my home brew 609 build( lots of pics )
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well I finally got to work on my 609 again
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look at the old dana 44
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complete 609
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another pic of 609
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empty spot
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goodbye bent ole 44
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609 installed flexed to left
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609 flexed to right
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marks on rotator flexed to left
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marks after flexing to right shows how much movement can be gained my way of doing it instead of a wristed arm
now all I got to do is finish trak bar mount and steering and she will be good to go for this weekend
look at the old dana 44
complete 609
another pic of 609
empty spot
goodbye bent ole 44
609 installed flexed to left
609 flexed to right
marks on rotator flexed to left
marks after flexing to right shows how much movement can be gained my way of doing it instead of a wristed arm
now all I got to do is finish trak bar mount and steering and she will be good to go for this weekend
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5,842 Posts
nice..cool little jig you set up for cuttin the tube on the lathe
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1,266 Posts
scared the sh!!t out of me but got the job done
I haven't done a final measurement but it should be 63" its 4 " wider than stock and thats all in the in the knuckles and hubs the distance from the inner c to the wms is 2 inches more than on the 44
I kept washing it after every trail ride but then I kept waiting on getting inner axles back from resplining and last trail ride it was to dang cold to wash it
yep there is a grease fitting to keep it packed full
I did this on a jeep for a buddy it has been on there for 2 years holding up pretty well so far
SaWeeeat! I am looking for help with one. I don't have the equipment. Curious where you got the outers, knuck out? Who did you order axles from? I didn't see a pic of the jig used as you welded the tubes?
I have bought a used sunray for the outers and 35 spline N-case detroit lockin' frickin' drop out. Now I need to rework the housing to fool-size and get new axles. I was lookin' at Currie for the axles and have three local sources to get help reworking the housing.
I like that you went all the way with shaving and back errr front brace!
I have bought a used sunray for the outers and 35 spline N-case detroit lockin' frickin' drop out. Now I need to rework the housing to fool-size and get new axles. I was lookin' at Currie for the axles and have three local sources to get help reworking the housing.
I like that you went all the way with shaving and back errr front brace!
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1,266 Posts
yep they are ford 44 bracket bored out to fit 60 spindles and redrilled to match bolt pattern then flipped around to oppiside side with 5/16 spacer to make them fit up the rotors/hubs ( thanks highonda) correctlyfordnut said:
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bought used inner and outer knuckles with about 6" of tube from Highonda here on pirate and also got used long side axles from him to have cut down to my custom lenght the ended up building diff to use stock chevy short side axle so only long side is customBlown said:
had a local guy spline my axle but ussually use Moser
a buddy that has a 4wd shop here in dayton helped with getting the tubes lined up and all the welding of tubes and internal gussets and brack brace. Then I machined out the the inside diameter of inner c's to fit dana 44 axle tubes and also machined out the 78/79 ford cast c's to fit over tubes then lined it all up and started welding also found part # for a seal to fit 44 axle tube and the 60 shaft here on pirate
also found a used 35 spline arb here on the list the bought the strange eco 3.25 n case and daytona pinion support
and after about a year of plannig and 3 months building it is almost done
That is a very cool buildup. Did you make the jig to keep everything lined up? That is the only thing keeping me from attempting the same thing. The way i was thinking of doing it, was to use the whole d60 axle tube and machine a 9" housing to accept the 60 tubes, then adding gusseting similar to yours.
Btw, the lathe cutter thing you rigged up looks scary as hell!
Btw, the lathe cutter thing you rigged up looks scary as hell!
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1,266 Posts
most of the line up was based off a 3" angle iron that we welded to the bottom of center housing and measured everything to it along with a alignement bar that to inner seals fit snug on
if we make anymore we will build a better jig system but for a one time thing we just made due and did alot of measuring and used a digital angle gauge it all came out very true
some slow stich welding to prevent warping and draw
if we make anymore we will build a better jig system but for a one time thing we just made due and did alot of measuring and used a digital angle gauge it all came out very true
some slow stich welding to prevent warping and draw
Very cool! I saw a jig on ebay to shorten 9" housings for drag racers. It was a Rod with aluminium bushings mounted on it with set screws the size of the bearings. The jig was mounted in a cut down 3rd case and you'd bolt it in the housing to keep it all lined-up. Then you still got to set the knucks for castor and proper pinion angle. Looks like you did great!
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well after first day out with new frt end it falled its test but only because I falled it in the money department I didn't have the cash to get 35 spine stubs and didn't want to buy lock outs or flanges for the 30 splines so I borrowed a set of old stock ford lock outs and the pass side internal spline to the stub axle was pretty loose and after a hr or so of good snow wheeling it stripped out while pulling a broken truck up a hill
so now it time to save some pennies and get some stub and flannges
I guess that will be my christmas for myself
so now it time to save some pennies and get some stub and flannges
I guess that will be my christmas for myself
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