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Full Float Ford 9" Build

Discussion in 'Builds and Fabricators Forum' started by jonah, Nov 11, 2019.

  1. Mar 17, 2021
    Joe Dokes

    Joe Dokes New Member

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    It will get more plenty of oil.

    check out this video.

     
    jonah likes this.
  2. Mar 17, 2021
    Joe Dokes

    Joe Dokes New Member

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    I’m logged in but having trouble viewing your recent photos. I’m getting an error message dating I don’t have access even though I’m logged in. Anyone know why?
     
  3. Mar 18, 2021
    Fireball

    Fireball Well-Known Member 2024 Sponsor 2023 Sponsor 2022 Sponsor

    Pullman, WA
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    By default, new people have to do a certain amount of activity before they can view pictures stored on the forum. You can post a request in this thread: Image Permissions - I Can't View Pictures and one of the moderators will fix you up.
     
    Joe Dokes likes this.
  4. Mar 18, 2021
    jonah

    jonah Member

    Huntington Beach, CA
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    Thanks for the video, it is cool to see the ring gear pumping all of that oil! My only concern with this 9" is that the top of the housing has a channel across the top, perpendicular to the ring gear that could interrupt the flow towards the pinion bearings, but i will take a closer look.
     
    Joe Dokes likes this.
  5. Mar 20, 2021
    jonah

    jonah Member

    Huntington Beach, CA
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    Full day in the garage and life is good!

    I should have bought one of these a long time ago.

    26109.jpeg
    26104.jpeg

    I got the traction bar brackets done, it took a bit of work since the two brackets are different where they attach to the housing. I also increased the fastener size to 5/8" since I had broken the 1/2" hardware twice. I Also squared up everything on the mill since I had originally built this freehand and there was some misalignment that probably led to breaking the bolts.

    26101.jpeg 26098.jpeg

    My plasma cutter can just barely get through this 3/8" material. But job done!

    26094.jpeg

    Did some tig welds, this is the best one, the rest were practically as decent...i promise.

    26096.jpeg

    All the welding tweaked the housing, so I need to shink the back again. I hit it with the torch and I am close. But it needs a little more, maybe 0.020" out.

    Funny thing, if you grab a part that you welded on a minute ago, it is still pretty hot.

    26093.jpeg
     
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  6. Mar 20, 2021
    Fireball

    Fireball Well-Known Member 2024 Sponsor 2023 Sponsor 2022 Sponsor

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    Been there, done that.
     
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  7. Mar 20, 2021
    47v6

    47v6 junk wrecker! 2023 Sponsor 2022 Sponsor

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    Looks great!
    So if your jeep brands YOU, who owns who?
     
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  8. Mar 20, 2021
    jonah

    jonah Member

    Huntington Beach, CA
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    Oh, I think we all know who is in charge!
     
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  9. Mar 22, 2021
    jonah

    jonah Member

    Huntington Beach, CA
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    Was making progress, then this happened:
    26194.jpeg
    That is touching and that sent me down the rabbit hole. Can't grind the caliper, too thin. Thought about rear mounting the rotor on the hub to push the caliper out of the wheel but that isn't ideal and would require machining the rotors, more complicated caliper bracket, more difficult rotor swaps. Wheel spacers of 1/4 - 1/2" will solve with current wheels, but I might just change wheels. I really don't want to run spacers anymore.

    On the upside I got my shafts:
    26198.jpeg
    26197.jpeg
    Dutchman, they look good. I really want to make my own next time. I will probably want a bigger lathe before that happens.
     
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  10. Mar 22, 2021
    47v6

    47v6 junk wrecker! 2023 Sponsor 2022 Sponsor

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    When
    I made my FF axle, I was going to make my own splines. The idea was house a rotary cutter that I made out of some stock that would hold a carbide insert for my mill. What killed that was the cost. To do it right I needed a real spacer to index the shaft correctly. Moser did min way below the cost of the machinery, so I sent them off. of course they didn't follow my instructions correctly and I had to modify then a bit, but it all worked out ok.
    Those look great.
     
