Who has built their own axle?

I have been doing some reading lately about what it takes to build and tinker with axles. I am talking some major fabrication work here too. Specifically I want a hi-pinion Dana 44 for my CJ.

I understand this is much work to do. Has anyone here done their own axle work? I know the easiest method is to have Dynatrac build my housing and I finish up the rest. I would like to hear stories and results of anyone who has experience with this.

Here are some articles I have found through the months of research.

Building a Hi-Pinion Dana 44

Narrowing a Dana 44

Dana 44 Solid Front Axle Information

Homebuilt High Pinion Dana 44

 

Under "builds" I'm just finishing up a Dana 60 rear for my CJ-6. I've built LOTS of custom axlehousings over the last 14 years (I work part time for a shop that does this). What do you specifically want to know. It's a ton of work. Are you wanting a high pinion front or rear? Reuse your existing housing and put in a center section (if the rear) or build an all custom unit? Lots of variables. Do you have access to a 60 ton press? How about a carbon arcing machine? A lathe to turn down the tubes? Some of this equipment is necessary or may not be depending on what you want to build and what kind of core axles are available to you..... Nickmil

 

I would like to get a high pinion 44 for the front. For now I am good with the factory 44 in the rear. I have a buddy who is ready to help me with this but I am thinking of just having it made. We will see.

Thanks.

 

Well, the only hi pinion 44 axles out there from the factory are all driver's side pumpkin. According to what you have listed you have an 18 transfer case which means you need a passenger side pumpkin. This means you will need to remove the tubes from the pumpkin, swap them from side to side, machine them to fit and for length, then have the axles shortened and re splined or have custom ones built. You will need a lathe large enough to machine the tubes, and carbon arc to blow the welds out without going through the short side tube (long side doesn't matter as it needs shortening anyway) and a 60 ton press large enough to press out the tubes and press them back in. You also need a fixture to keep from crushing/distorting the pumpkin as you are pressing the tubes back in.
There are other choices than Dynatrac if you decide to have some built, although they build a great product. Tri-County Gear, Currie, R&P, etc. all build custom axles as well. You might want to call R&P at 503-557-8911 as they may be less expensive or can direct you to someone in your area.....Paul is willing to discuss your needs as well vs. some places that just want your credit card #.....

 

Yep, the pumpkin would be on the wrong side. I would not be able to accomplish this modification on my own but I have a buddy who could help me get into trouble.

Thanks for the advice.

 

TexColorado,

Have you talked to these guys,

http://home.foothilloffroad.com/


I am looking to do the same thing. I want mine the same width as my widetrack Dana 30. I've heard conflicting stories about being able to use a high pinion without hitting the oil pan. I would like to keep from outboarding my springs if I can.

If you find a good option would you let me know about it? I am just north of you on 395.

 

I haven't checked them out but I will look into it. Thanks for the link.

I bet if the HP 44 was able to hit the oil pan, it could be limited to avoid that in the first place.

 

I would give Spidertrax a look. They have custom built 9" housings for about $500 on up. You can buy a built housing from them and install a true hi 9 third member for a front axle. This would be stronger than a front 44.
http://www.spidertrax.com/3-OD-x-3-8-Wall

 

I need to find help with the housing ends to put on, once I narrowing the d60 for the rear.
I don't think the orig can be saved.
any pics, info on how to do the housing ends?
I have a D60HD from 72 dodge truck.
thanks,
BH

 

PM Jeepaholic on here, he has built one and it is for sale. IIRC it is almost exactly NT CJ 30 width.

 

here is a link to my build. i added wider 44's front and rear and added disk brakes to the rear.
http://www.fourwheelstampeders.ca/forum/viewtopic.php?f=26&t=2545

 

I picked up a Dana 44 HP out of a 79 Ford Bronco for free. It is basically just the housing, tubes, and knuckles as everything else was gone. Shouldn't be a problem to get the spindles and brakes and such. I will need new axle shafts anyway.

I have some measurements to take on the housing before I start cutting and trying to pull the left side tube out. I have read articles on this but any other information you guys can give me will be helpful.

One thing I don't know out of many regarding this process is what is used for the new axle tube. Is it a special tube? I would think it is.