My Ultimate HP 60 Build

Its finally time I contribute something useful to the Adv Fab section here I spent years learning and figuring out what was the best and all the little tricks and small things that go the distance, and now I have the chance for my first hardcore serious build. I'm going all out and building it pretty much as strong as possible. Input is very welcome!!


CURRENT PLANS:
-Narrow PS 4.625"
-Truss the heck outta it
-Shave job
-Ruffstuff cover
-Clayton style LCA mounts and coil buckets
-3 link upper built into PS of the truss
-Chop and plate stock knuckles, add 5th bolt and such
-Ballistic high steer arms, crossover style with TRE's





It all started when I was walking around an auto swap meet and found a set of late 80's F350 axles for $300. Bought them, resold the 10.25, and ended up with a complete HP60 for 200 big ones.




Finally decided I needed a place of my own to work outta, so I went and bought a 20' shipping container. Its worked out to be a sweet little workshop.





Teardown began and work started on the housing. Kinda wierd working on this stuff, I'm so used to D30 stuff






First order of business was the casting for the leaf spring perch on the DS. I trimmed about half of it off to give me enough tube to work with for a link mount. Also, cut off the PS brackets.








Time to get down to business with narrowing the PS tube. Did some measurements and figured out what I wanted to do. Started with my Rigid chop saw. 1/2" tubes put a beating on it so I borrowed a friends Milwaukee that made cake outta the job.

Cut out the tube from inside the inner c and started to clean it up to be welded back on.





Got out the sledge hammer and did my Hulk thing, turned green, and wailed on the C until i was happy with where it was. I got real close on my first shot and was only off by 1* on the caster angle. I tapped in back to match the other side/factory specs.





This is where I was at this point. I wanted to rearrange the shop and decided to hang the 60 from my engine hoist so i could burn on the inner c with some big manly welds.





Threw a bunch of metal at it and did the tubes to the center section at the same time. For extra measure i did the very end of the tube to the other side of the inner c.

So at this point the housing was all back together and narrowed Time to get some wood and start building the template for the truss. Its being notched and shaped to follow the contour of the housing for a nice snug fit so it can be completely welded to the axle.





Got bored one night and decided to try out the new TIG welder I had at my dissposal now and make some inner c gussets. Yeah yeah I know, probably doesnt need it, but it looks cool.






Scored 8 feet of 3" x 6" 5/16th wall rect tubing for $40. This will become the truss material for both axles now. Since I dont have a plasma yet, it was all cut out with a half dozen cutoff wheels.

After grinding and making some finishing touches, this is where I stand as of right now. Its currently jsut tacked on it 4 spots so I could figure out if I'm happy with it. I think i may trim a little more off of the back side to try and lean the truss back so its more perpendicular to the ground when the pinion is rotated up a few degrees.

Yum.

um sweet! did you just want to keep stock width? what was your reasoning behind that?

Lame.

Just wondering how you plan to use the Clayton style LCA mounts and coil buckets with that truss

how much was the shipping container? :eyes:

When are you gonna pick up a phase converter and get that Bridgeport running for the shave job? If it's the normal 1HP 220/230V 3ph motor, I think this should set you up pretty well: http://cgi.ebay.com/1-3-Hp-Static-P...lectrical_Equipment_Tools?hash=item2c51ce877f

Fullsizexj said:

Just wondering how you plan to use the Clayton style LCA mounts and coil buckets with that truss

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I think he's planning on building similar mounts, not necessarily purchasing them.

Though, IIRC, he wants to use the HDPE coil inserts he sells.

still, he is either gonna have to cut the truss down to tube level or use some short coils, otherwise he will have 4-5" in lift just with the coil bucket plates

aparke4 said:

um sweet! did you just want to keep stock width? what was your reasoning behind that?

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I didnt want full width, but I wanted a little bit more then stock. This seems to be about as narrow as possible with a 60 running coils. Itll also match up nicely with a C&C 14 bolt out back.

Fullsizexj said:

Just wondering how you plan to use the Clayton style LCA mounts and coil buckets with that truss

Click to expand...

Like Colin (Moparmanic) said, I wanna make the LCA mounts like his, nothing below the bottom of the axle tube. As for the coil buckets, if I dont make my own, Ill buy Claytons ones. Ill be notching the truss out where the buckets will mount. I think Im gunna build about 2" of lift into the mounts alone.

ehall said:

how much was the shipping container? :eyes:

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$1300 delievered. I got one with the smooth side outside so it would be easier to mount windows and stuff. Heres a link to it: http://www.naxja.org/forum/showthread.php?t=1006748

kastein said:

When are you gonna pick up a phase converter and get that Bridgeport running for the shave job? If it's the normal 1HP 220/230V 3ph motor, I think this should set you up pretty well: http://cgi.ebay.com/1-3-Hp-Static-P...lectrical_Equipment_Tools?hash=item2c51ce877f

Click to expand...

I have to get off my ass and borrow my buddy's forklift so I can move it in still. Thats probably what Ill get for a convertor, or something jsut like it. I should be fine with a static setup.

will this ultimate 60 have hydro steer?

As of right now, itll only have hydro assit. I didnt wanna go all out with full hydro to begin with cause it still be in a full bodied(ish) XJ that will see a fair amount of street time. Down the line, if the jeep goes more towards the buggy side, it may get full hydro.

my 60 is cooler nice work Ross

Bill's is better. It's gonna have RCV CV's.

Dundy said:

Bill's is better. It's gonna have RCV CV's.

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no its not, he gots Blah H1's i got pimpin Stazworks with 2"BS

Good timing, I start my 60 build soon, although it will be full hydro and air shocks (makes that truss action easier to do ya' know!)

Dundy said:

Bill's is better. It's gonna have RCV CV's.

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Bragging for me since I don't?

ROBZ95Xj said:

no its not, he gots Blah H1's i got pimpin Stazworks with 2"BS

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Eh, they'll do for now.

Jump This said:

... full hydro and air shocks (makes that truss action easier to do ya' know!)

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I told him that too!


Ross, what are your plans for gears/locker/shafts/3 link joints?
You aren't still planning on 35s are you? Not that there is a problem with 35s on some other front axle, just with that super heavy D60 you're building up front it will be.