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Discussion Starter #1 (Edited)
MOST CURRENT PROGRESS PIC




I started then quit building a full tube chassis vehicle about 5-6 years ago on mog axles.

Getting started on that project again but it has different direction now. I just don't have the time to compete running multiple business, nor need the competitive outlet as I get that elsewhere. So I am sacrificing weight for comfort.

A Dodge Durango may seem like an odd choice. I selected a 4 door rig for easy access for the kids in the rear. But it also had to have a short(as I could get) wheelbase and an engine that could be modified to achieve my power requirements. I was also already familiar with the vehicle from previous ownership and cost was reasonable. With the Supercharger and a few add ons I should have a reliable 600hp and 600lb-ft range.

Other Features:
Full Exocage
4 wheel Steering
Central Tire Inflation System
 

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Discussion Starter #2 (Edited)
Start with the a refresher on the axle build.

First I imported unimog axles from Germany. These happened to be factory reconditioned units that I immediately tore down. I cut down the tubes and rewelded them in the new locations to get the correct offset. I had to then slap the flange on the lathe and turn in down prep for welding to the new locations.



Here they are welded back up with the gear box removed from the end of the axles



Next came the brakes. Stock brakes are massive 70lb drum brakes and also the bolt pattern for the axles is an oddball pattern only used in military applications. So I torched all that off along with the stock flange off the axle hub. Had new wheel mounting flanges CNC laser cut. Turned a new register on the hub and pressed them together. A friend Tig welded them together.



Then came drawing up and CNC laser cutting some brackets for the brake calipers. These brackets also reinforce the entire hub portal box. This is a weak area in the axle that needs this bracing to handle the 47” tires I had planned.

 

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Discussion Starter #3 (Edited)
Here it is after mounting the standard chevy disc and the bitchen corvette 4 piston calipers I bought from the junkyards. There was a little grinding needed to fit them inside the wheels I have.



Then came adding link mounts to the axle. Notice how the outer link mount spans the tube to flange weld. Reinforcing this point and allowing force to transfer directly from the tires to the frame bypassing this failure point. That tube weld joint is a weak point compared to traditional axles due to the additional leverages placed by offsetting the wheel. Problem fixed here.



Upper and lower mounts done along with reinforcing and mounts for steering cylinders. The are custom double ended 2" bore by 10" stroke rams needed for the 45degrees of steering these axles have. They were manufactured with extra sealing and a few other features for rough offroad environment... unfortunately they are not mfg anymore.


 

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Discussion Starter #4 (Edited)
And the front axle. Remember 4 Wheel Steering!
The front axle runs off a danfoss orbital valve while the rear is controlled with a joystick and simple manifold.



Final bracing on the box to make extra sure it doesn’t explode. I realize you can’t really tell whats going on but I basically used the stock cast gearbox as shell and built a steel exoskeleton around it reinforcing the front and back of the gear bearing areas. All the bolt holes are thru drilled so that the entire box and bracing system is clamped together.



Of course I needed some bad ass steering arms so these were CNC burned and formed before welding up. Double sheer on heim joint and they CLAMP the portal box to its mount making the stricter stonger. The pattern encircles the entire backing plate/portal box. It took me a few tries to get that bolt pattern and clearances perfect so that this would work.



Rear axle steering at full lock.



Front Axle displaying the ackerman based on the original vehicle wheelbase with the inside tire turning on a much tighter radius.

 

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Discussion Starter #5 (Edited)
New axle shafts made of 300M by CTM racing.



I also took all the internal gears and joints and had everything Cryo Treated by the company that pioneered cryo treatment of metals. And why the hell not… build my own freaking Central Tire Inflation System? Designed and had my own custom hub bolt that integrates with a Dueblin rotating union to feed air to and from the tires while driving. machined from 4340 barstock.




And here is the final mockup with the 47's. Some pretty amazing clearance. I thing there is a good 8" on top of that 5 gallon bucket before reaching the axles.

 

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Awesome!

What size wheels are those?
Are you steering arms hitting the tire?

Glad you didn't give up on the axles!
 

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Discussion Starter #9 (Edited)
Awesome!

