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Old 08-27-2012, 03:31 AM   #51
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Nice job for only 30 min! Love the 69 too!
Thanks on both. I have learned to use every spare minute I get in the shop. I had done a bunch of measuring and planning so I was pretty sure it was gonna fit.
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Old 08-27-2012, 11:43 AM   #52
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looking good.. want to see more pics of your steering ram setup when its hooked up..
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Old 08-27-2012, 08:15 PM   #53
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looking good.. want to see more pics of your steering ram setup when its hooked up..
Will do. It is ready to mount as it is. Once all the mounts are on and hard tacked to test for binding I will get more pics. Maybe Labor Day I will get out there. If you look at the old pics of it I just duplicated what was there; ram is just parallel to the tierod and pivots on the mount to account for tierod moving in and out when steering. Works like a champ.
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Old 08-27-2012, 09:36 PM   #54
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Looking real good chris. Glad it's going together so smoothly.
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Old 08-28-2012, 08:07 AM   #55
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Looking real good chris. Glad it's going together so smoothly.
Thanks. One thing I am sure of is that there is plenty of time for lots of pain in the butt. I did not mention that it is looking like my drive shaft may be about 1/2" too long. Its not a huge thing, but something I had not planned on. I guess I can take the time I figured I would use on the tierod and cut down a drive shaft instead.
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Old 09-08-2012, 08:56 PM   #56
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Not a big update, but did get all the fab work finished up today for the most part. I like fabbing, but I am ready to start assembly. I got the brackets all welded up, but I am not just tickled with the quality because my MIG was giving me fits. It ain't super pretty, I spent 100 hours tigging my axle brackets fabulicous, but I think it will work.






An interesting point that is a little different is that my panhard uses a steering joint at the axle end. I was going to go with a heim, but this works well so I found a 1" chunk of steel in the scrap pile and made my own tapered hole. I did not have a reem so I used a 5/8 drill to start and tapered it with a carbide burr and finished with a sanding roll. It pulls up nice.



I also cut 2.75" out of my rearward front drive shaft and added 2" to the forward shaft. This got me room for the 60 and improves my driveshaft angle at full droop considerably. I used angle iron and a series of clamps and vices to put them back together. Ended up with about .040 runout which I think will work. I also replaced the carrier bearing on this assembly which was completely jacked. It explains crazy vibrations at speed on last trip out.
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Old 09-16-2012, 09:10 AM   #57
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I have made some progress, but no cool pictures or anything. I got the spiders welded up last night and got the new ball joints installed my brother-in-law donated from his pile of stuff.

I did have a little bit of an unexpected deal with welding the spiders; while it was cooling there was an unsettling *PING* and the carrier actually jumped. It scared the (insert explicit here) out of me! After inspecting it, there as a weld that cracked right now the centerline. I was actually blowing it off with an air hose to get the loose spatter out and I guess it was too hot. I went ahead and hit it again on the cracked weld first and then overlayed opposite weld and then flipped and repeated on the opposite side to try to even out tension. It seemed to crackle a couple of times when cooling, but no loud noises or jumping. I guess when I welded it there was alot of tension created with the weld draw. I'm gonna run it and hope for the best.

Also time for a budget update:

Diff - $150(done)
Gears - $150(done)
Slugs - $50(done, but thinking of getting something else)
Superior Outers - $300(gottem)
Tabs and such - $100(done)
Misc. - $200(bought and resplined long side chromo axle for $155, and a couple things at orielly so far)
More Misc - $26 for 1310/1350 conversion joint

Total - $976 so far for just the axle.

Thinking about spending a few $$$ on a short side chromo just so I am chromoly all the way across. Budget is bad thin since I cant get my 44 sold and I bought another 60 for the rear.

Yep, I picked up a narrowed semi float 60 Friday for the rear. It has all new parts, 5:38's, detroit, mosier 35 spline axles, and is the exact width of my 9". I got a deal at $500 so I had to buy it...had too! I just have to have to redrill for 6x5.5 cause it is 5 hole now. I think I'll have to weld up two holes to make it work. Gotta find some machinable welding rods to fill it with. It will be a simple swap as far as axle swaps go.
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Old 09-16-2012, 11:52 AM   #58
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I like watching builds. Thanks for the info. Unfortunately the ting you here is the weld cracking again but it happens to all of us when welding nodular iron to cast carriers. I run a welded 60 carrier that I broke twice. The last time, I put bolts in the spider gear teeth on all sides so if the side gears let loose the bolts jam the together.
Crazy I know, but 3 times to Clayton now and 2 times up slims slope and no breakage

Keep it up man. Can't wait to meet some of you guys.
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Old 09-16-2012, 12:04 PM   #59
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I'm sorry, nodular iron is cast iron. I meant hardened steel. I just thought about that. Lol
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Old 09-16-2012, 07:13 PM   #60
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TBASTM, I think that the case is cast steel, but I could be wrong. Usually when breaks on cast piece it is at the cast piece, and I have had this happen. This weld actually snapped in the center of the bead which was a first for me. The carrier actually jumped on the work bench when it happened and I jumped back...it was kindof nuts...scared the pee out of me.

Here is a pic of it finished and gears installed for initial pattern testing. As you can see I threw some 1/4 plate steel between the gears on both sides and welded it...welded it alot. I was going to try to get them done but found my new gears are for preload shims on the pinion where the old set was for crush sleeve. Gotta get some shims to finish the setup, but the initial pattern I did with grease looks like its gonna be close enough with the old gear shim setup. I am gonna try Ryan's suggestion for lipstick on the gear pattern .



