Corporate 14 bolt before:
http://jeep-club.irtech.com/phils_mods/14Before.jpg
After (and no, I did not cut it with the carrier in):
http://jeep-club.irtech.com/phils_mods/14After.jpg
The piece I removed:
http://jeep-club.irtech.com/phils_mods/14Removed.jpg
The plate:
http://jeep-club.irtech.com/phils_mods/14Plate.jpg

Right now it is at the machine shop having the ring gear ground down, and the plate TIG welded on. Should be able to reassemble this weekend. All the strength of a FF 14bolt with the clearance of a Ford 9" :)

Phil

sweet, But I have come to expect that from you.

What did you use to cut it? Nice straight cut there.

Originally posted by Bert
sweet, But I have come to expect that from you.

What did you use to cut it? Nice straight cut there.

Thanks man.
I'm glad you like the cut, I started it with a Skil saw set at an angle, then finished with a sawzall ;)

Funny - A friend of mine made fun of me cutting it with a skil saw, and said it should be done with a band saw or I will fawk it up. He was mistaken, it sure was easy to cut, and came out great. But what does he know, the axles he swapped in are stock D44's ;)

Phil

Very Nice!!

:eek:

not bad philly , especially from a canuck like you :flipoff2: real sweet dude ill be posting some pics of my shit as soon as i learn how to do so:D ...

very nice!! more pics of the flange when you get it back

Originally posted by 1TONTJ


Thanks man.
I'm glad you like the cut, I started it with a Skil saw set at an angle, then finished with a sawzall ;)

Funny - A friend of mine made fun of me cutting it with a skil saw, and said it should be done with a band saw or I will fawk it up.
Phil

That's how I cut my 60. A skil saw with a metal blade cuts cast iron like butter. Then you wind up with that last inch or so that needs to be cut with the sawzall.

Nice clean work.

Question, how much is the shop charging to shave the ring gear? I still need to do that, I've done a little experimenting with an extra gear and it looks like a drum sander on my drill press is the only thing that works decently.

What size of a plate did you use?
How much did you shave the ring gear?

Great idea! I had never thought of using a skil saw to cut metal. Hmmm . . .

Machine shop is charging CDN$75 (less than US$50) to machine the gear.
Gear is having 1/4" of the radius taken off.

Plate is 1/2" thick.

Phil

Love it!!! :flipoff2: Now what cha gonna do to the cover?

Steve

Did the shop say how they were turning the gear down?? Be curious if they were grinding or machining, and what tool they are using....



ya, some pics when it gets back, as well as a side shot, you didn't cut it perperdicular to the cover?? Will you still be able to get the ring gear in???

I'm going to figure that out on the weekend ;-)

Phil

Originally posted by RustoleumWhite
Did the shop say how they were turning the gear down?? Be curious if they were grinding or machining, and what tool they are using....



ya, some pics when it gets back, as well as a side shot, you didn't cut it perperdicular to the cover?? Will you still be able to get the ring gear in???

Not perpendicular to the cover since I was trying to make the plate paralell to the ground. Ring gear should just barely fit in (I hope ;-) )

They said they were grinding it (three hours down and the motor blew - it is being rewound now) and have 3/16" off so far.

Phil

one ton..

We can do the ring gear grinding too. Just have to use a diamond precision grinder or a diamond cutting tip on the ol' lathe. :D

Next years project... not yet... too many other things first. :D

They're going to finish it tommorow. Still only $50
No way i could get you to do it for cheaper if I had to mail it to you... Plus it will be ready tommorow.
Then next week - they do my front...

Phil

Wow, 3+ hours and $50! Our shop rate is $72/hour!

Pete

But he just "let it go" - didn't stand there for the whole three hours.

Phil

how are you gonna make the rear cover and have you thought about flex issues? I know a guy that did your exact pic and for a cover he had a 1" thick ring cut the shape of the diff cover then made the inner cover area out of 3/16 plate....it was very trick and looked like it would give a ton of support to stiffen it up... just a thought.

I like my 60...:D

Originally posted by 1TONTJ
But he just "let it go" - didn't stand there for the whole three hours.

Phil

Yup, same here.

Pete

I like the idea of cutting it down with the skil saw...think I'm going to have to try it:D

Nice Phil,

It looks good. I plan on doing that to mine too, but I want to practice on some dana 44's I have lying around first. Looks like you were able to get a nice clean cut with the skill saw and the sawzall.

