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-   -   Finished the fabbing on my 9"... tons of photos.. 56k'ers beware! (https://www.ranger-forums.com/drivetrain-tech-37/finished-fabbing-my-9-tons-photos-56kers-beware-36821/)

rngprerunner 02-04-2007 10:41 PM

Finished the fabbing on my 9"... tons of photos.. 56k'ers beware!
 
So... I finally got the back ordered pieces for my axle last week and have been working hard ever since. I ran into a little snag last week when I ran out of gas (for the welder) so I had to wait till this weekend to finish the work (damn real job.. lol).

Last we left off I had just added the skid plate and fill plug.
(nevermind the arrow..lol)

http://img267.imageshack.us/img267/1066/36214325qy2.jpg

Since then I have added a breather. Since the stock one would be covered up I took it off and filled it in. The new one went on the back with a weld on bung and aluminum -8 AN fitting.

Breather Hole
http://img248.imageshack.us/img248/1...herholeiy0.jpg

Bung
http://img257.imageshack.us/img257/3...herbungpx0.jpg

AN Fitting
http://img254.imageshack.us/img254/7...atheranqm3.jpg

Breather
http://img184.imageshack.us/img184/7...erfinalnp1.jpg

http://img184.imageshack.us/img184/3...rfinal2xp8.jpg

Stock Breather Hole Filled
http://img183.imageshack.us/img183/7...rfilledah1.jpg


Now the fun begins. The upper link mounts.

Crown Piece Mockup
http://img183.imageshack.us/img183/2...nmockupzv5.jpg

Tab's Mockup
http://img183.imageshack.us/img183/9...bmockupfd8.jpg

Tab's Tacked
http://img296.imageshack.us/img296/4...stackedub3.jpg

http://img187.imageshack.us/img187/7...tacked2tr7.jpg

Tab's Welded
http://img47.imageshack.us/img47/8843/tabsweldednd9.jpg

http://img256.imageshack.us/img256/9...welded2dw5.jpg

Crown Welded
http://img401.imageshack.us/img401/2...nweldedzo9.jpg

http://img401.imageshack.us/img401/2544/crowwelder9.jpg

Trim Mockup
http://img256.imageshack.us/img256/2...mmockupgg3.jpg

http://img374.imageshack.us/img374/2...mockup2rh8.jpg

Trim Welded
http://img374.imageshack.us/img374/1...mweldediw8.jpg

Top Tacked
http://img123.imageshack.us/img123/3...ptackedcl9.jpg

Top Welded
http://img402.imageshack.us/img402/6...pweldediy2.jpg

http://img402.imageshack.us/img402/5...welded2de7.jpg

http://img123.imageshack.us/img123/8...welded3tm8.jpg

Limit Strap Tabs
http://img123.imageshack.us/img123/9...bweldedjc9.jpg

http://img180.imageshack.us/img180/8...welded2ak8.jpg

And We Are Done!

http://img180.imageshack.us/img180/9629/overallbv1.jpg


It is sitting right now with a coat of POR-15 drying. It just needs to go to Currie to be straightened then I can get the breaks on and finish assembling it.

What do you think?

Gearhead61 02-04-2007 10:47 PM

Did the heat from all the welding warp the housing? The tubes? What all needs to get straightened? How do they even do that?

That looks really good! What goodies are going inside it?

KARPE 02-04-2007 10:51 PM

looks like it weighs about 900 lbs now, but could fight 30 elephants blindfolded. So you win!

rngprerunner 02-04-2007 10:55 PM


Originally Posted by Gearhead61
Did the heat from all the welding warp the housing? The tubes? What all needs to get straightened? How do they even do that?

That looks really good! What goodies are going inside it?

The axle tubes warp from the heat. I preloaded it before welding the truss, but I don't fully trust just that.

What they do is cut the ends off, run a strightning rod (basicly a 'true' solid rod) through the center then weld the ends back on.

Plan is 4.56's and a detroit.. but I haven't gotten that stuff yet so who knows.

