I'm wondering if the axle shaft could be machined down a little, and a hardened repair sleeve pressed on, then ground to the proper diameter for the bearing to contact? I'm thinking of using air hardening tool steel, and shrink-fitting the sleeve into place. The process of heating the sleeve to expand it and shrinking it onto the turned-down axle shaft would also harden the sleeve as it cools. Then a tool post grinder on the lathe could be used to establish the final outside diameter.
Jerry
If the shaft was turned down to precisely the right diameter, a sleeve of the correct size could be installed, and probably dispense with the final grinding. There's probably enough tolerance in the axle bearing surface diameter from the factory to allow that.
Still going to be expensive though. There are probably still enough usable axles that can be had for a cheaper cost.