What size wheels are those?
Are you steering arms hitting the tire?

Glad you didn't give up on the axles!
Don't remember wheel size it's been so long. There are staun beadlocks inside.

The steering arms don't hit the tires but will with the least bit of bulge. They will be clearanced in the two ends to eliminate that. They won't work the way they are now. Very pleased with how stout that setup is and how it actually reinforces the structure however. Little bit of work and they will be perfect.
 

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are those toyota ifs calipers? let us know how they work! power assist im sure?
 

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Discussion Starter #11
are those toyota ifs calipers? let us know how they work! power assist im sure?
Here it is after mounting the standard chevy disc and the bitchen corvette 4 piston calipers I bought from the junkyards. There was a little grinding needed to fit them inside the wheels I have.

Corvette 4 Piston Calipers.

Plan on power assist as well.
 

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Good to see your back at it I've read your old threads before when I was researching my portals.TMR wont make those link brackets anymore I have a set similar im making myself tho.Always wanted to do a Dakota mog build for my son hes stuck on wanting a v8 and a truck so I told him be a good platform.As you already stated I knew lots of cutting would be involved esp the Durango hed prob truggy the rear so that would help his case.I may have to try and get my build moved over here its in hardcore right now and I just gave up on it.No one ever seems to be intrested the mogs are like redheaded step children to most I think.Im watching now man keep it up very intrested looks great so far.I like the hi steer arms you may need to make a few sets of those!:smokin:
 

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I notice in those Ackerman pics you don't have the factory steering stops bolted on. Are you going to try for something more aggressive than the 30* and 40* factory steering angles? I wonder how much more is possible before you completely bind up the joints or just tear the kingpins to shreds with the ram?


-G
 

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How much did you cut off the housings? With the new hubs did you measure WMS or even outside to outside of tire? I've been playing with measurements forever I need to cut my housings just trying to decide where I want to end up.Stock D60s are what 69.5 mogs are 72ish I cant remember id like to be a bit wider than stock D60 with quite a bit of backspacing on my wheels.
 

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How much did you cut off the housings? With the new hubs did you measure WMS or even outside to outside of tire? I've been playing with measurements forever I need to cut my housings just trying to decide where I want to end up.Stock D60s are what 69.5 mogs are 72ish I cant remember id like to be a bit wider than stock D60 with quite a bit of backspacing on my wheels.
 

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Discussion Starter #16
I notice in those Ackerman pics you don't have the factory steering stops bolted on. Are you going to try for something more aggressive than the 30* and 40* factory steering angles? I wonder how much more is possible before you completely bind up the joints or just tear the kingpins to shreds with the ram?


-G
Those are old pics. With the 47's on the current vehicle its looking like I'll end up with 30deg in the front. I'll likely shim the double ended ram to control the stops.

I don't know what the rear steering will be. It will be pretty limited unless I tub the rear of it.
 

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Discussion Starter #17
How much did you cut off the housings? With the new hubs did you measure WMS or even outside to outside of tire? I've been playing with measurements forever I need to cut my housings just trying to decide where I want to end up.Stock D60s are what 69.5 mogs are 72ish I cant remember id like to be a bit wider than stock D60 with quite a bit of backspacing on my wheels.
I cut 7.5" becasue that offset the front and centered the rear when using two steering axles by shortening short side of one and longside of another.

I would have to check but think i'm 69.5" @ WMS. Its been a long time and dont rmember unless i check my records or measure.
 

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Very unique and cool project!
 

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Looks good. And I thought I was looking for a tough project with F+ R steer 406's and 43's in an early bronco. Got your work cut out for ya..........
 

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Discussion Starter #20 (Edited)
thanks for the positive comments gents.

I've made a little progress but nothing picture worthy yet. coilovers arrive soon. I think I still have bumps in my shop from the planned buggy build and a currie anti-rock bar. although not sure if it will be the right width with the new build.

in the interim here are a couple more pics of my steering arms. as noted before they need some shaving done to clear the tires but real happy with the double shear and reinforcing the box to backing plate connection.



yes thats cobwebs....



 
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