Originally posted by Colt
Be cautious. Increasing the axle, and using it, could make the frame bend.
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If the heavier axle was another torsion axle it might be possible that that could increase stress on the frame rails, although unlikely. But a leaf spring axle will reduce frame bending stress. That is because the moment (torque) from the load on the torsion axle must be resisted by the frame. causing it to twist. And this twist is concentrated at a single point where the axle is attached to the frame rail. With a leaf spring axle there is no twist applied to the frame, the forces are vertical and spread out to two points (each end of the leaf spring).
A good discussion of the mechanical engineering considerations is here:
So changing to a leaf spring system could be a good move if the installation works out, looking forward to seeing the final results.
BTW, the load on the spindle of the torsion axle is not increased by the inboard attachment points of the axle to the frame. What is increased is the load on the axle tube itself. So, if the spindle is what was originally bent that would still have occurred if the axle had been attached further outboard.
Bottom line is that the 3500 lb axle is marginal for the application if the trailer is run near full load. You can get 2x or 3x bump loads from pot holes if you hit them wrong. That means you can get loads of up to around 3500/2*3= 5200 lbs on a wheel.