Varg In Jeep's Clothing

X2!

 

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...

 

"Might as well..."

 

Oh praise all that is glorious, we are working on the Varg again . I say we like I'm there, but I'm so emotionally invested

 

just read the whole thing....now im addicted! such awesome work! I cant wait for more...

 

He is an “Artist.”

 

I am so glad this project is on again. Like waiting for a sequel to a great movie!

 

I'm awaiting the next installment on this thread like I wait for the UPS truck.

 

I don't know what you guys are getting so excited about. I was just pulling it out to clean around it.

 

“Tease”

 

I wish there was an easier way to cut mounts off of an axle. And by golly, that was a lot of mounts!




All cleaned up and prepped for surgery.

 

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.




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






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.)




Test fit after the section was removed. Looks good.




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.

 

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?

 

Darn it, I'm only getting an X and "img" instead of pics. I liked it anyway, in anticipation.

 

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. 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.

 

Images work fine over here.

 

That's a cabinetmaker/ trim carpenter trick!

 

Keep cutting it too long until it fits! That was our mantra in the hardwood flooring business.

 

My knees hurt just hearing those words.

 

So many little pieces.
I still have two days of cleanup, V-ing and welding to do, but...

Any guesses?