toy/ford lightweight hybrid front axle build - Pirate4x4.Com : 4x4 and Off-Road Forum
 
Pirate4x4.Com : 4x4 and Off-Road Forum  

Go Back   Pirate4x4.Com : 4x4 and Off-Road Forum > General Tech > General 4x4 Discussion
Notices

Reply
 
Share Thread Tools Display Modes
Old 11-15-2009, 08:12 PM   #1 (permalink)
Wheeler
 
joefab's Avatar
 
Join Date: Oct 2006
Member # 81455
Location: Grass Valley, CA
Posts: 398
toy/ford lightweight hybrid front axle build

We are building a supa light crawler with shop leftover junk and when deciding on axles we chose toy's for weight reasons but we wanted a little more strength in the joint and knuckle area as we are going to run 40's.. so we came up with this plan (based loosely off of other builds on the site).

so here it is.
Tacoma rear axle chopped re-tubed with ford ttb50 sheetmetal "c" and outers

Hopefully the pics will load up without issue
Name:  1030092054-00.jpg
Views: 2781
Size:  49.7 KB

Name:  1030091859-00.jpg
Views: 2714
Size:  55.6 KB

Name:  1101091400-00.jpg
Views: 2869
Size:  57.3 KB

Name:  1103091747-00.jpg
Views: 2718
Size:  30.7 KB

Name:  1103091914-00.jpg
Views: 2724
Size:  43.7 KB
joefab is offline   Reply With Quote
Old 11-15-2009, 08:17 PM   #2 (permalink)
Wheeler
 
joefab's Avatar
 
Join Date: Oct 2006
Member # 81455
Location: Grass Valley, CA
Posts: 398
more pics

Name:  1104090750-00.jpg
Views: 2726
Size:  56.7 KB

Name:  1106091943-00.jpg
Views: 2735
Size:  49.6 KB

Name:  1106091945-00.jpg
Views: 2705
Size:  59.9 KB

Name:  1101091106-00.jpg
Views: 2700
Size:  43.8 KB

Name:  1106091944-00.jpg
Views: 4709
Size:  62.5 KB

I removed the stock camber adjusters and machined fixed slugs and tig'd them in place.

machined slugs for the 3rd

machined the diff side of the axle tubes for the seal

measured, cut and welded her up
joefab is offline   Reply With Quote
Sponsored Links
Old 11-16-2009, 03:41 AM   #3 (permalink)
Zeus of the Sluice
 
Hvy_Chevy's Avatar
 
Join Date: Oct 2002
Member # 14094
Location: Maine
Posts: 4,720
Send a message via AIM to Hvy_Chevy
what joints can be run in the Ford stuff? Think it'll be stronger than 6stud knuckles and Longfields?
__________________
Size does matter.
Leave the Zukes to those who really understand.
Hvy_Chevy is online now   Reply With Quote
Old 11-16-2009, 05:53 AM   #4 (permalink)
Wheeler
 
joefab's Avatar
 
Join Date: Oct 2006
Member # 81455
Location: Grass Valley, CA
Posts: 398
Well we wanted full width axles, and we wanted to run 40's for clearance, but in my past experiences toy's with spacers and 40's will kill the trunnion bearings. We will be running 60 shafts so the joint strength should be good.we have shaved all of the cast brake bosses off of the knuckle and we are running a smaller rotor and caliper units for weight. This build is more of an exercise in frugality. there are plenty of alternative ways to build an overall better axle BUT we will have only the cost of shafts, seals, tube material, U-joints when we are done. so it will be pretty inexpensive for a light and fairly strong axle.

