After almost a year I finally got back to building this axle this weekend. The reason for the build it to put 35's on my XJ with 4.88's (I might try 4.56's), get the maximum clearance under the axle possible and NOT have it break in the rocks. I dont do mud unless I have to drive through it to get to the rocks. I want to keep my XJ as low as possible and maximize clearance underneath by tucking everything up as much as possible.
I looked at building a D44 and a D60 (sitting on a front 79 F350 SRW D60) but I decided to build the D30 up.
Here is why:
1) On 35's a D30 has as much clearance under it as a D60 on 40's
2) With the WJ outers I get the improved braking expected from a D44 swap.
3) The sleeved and trussed Dana 30 weighs less than the D44 and A LOT less than a D60.
This build is pretty much a copy of what Cal did, though with a few minor details changed. One not so minor change was my decision to slit the sleeve from one end to another so it would slide over the axle a lot easier. I spent a lot of time (4-5 hrs) belt and hand sanding the tubes along with cleaning up burrs in the sleeves after drilling to make sure it all fit tight. Even with this I am really happy I slit the sleeve. The slit will be welded up.
The first step was to strip the donor D30. Here is a thread from last winter on cutting free the inner C's. http://www.naxja.org/forum/showthread.php?t=979657
Anyhow here is the desired end state, XJ on 35's. Nothing new here, but it sure looks better on 35(s) than on 31's.
Last night I welded up the nicks in the axle tube. Preheat with propane, weld with a Miller 110V, wrap in rags, weld on the other end, gring the first side, grind the second side, and repeat until its all smooth and clean.
I test fitted the C's. They went on much easier (5lb hammer) after using a cylinder hone to remove just a few thousandths from the inner diameter of the C's.
When the C's were cut off the cut went deeper into the C in some places than in others. I spent a lot of time cutting the tubing so it would butt up against the axle center section AND be within 1/4 inch or less of the C's all the way around. This should allow for a great weld between the C and sleeve and the center section and the C.
I cut a lot of 1" dia rossette weld hols in the Sleeve. I want the sleeve to stiffen the tubes in torsion, the truss takes care of bending.
Here are a couple pics of the axle with the C's and the sleeves tacked on.
Sunday I go over to a friends house and use his 220V MIG to burn it all in. Then its on to the Truss.
The big decsion I have to make for the truss is should I keep it one piece over the top of the center section (cutting off the cast upper control arm mount on the DS) or should I build the truss in a left and right side, keep the cast upper mount and rely on the welding of the truss to the center section to provide all the rigidity. I am leaning towards leaving the cast upper mount in place, building the truss as a LH/RH pair and welding them to the sleeves and center section. Comments & ideas welcome on this.
John
I looked at building a D44 and a D60 (sitting on a front 79 F350 SRW D60) but I decided to build the D30 up.
Here is why:
1) On 35's a D30 has as much clearance under it as a D60 on 40's
2) With the WJ outers I get the improved braking expected from a D44 swap.
3) The sleeved and trussed Dana 30 weighs less than the D44 and A LOT less than a D60.
This build is pretty much a copy of what Cal did, though with a few minor details changed. One not so minor change was my decision to slit the sleeve from one end to another so it would slide over the axle a lot easier. I spent a lot of time (4-5 hrs) belt and hand sanding the tubes along with cleaning up burrs in the sleeves after drilling to make sure it all fit tight. Even with this I am really happy I slit the sleeve. The slit will be welded up.
The first step was to strip the donor D30. Here is a thread from last winter on cutting free the inner C's. http://www.naxja.org/forum/showthread.php?t=979657
Anyhow here is the desired end state, XJ on 35's. Nothing new here, but it sure looks better on 35(s) than on 31's.
Last night I welded up the nicks in the axle tube. Preheat with propane, weld with a Miller 110V, wrap in rags, weld on the other end, gring the first side, grind the second side, and repeat until its all smooth and clean.
I test fitted the C's. They went on much easier (5lb hammer) after using a cylinder hone to remove just a few thousandths from the inner diameter of the C's.
When the C's were cut off the cut went deeper into the C in some places than in others. I spent a lot of time cutting the tubing so it would butt up against the axle center section AND be within 1/4 inch or less of the C's all the way around. This should allow for a great weld between the C and sleeve and the center section and the C.
I cut a lot of 1" dia rossette weld hols in the Sleeve. I want the sleeve to stiffen the tubes in torsion, the truss takes care of bending.
Here are a couple pics of the axle with the C's and the sleeves tacked on.
Sunday I go over to a friends house and use his 220V MIG to burn it all in. Then its on to the Truss.
The big decsion I have to make for the truss is should I keep it one piece over the top of the center section (cutting off the cast upper control arm mount on the DS) or should I build the truss in a left and right side, keep the cast upper mount and rely on the welding of the truss to the center section to provide all the rigidity. I am leaning towards leaving the cast upper mount in place, building the truss as a LH/RH pair and welding them to the sleeves and center section. Comments & ideas welcome on this.
John
