building the bullet proof D30 housing

[Mr.OverKill]

start with a D30 and sleeve it with 3 inch OD tube then build stronger bracketry adding the personal touch.
http://i6.photobucket.com/albums/y241/steagall9301/09-17-06_1730.jpg
these are the LCA brackets
http://i6.photobucket.com/albums/y241/steagall9301/09-20-06_1840.jpg
all tacked on
http://i6.photobucket.com/albums/y241/steagall9301/09-20-06_1841.jpg
still need gussets and weld out and the truss for the UCA attach points over the dif and on the passenger side will be 2X4 square tube cut to shape and fourned to fit the dif housing ( whitch has been rotated as well) the lower control arm mounts were raised 3/4 of an inch so the arms them selves will deflect the impact of the stray rock pluss they will be skidded too. alot of work done and more to come but i should be done soon enough for this season.

[tealcherokee]

so instead of polishing a turd.... your plating a turd?

[88flexj]

If you are going through the trouble of new brackets, why not put them on a worthy axle? I am not flaming you,it's just that the housing is only part of the problem with the turdy.

[gorp]

are you going to get an better shafts.

[IntrepidXJ]

nice work.

not everyone needs a bigger axle in the front of their rig....polishing the 30 isn't always a lost cause.

[cassio]

nice work.

not everyone needs a bigger axle in the front of their rig....polishing the 30 isn't always a lost cause.

i totally agree if you already have it and im guessing its already geared
not everyone has the money to go axle shoping and start all over from scratch

cas

[KarlVP]

I just trussed mine on my TJ from Knuckle to Knuckle with Dom tube. I incorporated the LCA mounts into it. For the pass mount, I made a little plate that works pretty well. It fits inside the mount to give it strength.

I know this is my TJ on an XJ board. But at least it is a HP XJ 30 under my rig.

http://img237.imageshack.us/img237/4673/3182006124yw7.jpg

[EricsXJ]

Nice job.

Is the 3" OD tube an exact fit around the D30 tube? I ask because I have had a similar idea of using half a tube welded to the bottom half of the D30 to act as a skid/truss. Any opinion as to how well this would work?

I've got too much invested in my 30... I may as well keep it. :)

[CanMan]

Is the 3" OD tube an exact fit around the D30 tube?

Depends on the thickness of the wall on the 3" OD tube. Nice work Troy. :thumbup:

[EricsXJ]

Depends on the thickness of the wall on the 3" OD tube. Nice work Troy. :thumbup:

Yeah okay... so I should have figured... :) How thick does it NEED to be for an exact fit?

[Roxtar]

Spent a lot of time and $ building as strong a D30 as I've ever seen:

http://i27.photobucket.com/albums/c192/kid4lyf/DSCN0023.jpg
http://i27.photobucket.com/albums/c192/kid4lyf/ID1137199031.jpg

Alloy inner and outer shafts.
Jantz Superjoints
ARB




Still didn't stop this from happening:

http://i27.photobucket.com/albums/c192/kid4lyf/D30ringgear.jpg

Ended up doing it all over (and then some) on an HP44.
Just a warning.

IOW, yes, it's possible to build a, somewhat, bulletproof D30 housing.
Unfortunately, inside, it'll still be a 30.

[NXJ]

Holy (chr)moly! What brand and ratio (teeth count) ring gear is that? You got me curious, proper gear pattern?

I don't see how sleeving the axle tubes will lessen housing flex (or do anything at all?), either.

[Roxtar]

Holy (chr)moly! What brand and ratio (teeth count) ring gear is that? You got me curious, proper gear pattern?

I don't see how sleeving the axle tubes will lessen housing flex (or do anything at all?), either.4.56. Motive Gear.
Everything set up perfectly.
35" Creepy Crawlers

[IntrepidXJ]

35" Creepy Crawlers

with my driving, i wouldn;t build a d30 if i decided to run 35's. however, it is perfectly acceptable to me to build it for the 33's I run :)

[NXJ]

4.56. Motive Gear.
Everything set up perfectly.
35" Creepy Crawlers
Hmm, what did the pinion look like after this incident?

[Roxtar]

Hmm, what did the pinion look like after this incident?Rough but better than the ring gear.

