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D27 Knuckle / Spindle Bolt Upgrade Issue

Discussion in 'Early CJ5 and CJ6 Tech' started by truckee4x4, May 10, 2020.

  1. May 10, 2020
    truckee4x4

    truckee4x4 Member 2020 Sponsor 2019 Sponsor

    Truckee CA
    Joined:
    May 30, 2008
    Messages:
    208
    Working on the front end this weekend, and attempting to follow Moses Ludell's instructions to upgrade the spindle / knuckle mating bolts from the stock "outside in" style 7/8" to "inside out" with 1.5" G8 3/8"-24 button head screws.

    I have new replacement knuckles from Kaiser Willy's that must have been different castings, on the passenger side one I had to die grind out some material to allow for the button heads to seat flush, and on the driver side one I did not.

    When I bolted everything up for a dry fit and pull test, the driver side won't sweep all the way back (left turn) as the head of one of the bolts hits the axle "ear" (where the kingpin sits).

    Anyone else hit this snag?

    I'm not sure I can (or want to) grind the head of the bolt enough to allow for the complete sweep, so about the only thing I can think of to do is to pull the offending button head and screw from the outside in with a shorter bolt at that location.
     
  2. May 10, 2020
    Jw60

    Jw60 Recovering Jeepaholic

    Sedalia MO.
    Joined:
    Oct 5, 2018
    Messages:
    538
    That is a common issue but doesn't make the highlight reel. Find where the bolt hits the ball at 3 and 9 then hit that with the grinder on the ball of the axle. Round the edges over nicely but use a small radius.
     
    truckee4x4 likes this.
  3. May 10, 2020
    Wyo Eeyore

    Wyo Eeyore Member

    Eastern WY next...
    Joined:
    Feb 22, 2006
    Messages:
    77
    I did this to our '64 CJ5 years ago. Just finishing up doing it to our '52 M38. Had to grind in the knuckles to get the button head to sit flat and had to grind the edge of several button head bolts as that was easier than grinding out the knuckle for clearance. I did not have to grind any where to get full left or right swing on any of the four knuckles I have done. Grinding the button a little flatter could help in the swing.

    I do not hammer either Jeep on the trails, but every once and a while a bump or hole will be hit that really shakes things. If this upgrade keeps the wheel on then it is worth the effort. While working on the M38 I decided to do a brake job. It has turned into a headache. Had to order replacement adjusting eccentrics. Now my work space is cold, hurry summer.
     
    truckee4x4 likes this.
  4. May 10, 2020
    wheelie

    wheelie beeg dummy 2019 Sponsor

    York, PA
    Joined:
    Mar 6, 2004
    Messages:
    3,642
    I had to grind the ball end on both sides of my 27. I had a minimal amount of material removed on the inside of the knuckle for the button head to seat against because I wanted to retain as much of the casting's integrity as possible as well as the threads.

    Mark where the screws hit. Grind a little and test fit. Rinse and repeat until your satisfied.

    I also marked where the rubber wipers were at so I didn't compromise their dealing ability but I did this before installing the screws. I knew I was going to have grind.
     
    truckee4x4 likes this.
  5. May 10, 2020
    44bz

    44bz New Member

    Oregon City OR
    Joined:
    Jul 30, 2018
    Messages:
    38
    The other option is to use studs for the two top and bottom holes then reuse the screws for the one remaining hole on either side. This is what I did on my CJ2a. Just as strong and no clearance issues.
     
  6. May 10, 2020
    Mcruff

    Mcruff Earlycj5 Machinist

    Albertville, AL
    Joined:
    Sep 22, 2002
    Messages:
    4,939
    Your actually suppose to spot face these areas instead of grind them. It makes the bolt seat square and flat. There was at one time a counterbore floating around the early cj5 guys. I have know idea who had it last. I know I sent a homemade counterbore out about 15 years ago or so.
     
    Steamboat Willys likes this.
  7. May 11, 2020
    wheelie

    wheelie beeg dummy 2019 Sponsor

    York, PA
    Joined:
    Mar 6, 2004
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    3,642
    Yep. Spotface is the best way to do it. It what I had done to mine. I bought the the tools and had a machinist do the work on a mill. I was going to try it on my drill press but I wasn't comfortable with that.
     
  8. May 12, 2020
    colojeepguy

    colojeepguy Colorado Springs 2019 Sponsor

    At the foot of...
    Joined:
    Apr 4, 2010
    Messages:
    4,816
    I did mine with the drill press...i also ruined one knuckle in the process! Its easy to get too deep.
     

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