To answer some questions.
The sleeve is 3" OD .250" wall DOM tube. It's an -exact- fit. I took the knuckles off, cleaned up the stock tube and pounded the DOM on. On the long side I hit a burr on the tube about 1.5" from all the way on (vintagespeed and I worked on this together to that point) and couldn't get it all the way past that burr. Ended up splitting the tube down one side, sliding it in place, compressing it and rewelding it. We had .5" holes drilled every 4" in a circular pattern down the tube and rosette welded it in place.
I then took it to Dan Turner at loosenuts and we welded the knuckles on, 12* pinion angle with stock caster, did the proper heat/cooling and used high nickle stick.
From here I let it sit in the garage for a month or so while I dealt with work stuff and pondered what to do for bracketry, when it came up that there were some favours I could do for troy, and he welds.. so I dropped it off with him. I left some very specific instructions, and a general guidline as to what I want outside of those. One minute ago is the first time I have seen the pictures of what he's doing, and I am very pleased as of thus.
When I get it back from him, it will be getting a Precision Gear r&p with all timken bearings. I have a set of Alloy USA CrMo 27 spline inners and an Auburn Ected sitting on the shelf, although I hear auburn has a 30 spline unit coming up, and if i can get confirmation of that, will hold off and do Alloy USA 30 spline inners with the Ected. Those will be mated with Alloy USA 30 spline outters and 30 spline Timken unit bearings, and a set of CTMs. I picked up a Crane diff cover to help prevent the pinion deflecting the ring gear, Alloy-USA tube seals for no particular reason really, WJ outer knuckles with some aftermarket rotors and calipers. I'll be using .291" DOM tube for the trackbar with 2" superflex joints at both ends, chevy high misalignment DLE's and WJ TRE's, all flipped over the knuckle, and .291" DOM tube for the steering links. RE HD trackbar bracket and brace, currie steering brace, and may throw a hydro assist ram into the mix later, that came off of a '73 F350 4x4.
I would think its clear with the time and effort going into thist, that not only were the time and funds available to do a 44, but that I would have known the risks of polishing a 30. The fact of the matter is the 44 is already sitting in my garage (from a 79 f250) but I want to see how far I can take a dana 30 - and after all, it was my money to waste.
-Cal