[Jump This]

You gotta' remember Troy works for cheap!:shhh:
I can understand the desire to build something that you already have.
You have the axel..locker....housing....its just you want it stronger....you have a metal supplier...you know how to weld....heck, your even somewhat accomplished at fab work.....why not add a bit of truss here....some better mounts there....and viola! You got one fancy (insert present axel here :D )
We know its not as strong as (insert 'next step' axel here.) but I learned a bit and I like working on my (or in Troys case, someone elses) junk!
Yeah....in the long run you probably end up with a Hi-9 because you like quality...but the trip oftentimes is more memorable than the destination.
Rick R

[Mr.OverKill]

forgot to mention that this particular axle is cal's and the truss is half built ( ruff cut with final fittment to do ) as of tonight all that is needed is the weld out of the coil buckets, LCA mounts, grind, final fit and weld out of the truss and fab of the upper control mounts and shock mounts. the track bar mount will be fit up and weld out after the axle is mounted for a guarenteed clearance and alignment. easy money!


the hardest part is getting my wife to let me spend the time in the garage to get it done after work every day!!




besides it gives me some experiance for when i build my own axle, housing and bracketry ( spider trax 609 knock off )

[cal]

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

[1996cc]

it was my money to waste.
-Cal

Must be nice.

[IntrepidXJ]

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.



that's funny....i have an HP D44 from a 78 f-250 in my garage and am continuing to build up my d30. i'm saving the 44 for when i finally decide i want to go with bigger tires :)

[cal]

I have another four wheel drive thats - gasp - more important to me than the cherokee, that I think's getting the hp44.

1962 Ford F100 4x4 Shortbed Unibody small rear window. The fifth year of the first overhead valve engine ford ever made (223ci i6), 4th year of factory 4 wheel drive. I broke a knuckle on the lp closed knuckle 44 a couple years ago, and while I found a replacement, its eats a kingpin bearing every 8 thousand miles or so and leaks grease into the front right brake drum. About two years ago I blew up the ford 9" in the rear and threw a 60 back there, so now it's time to do a front to match. Originally I grabbed the hydro assist stuff I listed above to go on that setup, but I think the jeeps going to get it instead.

http://www.shadowco.org/~cal/4x4/F100/New-2.JPG

Here's the old rear end. First housing failure I ever dealt with. I'm hoping not to have housing problems on the d30 ;)

http://www.shadowco.org/~cal/4x4/F100/9inch/9inch1.jpg

[Jump This]

that's funny....i have an HP D44 from a 78 f-250 in my garage and am continuing to build up my d30. i'm saving the 44 for when i finally decide i want to go with bigger tires :)
Ummm...could you load that 44 onto the plane with you when you come on out...I'll supply cash incentive!! ;)
Rick R

[IntrepidXJ]

Ummm...could you load that 44 onto the plane with you when you come on out...I'll supply cash incentive!! ;)


i will use it one of these days....so no thanks. though, it would be funny to see what the airline says if i dragged in an axle to be checked :D

[hadfield4wd]

i will use it one of these days....so no thanks. though, it would be funny to see what the airline says if i dragged in an axle to be checked :D
You could put it in a golf club bag.

[Mr.OverKill]

truss is fit up and the vent mod is designed, i just need to fit the vent tube in and seal it up prior to welding the truss on, the truss is 2X4 square tubing and tight as i could get it to the dif and tubes, i will try to get pics tomorrow. :photo:

[GSequoia]

Try, make sure to fab up a few practical jokes for Cal to find after he gets it. I don't think they make him work enough at work so he needs something to occupy his mind.

[cal]

dude f* off. ;) I havent had a day off in several weeks and it's making you less funny :)

[Mr.OverKill]

dude f* off. ;) I havent had a day off in several weeks and it's making you less funny :)( to the tune from lion king ) can you feel the love tonight........

[Mr.OverKill]

here is the truss pics i promised
http://i6.photobucket.com/albums/y241/steagall9301/CID__09-27-06_1627.jpg
other than these gaps at the dif ( needed for the vent tube and alignment issues ) the largest gap is 1/16" along the tubes to reduce the risks of warpage
http://i6.photobucket.com/albums/y241/steagall9301/CID__09-27-06_1623.jpg

http://i6.photobucket.com/albums/y241/steagall9301/CID__09-27-06_1624.jpg

well i have alot of welding to do in the very near future, every thing is tacked or just sitting on the axle untill cal gives it the once over and the go. the UCA mounts are the seccond to last things going on along with the shock mounts. then once we mount the axle on the jeep we will design and fit up the track bar mount.

questions comments or concerns are welcome

TIA

[cal]

It looks good! I need to hurry up and order material for the trackbar and some other goodies (DLE's, a few more superflex joints, etc). I'll try and nail down tonight what my weekend schedule looks like, so I can roll down your way. I'm thinking sunday, but thats my 30th birthday and everyone seems to think its more important I see them than you? :(

I'll give you a call in a couple hours or in the morning, depending how work goes.

