work party, escondido

got everything welded up except for the butt weld for the inner c's which i'm going to have someone else do that has a much bigger welder. i dont feel comfortable doing it with mine. i'll also gusset the inner c's. it'll be all done tomorrow and dropped off for gear install. I'm pretty happy with how it came out aside from a few ugly welds since im new at stick welding. they're strong though. all the brackets were mig welded. it's set up for a 3 link with coilovers.

to recap, it's a 79 full size bronco high pinion dana 44 housing which i retubed. It has dana 30 inner c's (i know i'll catch crap for that). the inner c's were sleeved with 3/8" wall 2.5" DOM, which was stepped down to 2.25" to fit inside the 3" axle tubes. it was rosette welded, and it will be butt welded and gusseted. I will be running wj knuckles for now, until i find some 94+ dodge dana 44 knuckles which will bolt up to the inner c's. the dodge knuckles use a unit bearing, and i can install a chevy unit bearing which is a 33 spline and can be drilled out to 5x4.5. I can also mount the later dodge brakes on there which are pretty legit, although i'd need to step up to 17" wheels.
i have chromoly shafts and a grizzly locker for it waiting to go in.
i just didnt want to deal with the weak 19 spline shafts and locking hubs that come on the dana 44.

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WOW is all I can say. Nice work again.:thumbup::wave1:
 
Looks great
 
Lookin' good, Dan. Not sure if this was already asked, are you gonna truss it?
 
thanks! not going to truss it, the 3" diameter 3/8 wall tubes are something like 2.4 times stronger than the stock dana 30 2.5x.25 tubes which i havent bent yet. my math could be off but i know it's a lot stronger.
 
thanks! not going to truss it, the 3" diameter 3/8 wall tubes are something like 2.4 times stronger than the stock dana 30 2.5x.25 tubes which i havent bent yet. my math could be off but i know it's a lot stronger.

Never know until you try!

Looks good dude, your XJ has come a long way since I first saw it at the start of the year.
 
thanks! not going to truss it, the 3" diameter 3/8 wall tubes are something like 2.4 times stronger than the stock dana 30 2.5x.25 tubes which i havent bent yet. my math could be off but i know it's a lot stronger.

Nope, assuming similar material strength, your math is right on.
 
Nope, assuming similar material strength, your math is right on.
sweet! well then i think it should be ok. i used DOM, i would assume the stockers are DOM or less as well



Hey Dan, I finally went and picked up those skyjacker shocks from Boostamante. Damn man thanks those things are like brand new!
sweet! hope they work out well for you. thanks again!
 
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