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Old 01-16-2010, 07:52 AM   #1 (permalink)
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Home-brew front axle and front 3-link build

After my stock pile of spare stock birfields ran out i decided it was time to order some longs. I figured i'd do it right the first time and order a set of custom length inners and build a housing to go with them.

The wms to wms will be 59.5", one inch wider then the rear

here is the list of materials i ordered from speedymetals.com

Product Quantity Length Sub Total:
1-1/4" {A} Rd Stressproof (or equivalent) Turned, Ground & Polished
1 72" $58.55

3-1/4" {A} Rd 6061-T6511 Aluminum, Extruded-12"
1 12" $46.77

2-3/4" OD {A} x 2.250" ID {B} x .250" Wall {C} DOM Steel Tube-48"
1 48" $60.55

3-1/4" OD {A} x 2.750" ID {B} x .250" Wall {C} DOM Steel Tube-48"
1 48" $78.83

Subtotal: $244.70
Shipping (UPS Ground): $49.18
Tax: $0.00
Total: $293.88


Then add $200 for machine work which means so far I've got just under $500 into the custom length housing. Still cheaper then all the other fabbed housings out there, maybe not as nice but i can make more for less

So here is what i am starting with


I used a pipe cutter to get the knuckle balls off the old housing


One more


I'll post some more pictures tonight
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Old 01-16-2010, 09:36 AM   #2 (permalink)
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Looks pretty good. I want to see more of it. What sort of plans do you have for trussing it, and such when done?
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Old 01-16-2010, 09:39 AM   #3 (permalink)
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subscribed... cant wait for more progress.

looks good.
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Old 01-16-2010, 10:30 AM   #4 (permalink)
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Very nice.. thanks for breaking down the materials used along with the cost.

Don't be afraid to post a lot of pics.

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Old 01-16-2010, 04:38 PM   #5 (permalink)
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ummm the Ruff Stuff axle is under $500
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Old 01-16-2010, 04:48 PM   #6 (permalink)
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I hate to say it, but RuffStuff has this housing for $480+shipping, you just need to rob the knuckle balls off your housing, or wait for them to offer balls.

That said, looks like yours will be built right. Keep up the good work!

edit: Got a phone call in the middle of posting, SSIC got to it before me
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Old 01-16-2010, 04:58 PM   #7 (permalink)
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why not just use a 9in?
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Old 01-16-2010, 05:45 PM   #8 (permalink)
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I thought about the ruffstuff axle, Im my opinion you still need the alignment bar to weld the knuckle balls on straight. I really wanted to use their HD knuckle balls though, too bad they aren't out yet.

Plus I may sell this axle down the road and build a set of matching axles 63" wms to wms

I already have geared and locked toyota 3rds other wise i would have went with the 9" or landcruiser 9.5". I also have a bunch of toyota housings to cut up and steal parts off of.
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Old 01-16-2010, 06:18 PM   #9 (permalink)
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I didn't get a whole lot done today, Mostly just alot of staring, thinking, and measuring

the tubes are in



The new tube was originally 2.75" OD but i had it turned down just enough to fit inside the 3.25" x .250" tube. The inside of the factory housing is still just a little bit smaller, so ground down the factory welds and split the seams a little.




I plan to gusset the tubes inside the housing sort of how the diamonds are.

I havn't decided if i want to sleeve the whole long side with the 3.25" tube yet (way overkill) or just enough to get the knuckle balls on.
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Old 01-16-2010, 07:56 PM   #10 (permalink)
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Dope.
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Old 01-16-2010, 08:03 PM   #11 (permalink)
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Nice job Sir.
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Old 01-16-2010, 09:49 PM   #12 (permalink)
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Awesome, shipping to 95667?
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Old 01-16-2010, 09:58 PM   #13 (permalink)
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Waiting to see more.
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Old 01-17-2010, 02:25 PM   #14 (permalink)
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I forgot my camera today but i got some cell phone pics, better then nothing i guess.

I started making the internal gussets


and i got the outer sleeves cut. the length will still need some fine tuning, I may end up trimming some more off

I'm going to take the outer sleeves back to the machine shop and have the knuckle balls pressed in. Then i'll make some final adjustments to the length and set the caster. After that it should be time to start welding everything up.
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Old 01-17-2010, 02:27 PM   #15 (permalink)
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I think i might hole-saw some material out of the sleeve on the long side to try and save a little weight
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Old 01-22-2010, 05:46 PM   #16 (permalink)
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Made a little progress if anyone cares


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Old 01-22-2010, 05:53 PM   #17 (permalink)
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Quote:
Originally Posted by ssic off road shop View Post
ummm the Ruff Stuff axle is under $500


Quote:
Originally Posted by Ryan31783 View Post
I hate to say it, but RuffStuff has this housing for $480+shipping, you just need to rob the knuckle balls off your housing, or wait for them to offer balls.


Why buy something that you can build yourself and then have the satisfaction of having done it yourself? Buying "pre-fabbed" parts is for people that cant do it themselves
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Old 01-22-2010, 05:59 PM   #18 (permalink)
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Nice work I cant wait to get going on a front axle, SUBSCRIBED
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Old 01-22-2010, 06:00 PM   #19 (permalink)
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Very cool man, looks great. What gears are you using, and what diff/locker?

Are you going to do the same thing or something similar to that other axle in the last pic?

Oh, and shipping to 97219
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Old 01-22-2010, 06:10 PM   #20 (permalink)
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Nice work
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Old 01-22-2010, 07:38 PM   #21 (permalink)
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Very cool man, looks great. What gears are you using, and what diff/locker?

Are you going to do the same thing or something similar to that other axle in the last pic?

Oh, and shipping to 97219
I run 5.29s with a lockright out back an aussi locker up front. I have a welded carrier I plan on replacing the lockright with eventually

The other housing was just for measurements
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Old 01-22-2010, 08:07 PM   #22 (permalink)
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LOOKING GOOD!! Carry on now! When can I mail you, mine? Practice makes perfect!
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Old 01-22-2010, 08:36 PM   #23 (permalink)
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awesome thread.
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Old 01-22-2010, 08:56 PM   #24 (permalink)
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Very cool work... I myself will be getting a ruffstuff housing if I can ever get back on my feet b/c I can't do this kinda shit. Kudos to those that can.
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Old 01-22-2010, 10:18 PM   #25 (permalink)
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Very nice work

Looks like you have a great start on one burly-ass housing.
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