99ranger4x4 02-04-2007 11:10 PM

DAM* thats one hell of an axle!!


looks great man, if it didnt weigh so much i would have u fab me one haha

Alon 02-05-2007 01:10 AM

holy crap man, that looks awesome. why did you go 4 link instead of 3? what lower links are you going to run?

i need to call you sometime this week, what are you doing for presidents?

also... i might want your leafs when you are all done with em

zabeard 02-05-2007 05:23 AM

very nice Jason.

Looks great. Alot of work into that. Can't wait to see the finished product.

bryanjints 02-05-2007 05:49 AM

not to affend anyone else and if I do I am sorry.

That is the most impressive "mod" I have seen anyone post on any forum I have ever been on. Just my .02

HighRollerII 02-05-2007 06:29 AM

lots of welding man..

now lemme ask you a question it might be dumb but im new to this link stuff..

how do you know the angles of the link bars comin off the axle..

jtslmn720 02-05-2007 08:24 AM

damn thats awsome... those welds are amazing

Gearhead61 02-05-2007 08:49 AM


Originally Posted by HighRollerII
lots of welding man..

now lemme ask you a question it might be dumb but im new to this link stuff..

how do you know the angles of the link bars comin off the axle..

Lots of measuring and experimenting with link lengths, mounting locations, etc. etc. You can find a 4-link calculator that will help you to estimate your squat, anti-squat, articulation, droop, etc. once your input your intended lengths, seperation, and link design. It can get really complicated really quickly.

Jason, could you describe this preload you're talking about? Could you mock up some sort of jig to attach the axle to while welding to keep it from warping? I'm imagining a metal frame that attaches to the pumpkin and bolts in at the brake flanges to keep everything straight while you're welding.

rngprerunner 02-05-2007 10:55 AM


Originally Posted by Alon
holy crap man, that looks awesome. why did you go 4 link instead of 3? what lower links are you going to run?

i need to call you sometime this week, what are you doing for presidents?

also... i might want your leafs when you are all done with em

The only reason I went 4 instead of three was simplicity. Though looking back now it probably wouldn't have been much more difficlut.. lol.. That and going with Giant I just had Geoff put the uppers together for me so I wouldn't have to. With as much as I'm working and how little time I'm going to have to do this I didn't want to mess with it.

Lowers are Giant WIY.. those are next on the list to be built, just need to procure a TIG.

Presidents. Dove Springs.

I'll let you know when I get ready to pull the springs.


looks great man, if it didnt weigh so much i would have u fab me one haha
This thing is probably somewhere between 70 and 100lbs now, its just heavy and awkward enough now where it is difficult to carry by my self, but not impossible. With all the guts in it it should be around 200lbs.


ason, could you describe this preload you're talking about? Could you mock up some sort of jig to attach the axle to while welding to keep it from warping? I'm imagining a metal frame that attaches to the pumpkin and bolts in at the brake flanges to keep everything straight while you're welding.
Think more low tech. I just had the axle on saw horses with the third member opening down, attached a chain to each end through the axle flange bolt holes. Then I placed a hydrolic bottle jack inside the housing sitting on the chain and applied presure until it pulled the ends down 1/4". Welded it up a realeased. Welding on a truss like this warps the housing ~1/4" so bending it the other way first counteracts the force of the heat. But I still don't fully trust it so off to Currie it goes!

Thanks guys!

blackbetty 02-05-2007 11:00 AM

damn those are some beee-a-utifull welds! nice work.

Gearhead61 02-05-2007 11:42 AM

Cool! How much does it cost to get an axle straightened like that? i can't imagine it would be cheap...

Roach2004 02-05-2007 11:56 AM

Dang Jason that looks good!

rngprerunner 02-05-2007 01:25 PM


Originally Posted by Gearhead61
Cool! How much does it cost to get an axle straightened like that? i can't imagine it would be cheap...

$50bucks. It takes all of like 10 minutes to do it. Set the axle on the jig, cut the ends off, run the rod through, reweld ends, done.

D. 02-05-2007 01:36 PM

Good Show! Keep up the excellent work.

Trigger01 02-05-2007 03:51 PM

Wow that's alot of work and it looks good!

Drayke 02-05-2007 05:22 PM

atta boy man!

So you chose MIG over TIG b/c of avaliability? right on.

yeah, i'd hit that.


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