BTW we ran 2.5" OD tubes for more clearance and we are going to truss the axle to gain back some strength-Joe
joefab is offline   Reply With Quote
Old 11-16-2009, 07:20 AM   #5 (permalink)
Registered User
 
Join Date: Jul 2004
Member # 33536
Location: Georgia
Posts: 3,167
are you concerned about the toyota third with 60 shafts and 40s? seems like that is your weak link now....
85blue4runner is offline   Reply With Quote
Old 11-16-2009, 07:45 AM   #6 (permalink)
Karnage
 
spidr's Avatar
 
Join Date: Oct 2005
Member # 55444
Location: Vancouver Island
Posts: 8,176
Quote:
Originally Posted by joefab View Post
We are building a supa light crawler with shop leftover junk
Damn it. I've been planning a toy/ttb build for over a year now.
Looking forward to how this turns out, mines slighlty different.
__________________
Sometimes you just gotta step back and take a breather.
spidr is offline   Reply With Quote
Old 11-16-2009, 07:47 AM   #7 (permalink)
Swamp Crawler
 
Blase's Avatar
 
Join Date: Dec 2005
Member # 63692
Location: Carencro, Louisiana
Posts: 2,019
I like the out of the box thinking on this one. Two questions

1) What if anything did you have to do to run the TTB knuckles? Look like maybe a square to round adapter??

2)Why TTB Knuckles? Are they lighter or just easier to get a hold of?
__________________
Quote:
Originally Posted by JR View Post
You know, Ifs is kinda like a vagine. It's soft,sexy and expensive.
Blase is offline   Reply With Quote
Old 11-16-2009, 07:50 AM   #8 (permalink)
Not 5S compliant
 
Scott@Rockstomper's Avatar
 
Join Date: Oct 2000
Member # 1889
Location: Firestone, Colorado, USA
Posts: 6,463
Did you run the housing bar all the way out through the spindle to get the inner C's on at an appropriate angle, since there's not really an axle tube to reference on those things?
Looks like some nice fab work.
Scott@Rockstomper is offline   Reply With Quote
Old 11-16-2009, 05:38 PM   #9 (permalink)
Wheeler
 
joefab's Avatar
 
Join Date: Oct 2006
Member # 81455
Location: Grass Valley, CA
Posts: 398
hybrid axle

We chose the ttb because they are pressed steel and can be welded cleanly also we were concerned with weight and the "C" portion is much lighter than the solid axle "c's" that we have in the shop. + they were cheap!
We are running a honda transaxle setup (with a little twist!) and the engine is lets just say well used and power will not be neck snappin! so I believe that we will be OK as far as breaking the diff. even if we did we could just swap in another chunk.
Yes I ran the alignment bar all the way through. I started with the short side and first fit a smaller 8" axle tube to carry the inner seal and for outer support of the "c". Then slid the C and the knuckle attached with spindle over the bar ( spindle fits PERFECTLY over 1.5" bar) then fabbed the c to the housing.
On the long side I fabbed the C to the axle tube first then slid that into the housing with the bar and spacers and welded it up.
joefab is offline   Reply With Quote
Old 11-17-2009, 10:26 AM   #10 (permalink)
Registered User
 
Join Date: May 2004
Member # 31400
Location: Arid Zona
Posts: 289
Quote:
Originally Posted by joefab View Post
We are running a honda transaxle setup (with a little twist!).
Twist? Going to run into 'nuther case??

Marv
marv_springer is offline   Reply With Quote
Old 11-17-2009, 03:25 PM   #11 (permalink)
Rock God
 
DozerDan's Avatar
 
Join Date: Jan 2002
Member # 9144
Location: NJ
Posts: 2,257
Send a message via AIM to DozerDan
What did you do to correct for the camber that is built into the ttb 50 outers?

I tried to use them on my super duty 60, and found they had about 10 degrees of camber built into them if not more.

Had to use 60 outers.
__________________
Dan Smith
'physically strong, mentally awake, and morally straight'

Fear is not an option!
DozerDan is offline   Reply With Quote
Old 11-17-2009, 03:33 PM   #12 (permalink)
Not 5S compliant
 
Scott@Rockstomper's Avatar
 
Join Date: Oct 2000
Member # 1889
Location: Firestone, Colorado, USA
Posts: 6,463
Quote:
Originally Posted by DozerDan View Post
What did you do to correct for the camber that is built into the ttb 50 outers?

I tried to use them on my super duty 60, and found they had about 10 degrees of camber built into them if not more.

