Hi headsup.
Not much welding on the stub to create that sort of stress except the undercut weld across the stub at the point where fatigue commenced. The axle material is probably the commonly used k1045.
Ground the surfaces smooth then ran single beads across centre each end to provide a weld preparation. Blocked up the broken end by eye, tacked the centre so could make a final adjustment then tacked each end of the prep area to fix the fore/aft alignment. Up/down (camber) I balanced as each run (downhand/top-overhead/underneath) was made, if pulling one way too much more weld opposite to balance. All carried out in situ, lying down in burnt spinifex, rocks and crows flying about waiting to see if we made it!
No trouble on the nearly 3000km. tow home, when checked I had the toe in spot on, camber 12mm in at the top (neg.)
Now correctly repaired, has done another 17000km. including more rough going.
Yes, I did contact the suspension manufacturer who didnt want to know about it. Brushed it off as abuse of the unit which if you saw where we have dragged the old girl you may tend to agree.
We have owned this van nearly 7 yrs. and have done most of the corrugated tracks plus places where tracks dont exist. The previous owner, a freelance outback photographer, also put the van to the test.
I simply put this episode down to being general "wear and tear", all our previous vans have suffered to some similar degree, broken A frames, cracked chassis, broken axle etc.
Having said all of that I probably now give the impression we are "gung ho" bush bashing "redneck" types who would destroy anything. Please be assured not the case, I am actually very cautious in our travels its just I often want to get into a particular spot, sometimes with damage potential.
Mike