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Post by dan99tj1 on Nov 19, 2010 20:54:02 GMT -5
Looking good, keep it up
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Post by auburnaviator on Nov 21, 2010 21:12:27 GMT -5
Very nice, I'll be asking for help probably sometime after christmas in setting up the gears/locker in my HP D44. Keep this thread updated so I can follow it for mine!
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Post by rccolacc on Dec 19, 2010 0:38:19 GMT -5
More welding/grinding on the frame underside:  Installed the inner axle seals on the Dana 44:  Used 1/2" all thread and fender washers. Made it really easy to install them  Added .005 shims to each side of the carrier and then pressed on the new carrier bearings. Rob Smith let me borrow the school's press and it made easy work on the bearings. Thanks Rob. After installation I checked the gear mesh:   I used the same shim thickness on the new pinion as the old one. Backlash was around .006"-.008" but was set with the carrier shims. I think the pinion depth is fine looking at the gear mesh. Opinions? Put the cover back on, new yoke and pinion seal, and it's ready for cleaning and welding on suspension brackets:  Until next time... -RC |
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Post by rccolacc on Jan 6, 2011 23:31:24 GMT -5
Tonight I put both front axles side to side. Compared the XJ Dana 30 to the Dana 44. Interesting to note-- the width of the axle between the balljoints is the same on both. I put both at a 6* caster, and measured the link and spring pad location on the Dana 30. I'll be drawing up the tabs and cutting them out soon and then welding them on the 44.   |
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Post by auburnaviator on Jan 8, 2011 20:26:50 GMT -5
Looks good man. I'll be shortening my hp d44 in the next month or two hopefully. I'll probably just cut the long side down to waggy or rubicon width and leave the short side the same length. Did you do anything special to cut the C's off and change their caster?
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Post by rccolacc on Jan 9, 2011 1:04:17 GMT -5
I didn't mess with the axle as far as the caster goes. I didn't want to open a can of worms there. I'll set it when I put the mounts on, and the pinion angle will be where it falls. Since I have hubs, I don't really care about the pinion angle too much.
-RC
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Post by auburnaviator on Jan 9, 2011 16:02:17 GMT -5
Gotcha, thanks. I don't know if I'll try to change the caster on mine when I shorten it or not. I don't have an axle jig set up to make sure I get them exact so I'd just be "winging" it which I don't know if I'm comfortable with...
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Post by rccolacc on Jan 20, 2011 23:57:50 GMT -5
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Post by rccolacc on Jan 21, 2011 10:27:55 GMT -5
Here's what I'm shooting for the axle to look like when I'm done:  The lower control arm brackets are slightly wider on the 44 than on the 30 because the diff is in the way. I wanted to weld the brackets on the tube and not the diff. Any pointers on how to make the truss top? I'm going to just try to heat and bend it, and weld it to the gusset. |
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Post by dan99tj1 on Jan 21, 2011 17:38:41 GMT -5
Rc, what are you using to cut your brackets, a grinder and a torch? The cuts look pretty good in the pics.
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Post by rccolacc on Jan 22, 2011 11:22:31 GMT -5
Actually just a grinder and a portaban saw. I got a 7" grinder though and it helps a lot getting into the part without the motor hitting. It would be nice to have a plasma cutter, but Mark won't buy one and let me borrow it.  -RC |
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Post by rccolacc on Jan 22, 2011 23:59:42 GMT -5
Got a better way to do the truss hopefully. I cut the inside of the gusset out already. I'm going to wait until after I bend the top plate and then match the gusset to it. Hard to describe really, but I think it's an easier way that forming the plate to the gusset.  Tacked on the LCA brackets (used the digital level from work):  Made spring perches/mounts:   Cut the old spring mounts off the Dana 30:   Cleaned up the mounts and tested the spring seat:   I hope to finish the UCA mounts and the truss tomorrow. I want to be done with the axle soon. |
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Post by auburnaviator on Jan 25, 2011 23:38:46 GMT -5
I am going to be doing the same thing to my HP 44. I mean getting it to fit under my TJ. I really like where yours is going. Keep the updates going, I'm following them closely.
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Post by rccolacc on Jan 26, 2011 16:49:26 GMT -5
Did more CADing. I think I got all the kinks worked out on the longarms. I got 4" of suspension uptravel before anything hits. I put a 25* bend in the longarms so the upper control arms line up better and the turning radius is good. Here's some screen shots of it at ride height:     I should be close to finished welding the brackets on the axle tomorrow night. I'll take pics. -RC |
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Post by rccolacc on Jan 26, 2011 17:00:09 GMT -5
Forgot to mention the longarms are 33" roughly eye-to-eye (Rubicon Express is about 36", but TJs have a 6" longer wheelbase). The upper arms are about 16" (also the same length as the uppers on a Rubicon Express).
Auburnaviator-- I kept all the 1:1 cardboard cutouts of the link mounts, and you're welcome to use them whenever you do your axle.
-RC
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