At one time finding the parts to build what is described today as a traditional hot rod was easy enough-early Fords were cheap and plentiful and the junkyards were full of the parts and pieces needed. But things have changed and some components, like early Ford banjo rearends, are getting hard to find. As a result it's often necessary to salvage axle housings that once would have been considered junk.
Ford's banjo rearends were unique in a number of ways, one of the most unusual features about them were the wheel bearings. Rather than the bearings being on the shafts, and the shafts in turn supporting the weight of the car as well as propelling it, Ford's rear wheel bearings were in the hubs and rode on much larger journals that were a part of the axle housing. That meant the weight of the car was carried by the larger axle housing much like heavy-duty truck axles do today.
While this arrangement had advantages from a load carrying standpoint, the drawback was the inner wheel bearing races were part of the axle housings, and that meant if a race became worn the housing had to be replaced.
As we said, at one time finding a good axle housing wasn't an issue, but since it's been over 60 years since they went out of production, they're a little more difficult to find. However, if you have one or a pair that are less than pristine there's a way to make them serviceable once more with repair sleeves installed over the original bearing surfaces.
A service provided by Ken and Nick Smith of the Hot Rod Works, saving these housings requires turning down the ends of the housings and pressing on new sleeves to make them good as new. Follow along to see what's involved in tuning up a Ford banjo.
 Although the size of the components...  Although the size of the components changed, Ford used the same basic rearend design from the Model T through the '48 model year. |  Among other talents, Ken and...  Among other talents, Ken and Nick Smith of the Hot Rod Works, are experts on early Ford rear axles, The can provide open drive conversions, late axles, brake swaps, quick change center sections and just about anything else a banjo rear would need. |  At one time an axle housing...  At one time an axle housing with a bearing journal this badly worn would have been scrapped, but now it's a candidate for repair. |
 Repair sleeves are readily...  Repair sleeves are readily available but the Smith's point out that the quality varies; they can provide the properly-hardened variety. |  Even if the housing ends are...  Even if the housing ends are worn they're still hard and must be annealed by heating then cooling slowly before they can be machined. |  To keep the end of the housing...  To keep the end of the housing located properly for machining, the inner end is held in the chuck while the bearing end rides on a live center via a special adapter. |
 The end of the housing is...  The end of the housing is turned down so there will be an interference fit between it and the repair sleeve. |  Installation of the sleeves...  Installation of the sleeves is made easier by heating, causing them to expand. |  Hot out of the oven, the sleeves...  Hot out of the oven, the sleeves are pushed on to the end of the housing with a press. Once in place the repair makes the housing good as new. |