I also got the frame notched for a little more shock clearance at full droop. shocks are super tight on clearance on the frame and at the tires.

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Old 09-16-2012, 09:01 PM   #61
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Yeah that's what I meant by side gears are hardened steel and the case is cast.

Looks good. The 1/4 plate will save you. Until you break the carrier :-)
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Old 09-16-2012, 09:04 PM   #62
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Nice job. I like the aluminum tape on the hoses to protect them. Nifty idea.
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Old 09-17-2012, 03:23 AM   #63
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Nice job. I like the aluminum tape on the hoses to protect them. Nifty idea.
Haha...yeah, it ain't too purdy but it works. I actually cut a piece of floor insulation and put under the HVAC tape. Those hoses were starting to cook running by the header and my steering was having overheating problems.
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Old 09-18-2012, 07:09 PM   #64
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Big mile stone today; I finished the machine work for the 6 lug conversion. I actually gave some bad information in my earlier post about not having to turn down the face face of the unit bearing to fit in the rotor. I had to turn it down about 1/2".

Here is the finished product.



Basically, I built a set of these:

http://www.polyperformance.com/shop/...g-p-18474.html

and a set of these:

https://www.4wdfactory.com/store/pro...g-Brake-Rotors

The rotors and disc premachined are $800. I have $60 in my new rotors and $50 in a used unit bearing in good shape along with about 6 hours in front of a lathe. Most of that was setup and figuring it all out. I could do a pair in about half that time now that I know what to do and how to set it all up.
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Old 09-18-2012, 07:13 PM   #65
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I also need to note that I talked to East Coast Gear Supply yesterday and got a shim kit on the way as well as some gear marking compound, so I wont end up using the lipstick trick. But, the big thing is that I can not say enough good about Chase and Ryan at ECGS. Those guys are great to deal with, have great prices and have given me discounts or free stuff every time I call. They are very knowledgable and Chase walked me through how to cut a groove in my axles with a die grinder to use the factory spicer drive slugs on the super duty. I will detail this later when I get to it.

Anyhow, call these guys if you need axle stuff. They are great!
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Old 09-23-2012, 09:09 PM   #66
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I got the gears setup this weekend. I had read that it was not possible to get an accurate pattern on used gears. I dont know if this is true, but it was kindof hard to figure out. We ended up setting it kindof root/toe heavy because at that point backlash was already over .010 and the only way to move it to the heal was to increase backlash...think I got all my terms straight. Anyhow, my brother was helping me and we kindof decided it was good enough to run trails . Had a little grief getting pinion preload set as well because I had a crush sleeve with the old gears and it took about 10x in and out to get it right, but I am happy with it after the last shim set.

I also got one hub drilled and studs installed. The studs I ended up with where right at 5/8" on the shoulder at the rotor and about .025 over that on the knurl area. The rotor holes were right at 5/8" as well so I was able to use them as a drill guide. That is why I chose this size. I used a carbide burr on a die grinder to add a little clearance on the knurl area and it worked out well once I got the hang of it.

I actually freehanded the first set of holes, but Chad talked me into some clamps which did make it a little easier.



And, here is the finished product on the spindle. I test if the brake calipers and the mouting should be easy and they will clear the wheels. It may take just a little bit of clearance grinding, but it will be very little if at all.

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Old 09-23-2012, 09:22 PM   #67
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Looks good Chris. Can't wait to with ya in Clayton !!
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Old 09-24-2012, 05:27 AM   #68
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Looks good Chris. Can't wait to with ya in Clayton !!
Thanks, and same here. I am getting excited about the trip. It will be a large time. I just hope I get to do more wheeling and less wrenching this trip.
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Old 09-24-2012, 05:47 AM   #69
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Looking good!
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Old 09-24-2012, 07:23 AM   #70
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Thanks, Mitch.
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Old 09-28-2012, 07:50 PM   #71
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I took the day off to work on the rig cause I was not going to make the trip to clayton without another full day. I got the brakes finished, steering finished, unit bearings finished, long side axle assembled and installed and a limit strap mounted on the long side. Passenger side is complete.

For the brake mounts I used 1/2"x3" bolts through the existing holes and cut 1/2" plate to mount to the caliper. I drilled and tapped the plate and welded it to the bolts. Here is the finished product.





I raised the steering up just a little since it was so low on the super duty knuckles. Later I will probably do a true high steer of some sort, but with my timeline it was all I had. It is a hard bushing welded to the knuckle.



I had to cut a groove in the axle to retain the spicer drive slugs since the super duty shafts do not have a groove for a clip. I ended up having to pull the center washer in the retaining pack that holds the shaft in the unit bearing. I used that washer behind the clip and left me only about 1/8" play in the slug on the shaft. I think it will be fine with a little slide.



Here is the side finished with the strap and steering. There is alot going on and it is extremly tight, but it all works. Bumps, straps, bolt heads, knucks, braces and everything is within 1/4" of each other.

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Old 09-28-2012, 09:59 PM   #72
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Looks good bud!
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Old 09-29-2012, 05:20 AM   #73
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Looks good bud!
Thanks
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Old 09-29-2012, 05:52 AM   #74
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I definitely dont have the motivation you do, damn nice work!
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Old 09-29-2012, 07:27 AM   #75
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I definitely dont have the motivation you do, damn nice work!
Thanks, Mitch. I gotta say I was pretty whipped after 8 hours in the shop going pretty much full throttle the entire time. It might have been due to working from 4am to 8am before I started in the shop.

At this point I am in semi-panic mode trying to get everything ready for clayton in two weeks. It is becoming less fun and more work cause most of this stuff takes twice as long as I think it will.
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