Duffil's 84 Xtra Cab is still bringing the suck

[Wermz84]

Very cool.    More Pics...

[Duffil]

Very cool.    More Pics...

all in due time, grasshoppa.

Big thanks to booger for some plate!!

[Duffil]

some more work from last night:
I used the press at work to bend this guy...1/4" plate



still need to slice the axle tube a lil bit and bring it down

[Duffil]

 






Big thanks to Steve!! Ordered yesterday at lunch, got it today!

[86bobbedtoy]

hay looks like that axle will be sweet ! !

[Jud]

I'm jelous!

[Duffil]

I'm jelous!

I'm broke.  Wanna trade? 

[Jud]

I'm broke.  Wanna trade? 

I might consider it! haha

[Duffil]

got the outside welded up tonight...should get the inside tomorrow and start on my gears. 

[86bobbedtoy]

WOW again great work!  nice welds, what welder you got?

[Duffil]

WOW again great work!  nice welds, what welder you got?

Thanks.
El Cheapo Harbor Freight Chicago Electric 220V unit.  I find that the higher I turn this thing up, the better they come out.  And the wirespeed is really fast, even at a low setting.

[Duffil]

Here is a rear view...you can see where I notched and dropped the axle tubes a little.

[*** YELLER ***]

Nice work dude


Nothin' says work bench like a couple of paper barrels and a folding chair 

[fordh8r]

Nice work dude


Nothin' says work bench like a couple of paper barrels and a folding chair 

Dude, you need to step up and use some stackable milk crates or a stack of tires even...


And very nice job on your mod there!

[Duffil]

Dude, you need to step up and use some stackable milk crates or a stack of tires even...


And very nice job on your mod there!

I can't.  Both of those options have too many movable parts and I might get confused.

[fordh8r]

I can't.  Both of those options have too many movable parts and I might get confused.

Plus they're kinda pricey unless you know where to shop...    

[Duffil]

 
got the case cleaned up last night, started today on getting the gears done.


froze the races and they fell right in!

It took me WAY too long to set the pinion bearing preload.  The solid spacer was about .010" smaller than the factory crush sleeve.
Solid spacer + .010" shim=full lock on pinion.
solid spacer by itself=no bearing preload.
there was a small .003" ridge on the front of the spacer, so I lapped it off with 400 grit and carb cleaner.

before:

after:

[Duffil]

 

I had to take off about .020" before I could get any decent preload with this thing.
this is where I ended up:

My SST:

after that, it was pretty easy...took me a little while to get the pinion depth correct, but it came out OK.
Not very clear, but here's my pattern:


and a fresh coat of flat black

[Jud]

Nice!

[fordh8r]

from the looks of those pics I'd run it!    

[Duffil]

from the looks of those pics I'd run it!    

I plan on it.  Hopefully under the truck tuesday night.

[*** YELLER ***]

nothing to see here movin along

















except the new stackable boxes for a work bench




             

[Gittinit]

That shave job looks good. Do ya know how much ya took out? I love the rounded plate. Are you gonna add some more protection for the ring gear.

[Duffil]

That shave job looks good. Do ya know how much ya took out? I love the rounded plate. Are you gonna add some more protection for the ring gear.

Thanks bro.  looks like around an inch.  I was planning on a piece of plate like the MC comp style guard, but I kinda ran out of steam on fab.  Maybe once I get the housing in.

[Duffil]

 

here's a before shot with a stock diff:

New axle bearings and seals, and the new one is in:

and a new clearance pic.

hopefully less of this:



Headed down tomorrow to get some rear driveshaft tube.

[Wermz84]

Awsome work!   your info on the spacer will help me out as well. 

[Duffil]

Built new rear driveshaft today.  I got some 2.625"x.120" wall tube yesterday, and had the yokes turned down to fit.  So far, the rear end is great. On/off throttle transition is very smooth, no humming or odd noises and the detroit seems to be working fine.  I got it up to 55 with the new shaft and it was waaayyyy smooth.  Better than it's ever been.

[Duffil]

I've noticed my housing has one small leak in it, in one of the corners i couldn't get to from the inside.  I'll stitch a bigger bead over the outside later.

[snowshoebrue]

who did you have turn that down? 

[Duffil]

who did you have turn that down? 

one of my customers. He and his dad are jeep guys, and we :bull crap: a lot.  He has a full machine shop at his yard.