use the fine thread series format for the thread as it will be easier to do and provide a more precise ajustment to the bearing assembly. The axle is located in two 3mm plates that are welded to the RHS and the axle. The welding of the two plates must be done with lots of care as any missalignment will render the project very hard to make or even impossible to do. There is a very easy way assemble and weld the structure and have a precision assembly to be proud of. I will explain this later, ask me if I forget.
The two 3mm plates are drilled out to 20.00mm using a stepped drill. I saw one in a tool shop that looked fabulous for this project.
These two plates are the heart of the project and must be made as precisely as you can. Make them as a pair for each side and mark them so they can be assembled in the same position that you made them. The plates must be a neat fit in the RHS. Dont forget to file a groove to clear the weld "rib" inside the RHS.
The biggest problem has been to upload the PDF files to the forum. I have had to use another forum, upload the files there, then transfer them back here. --- Laurie, could you please, please include the pdf. format for uploading the files please?
I tried to use a conversion to jpeg but all the detail was lost. Using the attached files, you can also enlarge the drawings and get all the fine details. Hey Cisco- can you find my name in the drawing?
I will try and upload the other drawings if I can remember how I did it

www.woodworkforums.ubeaut.com.au/attachment.php?attachmentid=100546&stc=1&d=1238107894

This section is a new edit to include all the extra info.

ahttp://www.woodworkforums.ubeaut.com.au/attachment.php?attachmentid=100554&d=1238111134

The above drawing shows how to put it all together. I forgot to add that you need to make four of the 3mm plates that are used to locate the axle. They are made in pairsand each pair is marked on the corners to facilitate alignment within the 35 x 35 RHS

Measure the exact amount of axle you want to have protruding out for the wheel to be attached to. Mark the point with a PEN! Do not scratch, file or cut a mark on the axle as this will create a point for a fracture in the future. Slide one of the 3mm plates onto the axle and locate at your pen mark. Now mark the axle on the other side of the 3mm plate. This length must be at least 61mm. To weld the parts a simple jig is needed. Cut off some 35 x 35 x 2 RHS about 80mm or 100mm at most. Clean all the burrs and sharp edges off from inside and out. This is the welding jig.

Fit one of the 3mm plates into one end of the RHS jig. The plate must be flush with the end of the jig and as square as possible to the axle. Slide the the threaded end of the axle into the hole in the plate.Slide the other 3mm plate over the threaded end of the axle and fit flush inside the jig. Do not touch or weld this threaded end of the Axle. Slide the axle further through the two plates so that the last mark you made on the axle is touching the 3mm plate. Tack weld the axle to the plate. Only a tack weld is needed in 3 or 4 places. Measure out a distance of 55mm from the plate and make another mark. Remove the axle and loose plate from the jig. Fit the loose plate into one end of the jig. Holding the axle by the threaded end, slide the axle and welded plate through the open end of the jig and through the "loose" plate. Align the last mark on the axle to the outer side of the plate. The end is now welded all the way round with a fillet weld. If you have done this correctly, you will have the two 3mm plates welded to the axle and the plates will be exactly 52mm apart and the 3mm plates will be perfectly aligned.
Slide the assembly into the end of your axle tube/s and locate as per the drawing. the "inner" 3mm plate should now be seen in the center of the 7mm dia holes in the RHS. A simple "Plug" weld will hold it all together and you can now run a small bead around the edge of the plate and RHS. If you cant understand this procedure, tell me (!) and I will submit a drawing/s to help explain it. When you weld the final bead and the 3 or 4 tack welds on the axle, wrap the axle with a protective tape to prevent splatter from damaging the bearing surface.

Hope this works for you all

Kody

washer and pin falls into the light is right category, I would use the spacers if youve got em. i always cut in dropoff saw and file to make mine. I cant see a 1" or 20mm nyloc coming undone in a hurry.
Have a look at how I set up Nappy Rush. I think its at the back of your shed somewhere

Caught out I was very happy with that mast till Wayne forbes turned up , not having raced for 7 months and flogged me in every race till I changed to a yacht with a softer mast.
For Enkel bitjer i made a softer set up that suits the sail better, and that is the mast i duplicated for Nappy Rush.
A girls gotta have a few secrets