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Varg In Jeep's Clothing

Discussion in 'Builds and Fabricators Forum' started by ITLKSEZ, Aug 20, 2015.

  1. Sep 20, 2017
    75 DJ

    75 DJ Member

    Des Moines, IA
    Joined:
    Sep 12, 2016
    Messages:
    58
    X2!
     
  2. Nov 16, 2017
    ITLKSEZ

    ITLKSEZ Hope for the best, prepare for the worst

    Liberty Lake, WA
    Joined:
    Aug 13, 2015
    Messages:
    6,656
    Let's drag this axle out to sweep under this jeep.

    While it's out, let's throw it up on some jack stands.

    While it's up on jack stands... :sneak:

    [​IMG]
     
  3. Nov 16, 2017
    Bowbender

    Bowbender I'm workin' on it!

    Northern Minn.
    Joined:
    Nov 14, 2014
    Messages:
    561
    "Might as well..." :)
     
    dozerjim and ITLKSEZ like this.
  4. Nov 16, 2017
    Muzikp

    Muzikp Active Member

    Sacramento Ca.
    Joined:
    Sep 27, 2016
    Messages:
    1,450
    Oh praise all that is glorious, we are working on the Varg again (y). I say we like I'm there, but I'm so emotionally invested :rofl::rofl::rofl:
     
  5. Nov 16, 2017
    baldjosh

    baldjosh Member

    pacific north west
    Joined:
    Oct 24, 2017
    Messages:
    451
    just read the whole thing....now im addicted! such awesome work! I cant wait for more...
     
    ITLKSEZ likes this.
  6. Nov 16, 2017
    Dphillip

    Dphillip Member

    Omaha NE
    Joined:
    Nov 25, 2008
    Messages:
    322
    He is an “Artist.”
     
  7. Nov 16, 2017
    PGHCJ5

    PGHCJ5 I smell something broken...

    'yinzertahn
    Joined:
    Jul 7, 2016
    Messages:
    100
    I am so glad this project is on again. Like waiting for a sequel to a great movie! (y)(y)
     
  8. Nov 16, 2017
    fhoehle

    fhoehle Sponsor

    Harford Township, PA
    Joined:
    Apr 11, 2012
    Messages:
    1,427
    I'm awaiting the next installment on this thread like I wait for the UPS truck.
     
  9. Nov 16, 2017
    ITLKSEZ

    ITLKSEZ Hope for the best, prepare for the worst

    Liberty Lake, WA
    Joined:
    Aug 13, 2015
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    6,656
    I don't know what you guys are getting so excited about. I was just pulling it out to clean around it. :whistle:
     
  10. Nov 17, 2017
    Dphillip

    Dphillip Member

    Omaha NE
    Joined:
    Nov 25, 2008
    Messages:
    322
    “Tease”
     
  11. Nov 17, 2017
    ITLKSEZ

    ITLKSEZ Hope for the best, prepare for the worst

    Liberty Lake, WA
    Joined:
    Aug 13, 2015
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    6,656
    I wish there was an easier way to cut mounts off of an axle. And by golly, that was a lot of mounts!

    [​IMG]


    All cleaned up and prepped for surgery.

    [​IMG]
     
    fhoehle, Bowbender, piffey263 and 3 others like this.
  12. Nov 20, 2017
    ITLKSEZ

    ITLKSEZ Hope for the best, prepare for the worst

    Liberty Lake, WA
    Joined:
    Aug 13, 2015
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    6,656
    The surgery went well.

    If you remember from a page or two back, I picked up an Isuzu Rodeo for the rear axle. Shortening the axle by exactly 7 1/2" on the driver's side will make it 55 1/2" wide WMS to WMS (same as the Toyota front axle), and will line up the pinion to within 1/2" of the t-case output.

    Here's how I make a perfectly square line around a tube. I cut a strip of aluminum flashing on the table saw, tape one end to the tube, wrap it, then tape it tight after it is perfectly lined up on itself. I then used an engraver to mark around the flashing.

    [​IMG]


    I made a disposable jig to hold the end of the tube perfectly in place.

    [​IMG]
    [​IMG]



    I then slid the jig out of the way to cut the tube. (Cutoff wheel in a grinder, then fine tuned with a grinder if you're wondering.)

    [​IMG]


    Test fit after the section was removed. Looks good.

    [​IMG]


    I took it back apart and ground 45° bevels on the cuts. I was able to tack and get a root pass on the inside of the tube (through the end) before laying any welds in the V, so I'm not concerned one bit with the strength of this modification.

    I present to you a driver's side drop, 30 spline, disc braked, Trac Loc'd D44. Now I have to send the shaft off to Moser to have them cut and respline the shaft.

    [​IMG]
     
    Last edited: Nov 20, 2017
    tymbom, 75 DJ, 47v6 and 6 others like this.
  13. Nov 20, 2017
    Dphillip

    Dphillip Member

    Omaha NE
    Joined:
    Nov 25, 2008
    Messages:
    322
    Well done!
    That aluminum fin cover is super cool. Moser did all my axle tube narrowing and axle re-splining work for me, really like those guys. Would a miter chop saw have given you the perfect cut on the tube?
     
  14. Nov 20, 2017
    fhoehle

    fhoehle Sponsor

    Harford Township, PA
    Joined:
    Apr 11, 2012
    Messages:
    1,427
    Darn it, I'm only getting an X and "img" instead of pics. I liked it anyway, in anticipation.
     
    Muzikp likes this.
  15. Nov 20, 2017
    ITLKSEZ

    ITLKSEZ Hope for the best, prepare for the worst

    Liberty Lake, WA
    Joined:
    Aug 13, 2015
    Messages:
    6,656
    Thanks! I'm going to clean up that cover and clearcoat it.
    I guess a perfect miter saw would make a perfect cut, but Harbor Freight isn't in the business of perfection. :D I trust my hand with a grinder more than a saw anyway. I'd rather "sneak up" on the line than try to hit it in one shot.

    Dang! Here's the album link.
    Shortened axle tube

    Edit: I just reloaded the images... see if that helps. I made that post down in the shop where there is sketchy internet.
     
    Last edited: Nov 20, 2017
    Hellion likes this.
  16. Nov 20, 2017
    Muzikp

    Muzikp Active Member

    Sacramento Ca.
    Joined:
    Sep 27, 2016
    Messages:
    1,450
    Images work fine over here.
     
  17. Nov 20, 2017
    Bowbender

    Bowbender I'm workin' on it!

    Northern Minn.
    Joined:
    Nov 14, 2014
    Messages:
    561
    That's a cabinetmaker/ trim carpenter trick! (y)
     
    ITLKSEZ likes this.
  18. Nov 21, 2017
    Posimoto

    Posimoto Hopeless JEEP Addict

    Minden, Nevada
    Joined:
    Aug 7, 2003
    Messages:
    4,538
    Keep cutting it too long until it fits! That was our mantra in the hardwood flooring business.
     
    Bowbender and ITLKSEZ like this.
  19. Nov 21, 2017
    ITLKSEZ

    ITLKSEZ Hope for the best, prepare for the worst

    Liberty Lake, WA
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    My knees hurt just hearing those words.
     
    Posimoto likes this.
  20. Nov 25, 2017
    ITLKSEZ

    ITLKSEZ Hope for the best, prepare for the worst

    Liberty Lake, WA
    Joined:
    Aug 13, 2015
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    So many little pieces. :susp:
    I still have two days of cleanup, V-ing and welding to do, but...

    Any guesses?

    [​IMG]
     
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