OK, so I spent some time working on this. I stripped the wood off, pulled the axle and had it welded, repacked one wheel bearing and reassembled the axle.
What I've discovered is that the entire trailer frame is bowed. Too much weight on all four corners at some point. Additionally, the springs are flat and allow the cast bump stops on the drop axle to hit the frame of the trailer. This would easily explain why the axle broke. The wheels and tires that were on it were bearing all of the weight of whatever was on the trailer. This would also explain a severly worn wheel bearing. The frame sits directly on the axle with no weight on it.
So, I have a couple of ideas. I think I'm just going to drill out the 1940's bushings for the rear of the leafs and put in some poly bushings and a spring lift kit. That should get the frame up off of the axle. There is no cross support to install a set of coil helper springs, and there is only about 3" of clearance between the frame and the top of the springs. I looked at the 'add-a-leaf' option, but there is no way to install them due to clearance and the bolt/u-bolt configuration.
I'm considering ordering another set of trailer springs, but it's been tricky finding 1 3/4" width springs that will bolt in the original locations on the axle. The current springs are about 33" eye to eye, and the closest I've found in the correct width is these:
http://www.jcwhitney.com/autoparts/Item ... 0000170563To install these, I'd need new hangers welded on, but I think that should be relatively cheap...
I don't know if the welds are strong enough to handle this, so your thoughts here would be appreciated. It's obvious that this frame has been heated in a couple of spots in the past. My plan is to use a 4x4 or 6x8 beam, hook a chain to one corner and the other end to an opposite corner and sort of cantilever crank the thing back into shape. Will it work, or will I just break the welds?