-C

[dallas xjs]

awsome work...with evo axle shafts i would put that up against any {well almost any} d 44...what about hydro assest on those knuckles??or a factory weld knuckle at that?? hats off to you and crew on that 30 build..||charles||

[Jump This]

awsome work...with evo axle shafts i would put that up against any {well almost any} d 44...what about hydro assest on those knuckles??or a factory weld knuckle at that?? hats off to you and crew on that 30 build..||charles||
Ohhhh GAWD!! Don't give these hackers any ego boost yet!:D

I still havn't seen Cal in his Jeep in over two years!
(and we are still kinda' ticked at Cal for spending two weeks on the Con without inviting all of us!)
Rick R

[ashmanjeepxj]

here is the truss pics i promised
http://i6.photobucket.com/albums/y241/steagall9301/CID__09-27-06_1627.jpg
other than these gaps at the dif ( needed for the vent tube and alignment issues ) the largest gap is 1/16" along the tubes to reduce the risks of warpage
http://i6.photobucket.com/albums/y241/steagall9301/CID__09-27-06_1623.jpg

http://i6.photobucket.com/albums/y241/steagall9301/CID__09-27-06_1624.jpg

well i have alot of welding to do in the very near future, every thing is tacked or just sitting on the axle untill cal gives it the once over and the go. the UCA mounts are the seccond to last things going on along with the shock mounts. then once we mount the axle on the jeep we will design and fit up the track bar mount.

questions comments or concerns are welcome

TIA

The trusss looks nice but dosent do much for the short side. coil buck kills the strength.

I havent finished burning mine in yet.. Its 2x6 3/8inwall box on a d60

http://www.wheelingarizona.com/forums/files/thumbs/t_000_0010_181.jpg
http://www.wheelingarizona.com/forums/files/thumbs/t_000_0009_740.jpg

[Mr.OverKill]

The trusss looks nice but dosent do much for the short side. coil buck kills the strength.

the truss is more to provide a weld point for the UCA mount on the dif and long side strength. the truss really isnt needed because the doubled thickness of the tubes ( 3"X1/4" wall tube over the 2.5"X1/4" wall stock tubes ) besides the paramiters of the coil bucket were spacific, the coil could not sit any more than 1/2" over ( higher than ) the stock bucket location.

[cal]

I'm confident the housing will never be the weak link in this axle. Troy is doing work far beyond my expectations. :) I just hope i'm able to return the favor to him.

[Jump This]

I'm confident the housing will never be the weak link in this axle. Troy is doing work far beyond my expectations. :) I just hope i'm able to return the favor to him.

Troys just hoping to be able to pick the damn thing up when hes done!
;)
Rick R

[Mr.OverKill]

Troys just hoping to be able to pick the damn thing up when hes done!
;)
Rick Rthey dont say that i have a 7500lb tubular XJ buggy for nothing!! :D

[flexinxj]

im loving the idea! ive been wanting to build my D30 and D35 and so many people are against it - NO FAITH! its all about living and learning, if it breaks you can always find a way to make it stronger (it just might cost alot)
whats with everybody wanting 1ton axles? theres no fun in that - fun is knowing you (and maybe some buddies) built it yourself to handle what your gonna do to it!
keep us posted even after you get it done - I WANNA KNOW WHAT HAPPENS

[GSequoia]

Actually Flexin I wouldn't bother building up a 35. XJ 44's are common enough and easy. The 30 is a bit different as it isn't too terrible an axle and can hold up decently - not that it isn't still a gamble ;)

[Mr.OverKill]

Actually Flexin I wouldn't bother building up a 35. XJ 44's are common enough and easy. The 30 is a bit different as it isn't too terrible an axle and can hold up decently - not that it isn't still a gamble ;)i would have to agree with that, the D35 is a true hit and miss proposition ( most the time its a miss ) the axle shafts are just too small. but with the alloy shafts you can get it to the strength of a stock 8.25 and then dump a load of time and materials in to trussing the outside and you might come up with an axle that can be locked with 33's

