full floater rear end

[cavey]

I built a full floater rear end for my hilux by obtaining a complete 80 series rear end which has the diff offset 100mm ( 4 " ) which makes one axle 200mm ( 8" ) longer than the other  and i had to get another short axle so the hilux diff would stay in the middle   I cut the ends off a hilux axle housing at the butt joint with the axle tubes and cut the stub axles off the 80 series axle housing about 3" in from the weld  then stuck the stubs in the lathe to remove the tube remains and the weld, I bought 700mm of hollow bar  80mm OD 55mm ID cut it in half and machined a step in one end to go inside the diff housing  and bored the other to slip over the 80's stub and bored the ID to 60mm so the wall thickness is 10 mm (3/8")  I dummied it all up with out welding and with the axles engaging in the side gears the same amount as the std hilux the wheel track would be 10mm greater than the hilux ( non IFS )  i tried to weld it up with just a length of threaded rod through the lot with nuts and washers on each end and then tack it then shove it in the lathe to check run out  which didn't work so i made a welding jig and welded the housing to it then weldedup the housing which did work

[cavey]

I washed the new housing out and painted it except where the perches live I assembled the whole thing to make sure that it all still went together  then sorted out the brake lines and handbrake then removed the hubs axles and backingplates then installed the housing under the truck  with marlin u bolt flip kit and got the pinion flange to point to the t case the tacked on the perches , removed the housing and welded up painted and bolted back under the truck and reassembled the housing

[cavey]

more pictures

[cavey]

more pictures

[ninja turtle]

badass