Got it welded and test fit the carrier.
Diff cover is cut and plated, just have to drill and tap the case fort he other two holes.

Before:
http://jeep-club.irtech.com/phils_mods/14before.jpg
After:
http://jeep-club.irtech.com/phils_mods/14after2.jpg

Phil

Here's the plate welded:
http://jeep-club.irtech.com/phils_mods/14welded.jpg

Phil

Nice job! Gozuki cut his D60 himself and had to use a diamond bit on the lathe to cut the ring gear. After that we decided to check around and I will have Hyro Jet do the work. They use abrasives and water. Cost should be under $40 to cut the ring gear. When I get to that point I will post pics. I'm cutting down a 14 bolt for my wagon.

Looks Great! how much clearance did you gain by shaving it??

Thanks CJ

show us the cover when you get it done :D good work

Originally posted by 1TONTJ
Machine shop is charging CDN$75 (less than US$50) to machine the gear.
Gear is having 1/4" of the radius taken off.

Plate is 1/2" thick.

Phil

1/4 diameter means 3/16 a side correct??? How much shaving can a 14 bolt ring gear be shaved without it affecting its strength? Would 1/2" diameter be TOO MUCH?:eek:

1/4" off the radius would be 1/2" off the diameter D=R X 2

1/2 " off the radius might be getting into the contact pattern?
when I shaved my bro's ring gear we took 1/4" off and we were still OK on the contact pattern.

here's a pic I found

http://www.sierrarockcrawlers.com/data/srcforumuploads/shaved_14_pic.JPG

Originally posted by TablerockToy
Looks Great! how much clearance did you gain by shaving it??

Thanks CJ

Just over 2" (same clearance as a Ford 9" now ;) )

Phil

Originally posted by clc900


1/4 diameter means 3/16 a side correct??? How much shaving can a 14 bolt ring gear be shaved without it affecting its strength? Would 1/2" diameter be TOO MUCH?:eek:

I actually tried it with only 3/16" radius (3/8" diameter) and it fit. So I stopped shaving the gear ;)

Phil

Originally posted by AIRZUKI
1/4" off the radius would be 1/2" off the diameter D=R X 2

1/2 " off the radius might be getting into the contact pattern?
when I shaved my bro's ring gear we took 1/4" off and we were still OK on the contact pattern.

here's a pic I found

http://www.sierrarockcrawlers.com/data/srcforumuploads/shaved_14_pic.JPG

That diff does not look like it was shaved much. I will post mine tonight or tommorow, it is almost finished.

Phil

Well the cover is finished except painting. All I have left to do is drill and tap the diff for the two new cover bolts.
Here are some pics of the cover.
Notes: 1. Sorry about the picture quality, the parts I ground/sanded are shiny and reflect the camera flash. 2. In the backside pictures of the cover it looks like I welded the back of the "guard strip", I did not - just a little heat through. The plate that extends the seal surface WAS welded both sides just to be sure it doesn't leak ;)

http://jeep-club.irtech.com/phils_mods/14diffback1.jpg
http://jeep-club.irtech.com/phils_mods/14diffback2.jpg
http://jeep-club.irtech.com/phils_mods/14difffront.jpg

Phil

For those guys who shaved their 14bolt, could you measure fromt he top of the housing (outside of the diff edge) to the top of the plate you welded in. Just trying to get an idea of how much you cut off. From the pics I think I may have cut too much off mine. :eek:

Got any pics of it installed on the truck?
I'm getting it done this week.

I'll take one for you if you want.

Phil

Oh, and an update. I have since switched to a 3/8" thick cover and didn't bother with the missing bolt (at the very bottom). Cover is so thick and strong it doesn't seem to need them. If it ever gives me any problems then I will add another bolt.

I will take pics in the next couple days.

Phil

Originally posted by 1TONTJ
Oh, and an update. I have since switched to a 3/8" thick cover and didn't bother with the missing bolt (at the very bottom). Cover is so thick and strong it doesn't seem to need them. If it ever gives me any problems then I will add another bolt.

I will take pics in the next couple days.

