Although the progress on my 45 Truggy project is painfully slow, I am completing some components both in the shop and in writing up reports on my website. I have just finished a report on the narrowing of the front Dana 60. If you have a few minutes and are interested in these things the illustrated report is HERE (http://darkwing.uoregon.edu/~jrice/cruiser/D60HD/D60.html)

I would appreciate any feedback, correction of mistakes or suggestions for areas where more information would be helpful.

Thanks for your interest and support with this project.

Ummmm, Beefy.
<img src="http://darkwing.uoregon.edu/~jrice/cruiser/D60HD/FrontD60-4S.JPG">

"The unmachined o.d. of the tube was more than 0.006" greater than the i.d., of the knuckle. Furthermore the i.d., of the knuckle had been scarred by the original press fitting and was high in places. "

Don't you mean that the i.d. of the tube was 0.006" less than the OD of the knuckle? I can't figure out why the o.d. of the tube would be a problem.

Otherwise, great write up. From one .edu to another, consider this peer review.

Jack,

Nice write up. Sounds like lots of fun. Must be nice to have access to a lathe and machine shop. My D 60 axles were made
to 65" WMS to WMS.

Charles

Thanks for the input Pin head. The knuckle fits over the tube. Normally the end of the tube would be machined to a constant outer diameter and then the knuckle pressed over it. In my case, the unmachined end of the tube after it was shortened was larger than the hole in the knuckle.

Ditto... great write up.

What size ALL THREAD did you use with that 200 ton press? I would expect to hear "SNAP!" during the pressing operation. Ya, once moving not too bad.

Oh, you need an Aloris tool post holder! :D

CK -- see, had you bought a GAS engine, you could have spent that extra $6K on a lathe & milling machine. :D :D :p

Tom :usa:

Tom,

It is a beauty. Nothing like looking at the Millermatic 210. I need to buy some wax so I can wax the outside so crap won't stick to it.

Only 6K for milling machine? One can dream??? :D :D :D

Charles

Thats bad ass.

I still think i had enough fun with a big hammer and dry ice when i did mine. But the press putton and whala thing rock if you got the tools.

The beast is coming together well for ya, looks like you will be done sooner than i will.

Ian-

Thanks, Jack!

Make me one? :)

Morgan

I must say....with the access you have to all of those fancy tools...It must really suck to be you!;)
Thanks for the awesome tech write up, excellent job!:skull:

Nice job Jack! More of the same from you, good documentation and of course the results are top notch. Keep it up!

Medusa -

Nice work, and a nice write up. Amazing that 'as-if' you didn't have the right tools, you were able to borrow some pretty trick stuff.

Can't wait to see the finished project! Keep it up.

Jim

Hey Man,

Your writups ROCK!!!

Thanks!!

Thanks, Guys, for all of the nice comments. This is really a fun project and I am pleased to be able to share parts of it with all of you.

Turns out the 10* of caster did not go away when the weight of the drivetrain was added. So, tomorrow I am going to hoist the whole axle housing up on the bed of the milling machine and mill out a 6* wedge from the spring perch cast into the center section. That will improve the pinion angle and bring the caster down to about +4*. Will post pics of that operation next week.

Tom-- the All THREAD I used is 1.5" in diameter and is hardened. I wasn't at all worried about breaking it. And, I can imagine how much an Aloris tool post for that big old Monarch lathe would cost:eek:

I added 8* + caster when I had my axle built!!

Steers AWESOME!!

I am not a expert buy any means
But

after cutting the end off chuck it
in the lathe the opisite way that you
did it.

then turn the excess material out
be care full when you get close to the
nuckel .

the weld will still hold the nuckel
on to the tube.
then meashure the shaft and take what ever is required for a press fit out of inside of nuckel

then cut the weld frome the back side.
Done.
Then it is a simple mater of heating
knuckel and frezeing tube
then pound on or press on nuckel.

I might not have done a great job of explaining this but if you think about it

This method I belive would be better than useing a grinder on the tube

Great write-up. What truck did your rear D60 come from? What ever it was it must not have been available in a 4x4 version or you would have had a front axle to match the rear. Or was the front axle from the doner vehicle not a 60?

awesome write up. I am assuming the basic method would work on a dana 44 or any front axle

thanks

arndog