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  11. Mar 22, 2021
    jonah

    jonah Member

    Huntington Beach, CA
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    Painted housing after another round of straightening. The traction bar bracket took some heavy welding and it warped a bit, maybe 0.050". But it came back again.

    Rattle can black:
    26201.jpeg
     
  12. Mar 22, 2021
    jonah

    jonah Member

    Huntington Beach, CA
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    I did have to do a little work to them, they left the end about 0.008 too big and it wouldn't fit in the spindle. Just a little kiss fixed them up.

    Entry cost of DIY is high, but it would be fun. I do know someone with a dividing head and a big (ger) lathe. Just need a cutter.
     
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  13. Mar 24, 2021
    jonah

    jonah Member

    Huntington Beach, CA
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    It is now fighting me at every turn, after burning me I think it is getting cocky. Went to install arb lines and there were clearance issues between the housing and the extra large bearing caps on the summit center section. I had to go after it with the die grinder. Then I stole my son's stash of silly putty to check (i need to replenish the supply before he notices). I think it will work..

    26274.jpeg

    26270.jpeg

    26273.jpeg

    Lifting that center in and out of the housing a dozen time wore me out! Slept good last night.
     
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  14. Mar 24, 2021
    Mr Vaughan

    Mr Vaughan

    it's always nice to get in bed after a day of hard work and sleep long and well.
     
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  15. Mar 27, 2021
    jonah

    jonah Member

    Huntington Beach, CA
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    Ordered some new springs since mine are drooping a bit. Picked up these revere eye springs from RE.
    26372.jpeg
    But there is a problem, these will hit the frame when compressed.
    26368.jpeg

    Those are getting returned.
    Did the final install on the center section.
    26370.jpeg

    Did a quick fit on the shafts and it is looking good.

    Started machining the caliper brackets.
    26366.jpeg

    I also bought one wheel to try out, the clearance issue on my current wheel is no good. I dont want to run a spacer so I am looking at some steel wheels.We will see.
     
    Last edited: Mar 27, 2021
  16. Mar 27, 2021
    Joe Dokes

    Joe Dokes New Member

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    Did you toss those other brackets you were making? That bracket looks amazing .
     
  17. Mar 27, 2021
    jonah

    jonah Member

    Huntington Beach, CA
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    Yeah, remember how I said a smart person would start with square stock...

    I started over on those.
     
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  18. Mar 27, 2021
    jonah

    jonah Member

    Huntington Beach, CA
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    Worked more on the caliper brackets today. These took all day, a lot of operations on the mill and had to make some tools on the lathe.

    Here is the set up on the rotory table I borrowed from TomTom. I had made a centering post for the table that had a 3/4" shaft. So on the lathe i made a puck the fit the post and the bracket. That let me cut outside circle.
    26399.jpeg

    I had face mill the entire brackets, both sides, spot all the mounting holes and chamfer the center hole to fit over the spindle. I made a mini scribe that could fit in the mounting holes for the caliper. I used that to locate the mounting holes in the bracket. With the rotor mounted to line up the caliper, it was difficult to mark those holes.
    26397.jpeg

    Here it is mounted up
    26395.jpeg

    I need a shim to get the caliper spaced correctly, it is .125"
    I probably built it too tight to the rotor hat. The outer pad scuffs the hat a little, I will have to clearance the backing plate of the outer pad but I am trying to get as much space as possible for the wheel clearance. I think it will all work but everything is tight.

    Here is the formula for ford fusion caliper mounting bracket, I really need a notepad in the garage.
    26393.jpeg
     
  19. Mar 28, 2021
    47v6

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    That bracket is hot!
     
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  20. Mar 28, 2021
    jonah

    jonah Member

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    I am pretty happy with it, thanks!
     
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