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custom building axles, D60 and Ford 9 questions

You can buy a hell of a lot of rig for 8-10k, shit I've seen some bad ass one ton rigs go for 5-6.
 
You can buy a hell of a lot of rig for 8-10k, shit I've seen some bad ass one ton rigs go for 5-6.

that's my point on why i'm building what i want rather than buying one.

609 is DONE!!!! Ends all 100% TIG welded on and straight, pucks both slide in and the bar spins with almost no effort.

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Ales22s welds, said they aren't the best but will work
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now..... how do i measure for axle length that i'll need? i'm going to be using the chromo cut to fit from ECG.

this how i use the ruff stuff bracket thing?
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I've been running front and rear 9's since 1992 in fact John Currie bought my hipinion 44 center section for $100.00 back in 92. They had just started doing hipinion 44 rears a year or two before. I ran 28 spline in the rear because I didn't have enough money at the time to go 31 and the locker I had was 28 spline Detroit. The axles were from a 1977 F150 rear 9 and front 44. I pick the truck version because the tubing was thicker in the rear and front even thicker. I drove the hell out of my 85 XJ with a V8 swap and 35's till 2006 then I swap them to my 96 XJ and drove it with 36 x15.50 MTZ's until last April 2013 when I broke a 28 spline axle at the splines (twist). I stepped up to 35 spline at that point. So if any one tells you that the 9's not strong don't take their word for it. The 9 is all Trophy trucks and any other modified class ran back in the day. I would not hesitate to run 37's to 40's if I had front Dana 60 outers! Another benefit is that 3 & 4 links are easily welded straight to or with a plate to the top of the axle housing!!! Can't do that to any other axle without adding lots of weight in trussing not to mention preheating and special rods! Remember back then it wasn't as easy, common or parts available like today!

I would love to do the full floater your doing. Great job and the jig is nice too!
 
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the only things OEM on this are the spindles and hubs, everything else is aftermarket with an ARB inside an N case turning 5:29s.... or 38s? i have to look at what i bought again hahah.

i went with a 9 because.... well all the pro guys use them and it's modular, i can slowly make this into an almost legit trophy truck grade rear easily by adding or swapping out parts on it.i also like the look of the aftermarket 9 type axle housings because it's different and usually only seen on actual race trucks. Then on the other hand i am building everything on my jeep with selling it later in mind, with a 9 type axle i can sell it complete for a decent price or piece it out for more because jeep people are the cheapest ****s i've ever met, well at least the XJ crowd.
 
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last fab part is here, Ruff Stuff 3.5in weld on disc brake brackets are here, ordered them on the 1st came in the mail today. i haven't gotten stuff that fast from companies in NY before. gotta love those guys.
 
making GM D60 dually king pin spindles into normal ones......

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then turning them into decent round things to make the lathe happier

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after all that they are at a pretty good starting point, also showed how far off those castings were. about 3/8 heavy on on side.
 
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changed shit around, ended up with this......

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then a front that's coming out a little different than expected


FD63A805-B8ED-4920-8CF5-13A80708F48B_zpsygv3kupm.jpg
 
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