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View Full Version : The Dana 34 Project: The Ultimate turd polish!



ironmanandy
08-11-2010, 12:22 AM
I have started building up my 2 door for next years season of Ecorrs,
I am building a dana 30/44 hybrid axle,
Pics up soon!

pingpong
08-11-2010, 11:34 AM
Curious on how you doing this. Are you re tubing a d44 center section and using d30 outers, or are you using a d30 Center, and then using d44 outers?

CT99XJ
08-11-2010, 12:45 PM
intrigued...

bookmarked to follow.

is this an XJ D30 with TJ D44 parts?

alwaysxj
08-13-2010, 12:12 AM
:popcorn::popcorn::popcorn::popcorn:
i want to see....

ironmanandy
08-13-2010, 07:13 PM
Heres the plan. I am using a YJ dana 30 center section and dana 44 axle shafts, axle tubes and outers the whole point is to have alot of ground clearance, lighter weight, and to do something I have yet to see anyone do!
I started with the carrier and here are a few images of the process to make my dana 30 carrier 30 spline.

Here are a few pics of the parts and comparison:
D44 spiders next to D30 obvious size difference. No way they will fit in the carrier.
http://i494.photobucket.com/albums/rr308/ibuildbigtoys/DCP_3744.jpg

This is the stock 44 spider next to the Ground down spider. I actually just chucked the gear in the lathe by the barrel and held a flap sander on the grinder to it until it was close and turned the rest off. I wanted it as tight a fit as possible to STRENGTHEN THE CARRIER when welded.
http://i494.photobucket.com/albums/rr308/ibuildbigtoys/DCP_3747.jpg

Stock set up.. Little gear lots of room in case.
http://i494.photobucket.com/albums/rr308/ibuildbigtoys/DCP_3748.jpg

The spider is a very tight fit and will add considerable amounts of strength to the case when welded in place. All gears will be welded to each other as well as the spiders to the Case. The once weak Case will be a very solid check of material.
http://i494.photobucket.com/albums/rr308/ibuildbigtoys/DCP_3749.jpg

Here is the progress dismantling the 30 and 44, still looks scary as hell at this point. I do understand everybody's doubts here LOL!
http://i494.photobucket.com/albums/rr308/ibuildbigtoys/DCP_3752.jpg

Here is a cool pic of my spring pad adjustable bump stop pads and my bump stops I have to this axle. I may switch to an Air bump set up from F-O-A
http://i494.photobucket.com/albums/rr308/ibuildbigtoys/DCP_3754.jpg

another with a tape measure to emphasize the BEEF!
http://i494.photobucket.com/albums/rr308/ibuildbigtoys/DCP_3757.jpg

I Hope this helps a little. I will add more pics as I make more progress I am waiting for my New plug weld drill bit to get here.

Having the long side tub ready to go I decided to turn it down today to make it fit the dana 30 housing.

I had to have a way to center the axle tube on the lather so I machined a center slug starting from a blank piece of 3" CR solid.
http://i494.photobucket.com/albums/rr308/ibuildbigtoys/DCP_3758.jpg

I sized one side to match the ID of the seal mount so this would fit tight and create a cap on the axle tube.
http://i494.photobucket.com/albums/rr308/ibuildbigtoys/DCP_3759.jpg

This is to size....
http://i494.photobucket.com/albums/rr308/ibuildbigtoys/DCP_3760.jpg

I flipped it around and center drilled it so that I can now center my Axle from the tail stock end.
http://i494.photobucket.com/albums/rr308/ibuildbigtoys/DCP_3761.jpg

Next I turned down a pc. of 1.75x.250 wall DOM to fit snugly inside the tube so that I could chuck it in the headstock with the outer C remaining on the tube.
http://i494.photobucket.com/albums/rr308/ibuildbigtoys/DCP_3764.jpg

I pounded the hold tube into the axle and chucked it up.
http://i494.photobucket.com/albums/rr308/ibuildbigtoys/DCP_3765.jpg

The center slug is installed and ready to turn!
http://i494.photobucket.com/albums/rr308/ibuildbigtoys/DCP_3766.jpg