Had to use 60 outers.
This was where I was going with my question--if he ran the housing bar all the way out through the spindle prior to/while welding the inners onto the tubes, then it'd be true and life would be good, this axle will just have more kingpin inclination than most straight axles (and the inners will be welded on at something skewed from what would be "normal" for a TTB). Could actually be a good thing depending on tire size and wheel offset, thinking about it.
Scott@Rockstomper is offline   Reply With Quote
Old 11-17-2009, 04:13 PM   #13 (permalink)
Registered User
 
Join Date: Feb 2009
Member # 130764
Location: Hebron, Ohio
Posts: 382
that's a damn cool axle! i would love to see a 9" with TTB outers though.
Ry_Trapp0 is offline   Reply With Quote
Old 11-17-2009, 04:54 PM   #14 (permalink)
Registered User
 
Mr.N's Avatar
 
Join Date: Sep 2000
Member # 1635
Location: Minne-so-cold
Posts: 4,063
Nice Job joefab!
__________________
Catholic | My Dana Articles and Info -> http://77cj.littlekeylime.com/web_rs44.html
Mr.N is offline   Reply With Quote
Old 11-17-2009, 07:32 PM   #15 (permalink)
Wheeler
 
joefab's Avatar
 
Join Date: Oct 2006
Member # 81455
Location: Grass Valley, CA
Posts: 398
toy/ford hybrid

Yes, as stated earlier the stock camber adjusters were scrapped and fixed position slugs were welded in.

Also one goal of this axle was to make it wider and to have the least amount of wheel offset so that the scrub radius would be near zero (stock toy's with wheel spacers for width would be no bueno!)

Also, Mr N. as we spoke before the 60 u-joint is .38" larger/longer from operating centerline to the needle bearing/seal edge. so the solution will be to move the spindle outward away from the diff with a .375" plate which will also double as the new caliper mount, then the u-joint should be bind free.

we blasted the housing (mainly the inner portion of the C to remove rust) so we could finish boxing in the C to the axle tubes.

some picsName:  1117091725-00.jpg
Views: 2106
Size:  62.3 KB

Name:  1117091718-00.jpg
Views: 2052
Size:  56.6 KB
joefab is offline   Reply With Quote
Old 11-17-2009, 08:59 PM   #16 (permalink)
Registered User
 
metty's Avatar
 
Join Date: Aug 2004
Member # 34363
Location: Raleigh NC
Posts: 387
you are the MAN! ill be keeping an eye on this one, been thinking of making one of these for my taco
__________________
'96 Tacoma 3 link SAS, coilovers, KM2s etc
metty is offline   Reply With Quote
Old 11-17-2009, 09:16 PM   #17 (permalink)
Registered User
 
Mr.N's Avatar
 
Join Date: Sep 2000
Member # 1635
Location: Minne-so-cold
Posts: 4,063
Quote:
Originally Posted by joefab View Post
we blasted the housing (mainly the inner portion of the C to remove rust) so we could finish boxing in the C to the axle tubes.
Nice touch with the gusset!
__________________
Catholic | My Dana Articles and Info -> http://77cj.littlekeylime.com/web_rs44.html
Mr.N is offline   Reply With Quote
Old 11-17-2009, 11:01 PM   #18 (permalink)
Registered User
 
Join Date: Oct 2007
Member # 101054
Location: Colorado
Posts: 951
Looks good so far. I like the idea.



Just be prepared to replace ALOT of pinions.......
dmsFab is offline   Reply With Quote
Old 11-17-2009, 11:23 PM   #19 (permalink)
Registered User
 
Join Date: Sep 2001
Member # 6892
Location: Danville, CA
Posts: 1,267
Quote:
Originally Posted by dmsFab View Post
Looks good so far. I like the idea.



Just be prepared to replace ALOT of pinions.......
Why have you blown up alot of taco 8.4" pinions?
__________________
Yarr!
I've been to the Hammers... There in the tool section at Home Depot.
Rally for The Hammers post #141
Rally for Tellico post #100
Blue-Beard is offline   Reply With Quote
Old 11-18-2009, 06:47 AM   #20 (permalink)
Wheeler
 
joefab's Avatar
 
Join Date: Oct 2006
Member # 81455
Location: Grass Valley, CA
Posts: 398
We won't be running deep gears in the thirds, So the pinion should be up to it.