Phil

Wait till you peel it back on a rock.... I would throw a bolt or two in it while its out and apart... :D Looks good anyway :D

I am NOT using that POS cover shown above any more. That was only temporary (was in a hurry to go to Tellico and Paragon in April). The new cover is slightly higher up than the bottom of the axle housing, so there is nothing for the rocks to grab, and the flange is very wide and 3/8" thick. No way are the rocks going to "peel it back" Maybe on one of those wimpy "heavy duty" covers, but not on mine :D
Oh, and it has been heavily tested (beaten, dragged, smashed).

I will take some pics soon to make it easier to understand.

Phil

Hey man, that's not a 14 bolt! Sure looks nice though. Those post 87 housings cool much better and are stronger than the old school housings. I settled for grinding my 14 bolt... I run mud so I can force my way through most of it all. Something to consider man, looks sharp.

Originally posted by MR4WD
Hey man, that's not a 14 bolt! Sure looks nice though. Those post 87 housings cool much better and are stronger than the old school housings.

I guess it's a 13 bolt now :flipoff2:
Yes, the heavily gusseted 2000 14 boltFF I got is very nice. Been working very well for me, and plenty of clearance.

Phil

Now you got a 13 bolt:flipoff2:

Originally posted by 1TONTJ
I am NOT using that POS cover shown above any more. That was only temporary (was in a hurry to go to Tellico and Paragon in April). The new cover is slightly higher up than the bottom of the axle housing, so there is nothing for the rocks to grab, and the flange is very wide and 3/8" thick. No way are the rocks going to "peel it back" Maybe on one of those wimpy "heavy duty" covers, but not on mine :D
Oh, and it has been heavily tested (beaten, dragged, smashed).

I will take some pics soon to make it easier to understand.

Phil

OH... My bad :smokin: Sounds like you have it all taken care of :D :beer:

what cover are you using? where did you get it?

Originally posted by vova
what cover are you using? where did you get it?

A Phil Jensen cover :D
I went out to the garage, and got some 3/8" plate and started torching/grinding/bending/welding... now I have a VERY strong cover.

Phil Jensen

Smooth like a baby's butt looks good man nothing like an extra couple of inches of clearance.:beer:

Im gonna start on this very soon! Talked to a shop here locally that will cut it with a wire deal. Said it heats up to over 3000 degrees and will cut the diamater of less than 1/2 the size a newspaper page. And it cuts fast. said it would also be perfectly round, better than any cutting tool will do. Only $62 an hour. said it would'nt take that long!. Now for the housing. Can you post some pics off the cover? Thanks, Dennis

3000 degrees ?? would that not take all the hardness out of the gear getting it that hot ?

- jack

Said that it is so thin, it won't affect the ring. Kinda like a laser cut or something. I will let you know how it goes after it is completed.

Originally posted by morpheus
3000 degrees ?? would that not take all the hardness out of the gear getting it that hot ?

- jack

I think steel has a melting point of 2,800 degrees Fahrenheit give or take some for different kinds of course. :confused:

Originally posted by KYJ10
Im gonna start on this very soon! Talked to a shop here locally that will cut it with a wire deal. Said it heats up to over 3000 degrees and will cut the diamater of less than 1/2 the size a newspaper page. And it cuts fast. said it would also be perfectly round, better than any cutting tool will do. Only $62 an hour. said it would'nt take that long!. Now for the housing. Can you post some pics off the cover? Thanks, Dennis

Wire EDM.... they kick ass....



Used for making dies and other stuff, the harder the material it is, the better it cuts, and hardly effects the prior treating of the materal at all (VERY small heat effected zone)..


cool deal, thats the way to go.

Yea thats what it was called. I just spoke briefly to him, but made it sound like it will slice that bad boy in a flash and will do it perfectly round and smooth. Thanks

Real nice work....neat n' everything.....

Here's a grand daddy for a stupid question, exactly what blade did you use? I tried a Vermont American and it quickly got "toasted". :mad: on a junk 60 housing I was playing with.
Should have tried a Norton.
BTW, very nice work.

Blade for what? Cutting the cast housing? I use a Starret blade in my portaband and it cuts it like budda.
For fixing the covers I use a piece of 1x3/4 and weld it into the cover to add some strength back to the housing and it gives me a place to hide the new bolts on the bottom so they don't get two hammered.
http://www.respite.org/images/cj66dean/shaved605.jpg

What did you use to weld the plate to the housing??
I have read plenty about the Dana housings taking Mig welding well, but I have not found any info on the 14 bolt welding procedures.

BTT :p

I would still like an answer to the above question.