The axle tube cut like butter but those damn plug welds get things a little hot!
http://i494.photobucket.com/albums/rr308/ibuildbigtoys/DCP_3767.jpg

Cut to size ready to go!
http://i494.photobucket.com/albums/rr308/ibuildbigtoys/DCP_3768.jpg

My camera died at this point. I took a soft wheel to the whole tube while the lathe was turning at 760. took about 3 min to have the whole thing shiny.

more pics to come

Mudderoy
08-13-2010, 07:53 PM
Wow, this is very interesting. I can't wait until the next show! :popcorn:

4.3LXJ
08-13-2010, 10:02 PM
Andy, you have more toys in your shop than I do. I am jealous.
:smiley-whacky084:

ironmanandy
08-13-2010, 11:09 PM
did you notice the RC rock buggy in the back of the picture.... I gotta wheel somehow.

4.3LXJ
08-13-2010, 11:18 PM
did you notice the RC rock buggy in the back of the picture.... I gotta wheel somehow.

It was hiding, must be a stealth buggy ... :rotfl2:

alwaysxj
08-15-2010, 07:05 PM
It was hiding, must be a stealth buggy ... :rotfl2:
it was in the 13th pic down...:driving::driving:

ironmanandy
08-16-2010, 10:29 PM
I actually drilled out the plug welds on the housing and got one side out on the dana 30 tonight. Ill try and post pics tomorrow.
A

pingpong
08-16-2010, 10:37 PM
I know the strength difference between the d30 and the d44.. how come you just didnt get a set of 30 spline d30 shafts and locker? Just seems like a lot of work to do to a d30.


I am pulling mine out and putting a shortened HP44 in it to fix my breaking issue

FunkSkunk
08-16-2010, 10:42 PM
basically because he's got the 44 in the shop = free

pingpong
08-17-2010, 10:58 PM
Just cause its free doesnt make it a good idea

ghost
08-18-2010, 08:33 AM
did you notice the RC rock buggy in the back of the picture.... I gotta wheel somehow.

You had a cabin and jeep at your disposol in Harlan on the 4th weekend.... but no you had to work.


Just cause its free doesnt make it a good idea

True but free makes it more tolerable to try some times. :popcorn:

4.3LXJ
08-18-2010, 10:53 AM
True but free makes it more tolerable to try some times. :popcorn:

You are absolutely right about that. A friend of mine came up with a 4 spider gear system for open D44s because of that. Besides, it is fun to experement.

ironmanandy
10-08-2010, 08:15 PM
hey guys things should start picking up here again so keep your eyes open.
A

4.3LXJ
10-08-2010, 09:19 PM
Waiting with baited breath

GT MOTORSPORTS
12-14-2010, 02:13 PM
A few years ago I remember reading an article about ARB and an axle company (Yukon?)getting together to make a hybrid dana30/44 they used D30 axle housing with D44 inner C's & knuckles and made the ARB carrier 30 spline with the D30 demensions(to fit the case ie bearings,races,shims) and the axle company made axle shafts to fit the diff and used D44 U-joints with D44 outers. The purpose was for rock racing and Rock racing where they needed the clearance. Either way its a cool idea to combine the 2 to come up with a fix for the some what hated Dana30.

Greg

loki_racer
12-15-2010, 11:43 AM
Andy, you're not gonna run that joker in ECORS. How about this, I drive up that and help you dispose of it under the front of my rig.

ironmanandy
12-16-2010, 12:35 AM
I dont think I am going to get to run ECORS as I am just too busy with ironman,
I have not even touched any of this stuff in months because i just have no time
Sorry
A

bluedragon436
12-16-2010, 12:38 AM
As much as I would like to see pics of your rig/parts hitting some good stuff... It is a nice thing to see a manufacturer who's priorities are getting his parts out there, and building them better or new products for all of us to enjoy...

