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The BillaVista 60
Building a Bomb Proof Dana 60 Front Axle |
The BillaVista-60 Super Dana 60 Front Axle Project.
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Introduction
2003 was a year distinguished by the continued explosive growth in popularity of hardcore off-roading, trail riding, and rock crawling. It was also a year that saw a massive increase in the availability of hardcore parts for the most serious rock crawlers and trail runners, thanks to a number of select companies (like those pictured above) stepping up to the plate and offering truly innovative, great quality parts - built specifically for the abuse we like to dish out.
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4x4s and off-road vehicles have always enjoyed a large amount of aftermarket support - but back in the good-old-bad-old days many of these parts were more show than go - think chrome diff covers! Thankfully times have changed, and products are now available that truly meet the needs of the hardcore 'wheeler. |
| The most exciting developments of the year, in my opinion, were in the area of product development for our venerable and beloved Dana 60 front axles. Sure, there are other axles gaining popularity, and "portals" may be all the rage, but nothing beats the tried and true American 1 ton axle for simple, available, brute strength and reliability - it's still the king of 4x4 front steering axles and is poised to remain so for many, many years to come. |
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Other more popular, but smaller, axles have enjoyed much greater aftermarket support in the past. Stronger aftermarket parts have long been available for the Dana 44, Ford 9", and Toyota axles of the world - but until recently support for the Dana 60 front lagged. That all changed in 2003 as competitors in various rock crawling organizations continued to push the envelope of what was considered conquerable terrain, with the attendant increase in carnage of parts. |
| Dedicated hardcore trail runners followed suit - creating and demonstrating a real demand for hardcore aftermarket Dana 60 support. Most notably - Pirate4x4.com's own legendary carnage-king, moderator and all-around hero/villain, Camo, drew enormous interest with his completely over-the-top unlimited build of a truly custom built-to-the-hilt front Dana60, known as the Camo-60. You can read about it here and here. Reading it inspired many a builder and no-doubt manufacturer to boot. It really brought to the forefront the concept of much needed aftermarket support for the Dana 60 front. |
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I knew I wanted to do something similar, if perhaps not quite so over-the-top exotic. So the first question to address was: exactly what did I hope to build/accomplish and how? The Dana 60 front axle is a terrific axle in stock, or lightly modified trim, but it still has it's share of weak spots. Some time ago, when I wrote the original Dana 60 Bible I compiled a list of known weak spots:
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Taking these into account I decided to set out to build myself the biggest, baddest, bombproof Dana 60 front axle I could, utilizing the best of the new crop of "off the shelf" products - at home, by myself, with my modest tools and facilities and hugely average mechanical skills. |
By undertaking the project and documenting the it here, I hope to accomplish three things -
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This article is the result. It is organized into 6 parts as follows: |
Part 1 constitutes the "tech primer" to establish a base of knowledge from which we can make well informed choices and decisions. Having a good rudimentary understanding of the tech behind all the hype will allow us to discuss product strengths and weaknesses from an informed standpoint. Heavily subdivided itself, this section contains a wealth of information on
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 Superior Axles & CTM U-joints |
Part 2 is all about the heart of the axle, and a product combination "match made in heaven" - the all new Superior alloy axle shafts combined with "Axle" Jack Graef's world famous CTM U-joints
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Part 3 is all about the bling! Seriously though - part 3 is about a unique and innovative product by one of the most well respected Pirate4x4 vendors that combines awesome strength AND some serious style - the Poly Performance Chrom-moly 35 spline drive flanges.
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 Poly Performance Drive flanges |
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Part 4 covers 2 different but equally impressive products from Crane High Clearance. One is the relatively simple but beautifully executed unbreakable life-time warranty super heavy duty diff cover...
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...the other is the most unique and innovative product seen yet for the Dana 60 front - the awesome new Crane "indexed" high clearance alloy steel steering knuckles.
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Part 5 is about the locker of choice
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| Part 6 details my ongoing testing of the BillaVista-60 as I put it through its paces in the real world. It is also a summary of the project - what did I like the most, what would I not do again, what would I do differently etc. |
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Superior
Axles & CTM U-joints |
CTM
U-joint |
Crane
Indexed D60 Knuckles |
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Crane
HD Diff Cover |
Poly
Performance Drive Flanges |
Superior
Alloy Axle |
CTM
U-joint |
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Contact Info:
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Poly Performance Offroad Products 725 Buckley
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CTM Racing Products, Inc. 32991 Calle
Aviador #E |
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Crane Hi Clearance Phone: 303-917-4851 |
Superior
Axle and Gear |
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