Thanks for all the suggestions, folks! I'm just getting ready to get back out there, and every one of these ideas sound good. As an old welder, the Mike B's idea of all thread to back it out was my first thought, since I recently had to weld a nut onto a stripped out tranny fill plug on my utv to get it out a couple weeks ago. But the idea of trying to weld a rod onto something so small without welding onto the pin housing too, kind of spooks me. I might weld everything together! I've got rods and a 110v flux core wire feeder, but I'll save that for last.
Got a lot of votes for pushing the king pin back up (I know it moved down some), since that is more than likely binding the bolt. Unfortunately, since I've got two good floor jacks, I think I gave my bottle jack away last year. I do have an ancient screw type jack which has to be manually turned by had with the rod sticking through it. I think I'll go to the pawn shop and see if I can locate one, or just buy one for that. (I held onto that bottle jack for years, never using it. As usual, once it's no longer around, I need it).
I've got a cheap air chisel and also a Bosch roto-hammer, but I'm pretty sure I'd mangle the bolt and the housing if I used the chisel, and the roto hammer is like a small suitcase, with spline type bits that are over a foot long. I'd have to locate something smaller, so that's out of the question.
I'm still considering making some sort of steel frame that would allow a bottle jack to sit (hang?) on the nut side and pull off the other side of the axle to force it out, if all else fails. As I said, I think I saw this idea on a youtube video on the margins of one I watched on king pin removal, and the guy was using it for the king pin. But if all else fails, I'll fabricate something along those lines. I searched the web and found something made for that- For $1,100. A cheaper version was there for over $700. For one job, I think I'll save my money and build one, or use it in case I actually DO have to pull the axle and take it to a shop.
Thanks for the suggestions on bracing the back of the axle with something to absorb the springing away from the blow. Never even considered that. Seeing that it's sitting on a couple of stands, hanging in space, I can't believe I didn't think of that. Too many years of pounding on beams, columns and braces that are firmly attached to other heavy metal where nothing moves an iota, no matter what you pound it with. When all else failed, as a connector setting the pieces with a crane, we'd unhook the piece after it was in place, and swing the ball of the crane's hook as far out as we could reach and slam that 800 pound puppy into the beam to scoot it over the last inch or so. Unfortunately, I can't get a crane today, and the ball is bigger than the space under the fender, anyway.
Reverting to the old methods from Ironworking often just don't work out in the driveway at home. Oh well... But thanks, guys, for the help. I'll report back later after I've tried these ideas out. Then there's the other wheel to go. You can bet I won't forget to pull the bolt on the other side! (Or go to dinner when my wife calls me.)