P.S. this is from some first hand experiance, my D35 was a good one but i never locked it and after watching a buddy of mine lock his with 33's snap 3 shafts in a week of crawling mild stuff..............well, you get the picture

[cal]

im loving the idea! ive been wanting to build my D30 and D35 and so many people are against it - NO FAITH! its all about living and learning, if it breaks you can always find a way to make it stronger (it just might cost alot)
whats with everybody wanting 1ton axles? theres no fun in that - fun is knowing you (and maybe some buddies) built it yourself to handle what your gonna do to it!
keep us posted even after you get it done - I WANNA KNOW WHAT HAPPENS

Yeah. I'm a little over $3,000 into a dana 30 and even *I* cringe at the idea of building a Dana 35..

Don't do it man! ;)

-C

[BlueGerbil]

over $3,000 into a dana 30

WTF?
Got some diamonds glued to the diff cover? Or what have you done to the axle?

[87manche]

it's filled with rare whale oil, $1K a quart :D

[cal]

You know. I'm still trying to figure out where it all went. :) I added up receipts and kinda cringed.. but when you start adding up a locker, gears, 30 spline shafts, 30 spline unit bearings, higher end WJ rotors and calipers, WJ knuckles, components for beefy steering, $400 in rod ends, $200 diff cover (crane), steel for this and that, superflex joints for trackbar and uca bushings, re HD trackbar mount and brace, etc, etc, etc.. it add's up. I knew going into this that I wasn't saving money vs building a 44, but came out very alarmed at just how much i really spent.

[djblade311]

we went to see it yesterday....yea cal was having issues picking up the housing off the rack. lol. It looks REALLY good. bastard.

[cracker]

I would rather see people polishing a 'turdy' then spending $ on a 44.

Skip the 44 and go 60 when you have to upgrade.

Good job Troy! Make sure that thing is heavier than my Spidertrax 60 :D

[Mr.OverKill]

well the truss and brackets are done, the UCA mounts are welded on, shock tabs are on ( just need drilled ) i have a few gussets i want to add but other than that the thing is done, i will post pics when the gussets and clean up are done, i might even hit it with paint first. the track bar mount and sway bar mounts will be later, after the axle is mounted and tested for clearance issues.

i start on the WJ knucles tomorrow



cal call me.

[Mr.OverKill]

I would rather see people polishing a 'turdy' then spending $ on a 44.

Skip the 44 and go 60 when you have to upgrade.

Good job Troy! Make sure that thing is heavier than my Spidertrax 60 :Dby the way i got 100lbs of lead filler for the spider trax for after the welds are done and we smooth it out, any we dont use i will flow inside the axle houseing to lower your COG :firedevil :laugh3:

[Roxtar]

You know. I'm still trying to figure out where it all went. :) I added up receipts and kinda cringed.. but when you start adding up a locker, gears, 30 spline shafts, 30 spline unit bearings, higher end WJ rotors and calipers, WJ knuckles, components for beefy steering, $400 in rod ends, $200 diff cover (crane), steel for this and that, superflex joints for trackbar and uca bushings, re HD trackbar mount and brace, etc, etc, etc.. it add's up. I knew going into this that I wasn't saving money vs building a 44, but came out very alarmed at just how much i really spent.That's why it pays to start with a plan.

[Jump This]

That's why it pays to start with a plan.


And take all the fun out of it? Bahh!! Humbug!!
Rick R

[cal]

That's why it pays to start with a plan.


I had a plan, I just decided part way into the project to take a little more time and money and see how far I could take it. I don't really think I'll go bigger than 35's in the next several years, so I wanted to build this to last.

[Roxtar]

I had a plan, I just decided part way into the project to take a little more time and money and see how far I could take it. I don't really think I'll go bigger than 35's in the next several years, so I wanted to build this to last.Interesting definition of little.

So you're going to run 35s on a $3000 D30, huh?

See post # 11 in this thread.
Happy trails.

[Mr.OverKill]

finished with another part of the mods on the adjenda for cal yesterday, can any one tell me what the mod is?? here is a clue
http://i6.photobucket.com/albums/y241/steagall9301/CID__10-06-06_1740.jpg

thats right, WJ knuckles!! the axle project should be done with the initial build/ fab stage this weekend, then its back to cal and the install so we can do the axle side track bar mount in place under the rig for guaranteed clearance. the final fab/build stage pics will be up this weekend.