Thanks Mr.N. I let the axle tube stick out as far as I could into the C without it hitting the Joint so that after the plate is added we would have a good overlap from C to axle tube.
joefab is offline   Reply With Quote
Old 11-18-2009, 06:52 AM   #21 (permalink)
Registered User
 
SeaBass44's Avatar
 
Join Date: Feb 2000
Member # 40
Location: 80 miles n-sac in Oroville, CA
Posts: 24,246
Quote:
Originally Posted by joefab View Post
We won't be running deep gears in the thirds, So the pinion should be up to it.

.
then you might be replacing output shafts in the toy t-case
__________________
[URL="http://www.12voltguy.com/"]12voltguy[/URL]
[EMAIL=info@12voltguy.com]info@12voltguy.com[/EMAIL][COLOR=Red]--[URL="http://www.davezoffroadperformance.com/"]davezoffroadperformance.com[/URL]
:evil: # 530.532.4529:evil:[/COLOR]
TTC 2010 1989 BRONCO
:evil:-[COLOR="Red"]Awesome web development for your business[/COLOR]. [url]www.mudnworks.com[/url] [email]mud@mudnworks.com[/email]
[URL="http://pirate4x4.com/forum/showthread.php?t=654231"]Pat's W I D E TOYOTA Front Axle[/URL]
--"07 RoadStar 1700-4sale"
SeaBass44 is offline   Reply With Quote
Old 11-18-2009, 07:49 AM   #22 (permalink)
Registered User
 
Join Date: Aug 2001
Member # 6382
Location: Colorado
Posts: 327
Quote:
Originally Posted by SeaBass44 View Post
then you might be replacing output shafts in the toy t-case
No toyota transfer case in a honda transaxle I'm aware of.
bobjohnson is offline   Reply With Quote
Old 11-18-2009, 08:55 AM   #23 (permalink)
Registered User
 
SeaBass44's Avatar
 
Join Date: Feb 2000
Member # 40
Location: 80 miles n-sac in Oroville, CA
Posts: 24,246
Quote:
Originally Posted by bobjohnson View Post
No toyota transfer case in a honda transaxle I'm aware of.
why not
__________________
[URL="http://www.12voltguy.com/"]12voltguy[/URL]
[EMAIL=info@12voltguy.com]info@12voltguy.com[/EMAIL][COLOR=Red]--[URL="http://www.davezoffroadperformance.com/"]davezoffroadperformance.com[/URL]
:evil: # 530.532.4529:evil:[/COLOR]
TTC 2010 1989 BRONCO
:evil:-[COLOR="Red"]Awesome web development for your business[/COLOR]. [url]www.mudnworks.com[/url] [email]mud@mudnworks.com[/email]
[URL="http://pirate4x4.com/forum/showthread.php?t=654231"]Pat's W I D E TOYOTA Front Axle[/URL]
--"07 RoadStar 1700-4sale"
SeaBass44 is offline   Reply With Quote
Old 11-18-2009, 05:16 PM   #24 (permalink)
Wheeler
 
joefab's Avatar
 
Join Date: Oct 2006
Member # 81455
Location: Grass Valley, CA
Posts: 398
No toyota T-case. We are running the Honda transaxle to a toy ifs front 3rd assembly then to the axles. But that will be another thread!
joefab is offline   Reply With Quote
Old 11-19-2009, 03:02 PM   #25 (permalink)
Registered User
 
Join Date: May 2004
Member # 31400
Location: Arid Zona
Posts: 289
Do I understand this right?
transaxle=>IFS 3rd (4.10?)=>3rds in the axle (4.10?) = a top speed of ~10 mph..?!

Great crawl gear tho!

Marv
marv_springer is offline   Reply With Quote
Reply

Thread Tools
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On



All times are GMT -7. The time now is 04:49 PM.


Powered by vBulletin® Version 3.8.6
Copyright ©2000 - 2014, Jelsoft Enterprises Ltd.
Search Engine Optimization by vBSEO 3.6.0 ©2011, Crawlability, Inc.