Steel is significantly easier to tack weld. The welding arc is much more stable and produces a small and stable melt pool. I tacked together the assembly in just a couple hours.
This is what the axle assembly looks like (the bolt plates are not yet tacked in place, and I missed a picture of those in this view). It looks similar to the original leaf spring axle assembly, but isn't red. I'll either see if work can powder-coat, or I'll paint it with enamel paint later. I did weigh the old axle components at 80lb toatl (30lb axle; 25lb/ea leaf spring, angle, fenders). The new torsion axle assembly weighs 52lb (22lb as shown below and 15lb/ea for the half-axle assemblies).
Show partially bolted in place in this view, the half-axles transfer load to the bar, which transfers loads to the steel angles, which transfers loads to the main aluminum beams. The bolts are just there to hold the assembly in place.
But, it turns out that the few tack welds did not survive the neighborhood drive. I was only rolling about 10mph, but the left axle literally broke off and rolled forward while the back corner of the trailer dragged along the ground. It was quite a noise and one neighbor came over. Two large c-clamps were enough to hold things together enough to limp home.
What's the saying from the movie Rounders? "If you can't spot the sucker, then you are the sucker." Said another way, "I am the crazy neighbor." It's probably more fun to be the crazy neighbor.
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