building the bullet proof D30 housing

[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]

Originally Posted by 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||

Ohhhh GAWD!! Don't give these hackers any ego boost yet!

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]

Originally Posted by steagall9301

here is the truss pics i promised

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




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

[Mr.OverKill]

Originally Posted by ashmanjeepxj

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]

Originally Posted by 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.

Troys just hoping to be able to pick the damn thing up when hes done!

Rick R

[Mr.OverKill]

Originally Posted by Jump This

Troys just hoping to be able to pick the damn thing up when hes done!

Rick R

they dont say that i have a 7500lb tubular XJ buggy for nothing!!

[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]

Originally Posted by 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

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]

Originally Posted by 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

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]

Originally Posted by cal

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

[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.