[Mr.OverKill]

other than a couple of shock mount holes to drill, its done ( unless cal has more requests that is )
http://i6.photobucket.com/albums/y241/steagall9301/CID__10-08-06_1801.jpg
http://i6.photobucket.com/albums/y241/steagall9301/CID__10-08-06_1715.jpg
http://i6.photobucket.com/albums/y241/steagall9301/CID__10-08-06_1713.jpg
and last but not least
http://i6.photobucket.com/albums/y241/steagall9301/CID__10-08-06_1712.jpg
well what do you all think?

[djblade311]

still needs bondo and clear coat!

[cal]

I think it looks like far more than I bargained for. :)

very nice.

[XJ_ranger]

do yourself a favor -
pull the carrier bearing caps and carrier, then stick a straight tube down the axle tube and look at it... make sure that all that welding didnt cause any warpage...

:anon:

[cal]

Actually troys been checking that at each stage of this, and I'll be checking it with a laser pointer before I have it geared. ;)

[cracker]

Looks great Troy!

Good Job!

[XJ_ranger]

Actually troys been checking that at each stage of this, and I'll be checking it with a laser pointer before I have it geared. ;)
good to hear.

get yer d300 yet? :gag:

[cal]

No, I havent had time to really think about jeep stuff other than taking Troy's calls. I'm best man of a 400 guest wedding this coming weekend, and thats getting 98% of my attention - my job gets the other 2. :)

I'll get caught up on everything this coming week.

Did i ever pay you for it? I am losing track of things lately.. :)

-C

[vintagespeed]

http://i6.photobucket.com/albums/y241/steagall9301/CID__10-08-06_1715.jpg
http://i6.photobucket.com/albums/y241/steagall9301/CID__10-08-06_1713.jpg

well what do you all think?

How did you attach the UCA mounts? Is there a reason you left the LCA mounts so large?

Overall it looks pretty okay! Glad to see the progress! :cheers:

[XJ_ranger]

Did i ever pay you for it? I am losing track of things lately.. :)
nope

not too worried about it... but id bet that ron is looking at it, thinking... hmm thats probably like $0.12 in scrap steel right there...

[cal]

Yea, I'll get on that..

[Mr.OverKill]

take two scene one, cals axle is on its way to be built internally so i am done with that one for now, this time its my own D30 ( unless some one wants to donate a HP D60 to me ) went to add the waggy 3/4 ton steering and found that the tie rod hit the drag link and coils even after i trimed the stock buckets. so what to do (before JV on the 18 of nov ) well cracker and i pulled the axle and i proceded to remove the coil buckets and track bar mount, the coils will be centered over the axle and about an inch higher i think. the LCA mounts are just going to be plated so i have exact placement ( or i might cut them off in a few days as i see how the coil buckets come out ) i am also cutting the drivers side UCA mount off for the single radious arm passenger side and lower long arm set up kind of like farmer mats just opposite sides.

well here goes the self imposed pressure but i think i will have pleanty of time for this, and crackers spiedrtrax 609 that i am starting this week as well, all before the JV run, well mabi not but its worth a try :laugh3:

[cal]

take two scene one, cals axle is on its way to be built internally so i am done with that one for now, this time its my own D30 ( unless some one wants to donate a HP D60 to me ) went to add the waggy 3/4 ton steering and found that the tie rod hit the drag link and coils even after i trimed the stock buckets. so what to do (before JV on the 18 of nov ) well cracker and i pulled the axle and i proceded to remove the coil buckets and track bar mount, the coils will be centered over the axle and about an inch higher i think. the LCA mounts are just going to be plated so i have exact placement ( or i might cut them off in a few days as i see how the coil buckets come out ) i am also cutting the drivers side UCA mount off for the single radious arm passenger side and lower long arm set up kind of like farmer mats just opposite sides.

Nice. I'll score you some alloy shafts for the front this week sometime and see if i can dig up some kind of upgraded ujoints. I think I have some tube-seals sitting around too, i might have some other goodies, i'm not sure.

-C

[cracker]

i might have some other goodies, i'm not sure.

-C

Troy likes goodies that vibrate ;)

[cal]

Troy likes goodies that vibrate ;)


Something like this?

http://www.bigteazetoys.com/yellowduck.jpg

[Jump This]

Something like this?

http://www.bigteazetoys.com/yellowduck.jpg

Isn't that available in a dolphin model? ;)