Mudderoy
12-16-2010, 04:19 AM
I dont think I am going to get to run ECORS as I am just too busy with ironman,
I have not even touched any of this stuff in months because i just have no time
Sorry
A

It's ANDY! :smiley-scared002:

FunkSkunk
12-16-2010, 11:29 PM
Here's a similar type of axle mod on pirate ---> http://www.pirate4x4.com/forum/showthread.php?t=914583

fitting Dana 70 gears into a Dana 60 or fitting D50 into a D44
http://www.pirate4x4.com/forum/attachment.php?attachmentid=545987&stc=1&d=1283453106

ironmanandy
12-17-2010, 12:40 AM
Yeah you should check out the gear adapting done by JANA they put huge R&Ps in d 44s and D 60s. Neat stuff!
I hope to have some neat stuff for yall in january we have some cool stuff in the works
A

ghost
12-18-2010, 09:13 AM
Intresting stuff. I avoid Pirate like the plague. Only section I go to there is the Tellico section. I ahve to say I'm dissapointed here too. This stupid floating add will keep me from staying here.

4.3LXJ
12-18-2010, 11:10 AM
Intresting stuff. I avoid Pirate like the plague. Only section I go to there is the Tellico section. I ahve to say I'm dissapointed here too. This stupid floating add will keep me from staying here.

Sorry you don't like the add. It disappears after ten posts. And I too avoid Pirate and all the crap that goes on there. Just post a little and the add goes away.

drew91xj
01-02-2011, 02:23 AM
alright i guess ill be that guy and ask why not use the 44 you have/had for cutting down? your using the tubes, knuckles and spider gears and i asume everything knuckle out to alow for quick trail repair.

BrianXJ
01-02-2011, 05:41 AM
:eek::shocker::notworthy:

4.3LXJ
01-02-2011, 12:30 PM
alright i guess ill be that guy and ask why not use the 44 you have/had for cutting down? your using the tubes, knuckles and spider gears and i asume everything knuckle out to alow for quick trail repair.

I will let Andy speak for himself on this, but I see where he is going. A smaller differential makes for more ground clearance in muddy areas where there are ruts, but the strong outers makes the axle just as tough as the 44. I will be doing something similar with mine and reducing the size of the pumpkins even further.

ironmanandy
01-03-2011, 12:32 AM
After a good bit of measuring and some research I have decided that the dana 30 center section is going to just be to weak for what I plan on using it for.

for me to run the 3 spline shafts I have to bore out the inner race for the carrier bearing and that will significantly weaken the carrier.

My intentions for the axle are to go in a race jeep. I am hoping for around 300 horsepower. The vehicle will be leaving the ground a lot and the dana 30 just wont be able to take the shock load of the start/stop of the wheels.

I have decided to do the same thing but with a high pinion 44.

I intend to use a ford HP center section, Get a conversion setup from Jantz engineering to run a dana 50 ring and pinion. I will need to find a carrier for 35 spline shafts and run dana 60 kingpin outers.

I also intend on keeping the 5 on 5.5 lug pattern.

I will machine the tubes and inner Cs for what I need and for weight savings vs strength.

More to come after I get caught up with Ironman.
A

ghost
01-03-2011, 07:55 AM
After a good bit of measuring and some research I have decided that the dana 30 center section is going to just be to weak for what I plan on using it for.

for me to run the 3 spline shafts I have to bore out the inner race for the carrier bearing and that will significantly weaken the carrier.

My intentions for the axle are to go in a race jeep. I am hoping for around 300 horsepower. The vehicle will be leaving the ground a lot and the dana 30 just wont be able to take the shock load of the start/stop of the wheels.

I have decided to do the same thing but with a high pinion 44.

I intend to use a ford HP center section, Get a conversion setup from Jantz engineering to run a dana 50 ring and pinion. I will need to find a carrier for 35 spline shafts and run dana 60 kingpin outers.

I also intend on keeping the 5 on 5.5 lug pattern.

I will machine the tubes and inner Cs for what I need and for weight savings vs strength.

More to come after I get caught up with Ironman.
A

Awwww.... I wanted to see the turd pollised!

ironmanandy
01-05-2011, 12:41 PM
I am sorry who knows maybe Ill finish it up when. I have nothing to do..... I don't even know what that means any more.
A

Mudderoy
01-05-2011, 12:58 PM
I am sorry who knows maybe Ill finish it up when. I have nothing to do..... I don't even know what that means any more.
A

lol, nothing to do, that's a good one.