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 Sponsor

    Des Moines, IA
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    X2!
     
  2. Nov 16, 2017
    ITLKSEZ

    ITLKSEZ Volvophilic

    Post Falls, ID
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    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! Sponsor

    Northern Minn.
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    "Might as well..." :)
     
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  4. Nov 16, 2017
    Muzikp

    Muzikp Sponsor Sponsor

    Sacramento Ca.
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    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 Sponsor Sponsor

    pacific north west
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    just read the whole thing....now im addicted! such awesome work! I cant wait for more...
     
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  6. Nov 16, 2017
    Dphillip

    Dphillip Member

    Omaha NE
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    He is an “Artist.”
     
  7. Nov 16, 2017
    PGHCJ5

    PGHCJ5 I smell something broken...

    'yinzertahn
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    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 Sponsor

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    I'm awaiting the next installment on this thread like I wait for the UPS truck.
     
  9. Nov 16, 2017
    ITLKSEZ

    ITLKSEZ Volvophilic

    Post Falls, ID
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    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
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    “Tease”
     
  11. Nov 17, 2017
    ITLKSEZ

    ITLKSEZ Volvophilic

    Post Falls, ID
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    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]
     
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  12. Nov 20, 2017
    ITLKSEZ

    ITLKSEZ Volvophilic

    Post Falls, ID
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    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
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  13. Nov 20, 2017
    Dphillip

    Dphillip Member

    Omaha NE
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    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 Sponsor

    Eynon, PA
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    Darn it, I'm only getting an X and "img" instead of pics. I liked it anyway, in anticipation.
     
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  15. Nov 20, 2017
    ITLKSEZ

    ITLKSEZ Volvophilic

    Post Falls, ID
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    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 Sponsor Sponsor

    Sacramento Ca.
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    Images work fine over here.
     
  17. Nov 20, 2017
    Bowbender

    Bowbender I'm workin' on it! Sponsor

    Northern Minn.
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    That's a cabinetmaker/ trim carpenter trick! (y)
     
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  18. Nov 21, 2017
    Posimoto

    Posimoto Hopeless JEEP Addict Sponsor

    Kings Beach, Ca....
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    Keep cutting it too long until it fits! That was our mantra in the hardwood flooring business.
     
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  19. Nov 21, 2017
    ITLKSEZ

    ITLKSEZ Volvophilic

    Post Falls, ID
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    My knees hurt just hearing those words.
     
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  20. Nov 25, 2017
    ITLKSEZ

    ITLKSEZ Volvophilic

    Post Falls, ID
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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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