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  1. #31
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    Default Re: My Dana44 Axle Build

    Quote Originally Posted by bugsjeep View Post
    Not that i have ever done anything like that, but I have heard they make remove the weld tools that work pretty good.....sometimes they even cause your shirt to catch fire.....not that I've done that either..
    I cut them off with a cut off wheel and re welded. However, once upon a time when I was a fireman I was at the fire house doing some welding and caught my Levi coat on fire while I was happily welding away. Started getting smoky inside the hood so I raised it to see what was going on. I had flames in my face. Patted out the flames to the laughter of my fellow firefighter. He was thinking of calling in a man fire and a full response
    230 hp 4.3L Chevy
    Built 4L60E with manual lockout
    Atlas 4 speed
    Griffin radiator
    On board air
    Warn 9.5ti on custom bumper
    7.5" RE front and bastard pack rear on custom long arms
    30 gal gas tank
    lockers
    And a bunch of other stuff

  2. #32
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    washington
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    Default Re: My Dana44 Axle Build

    Quote Originally Posted by 4.3LXJ View Post
    I cut them off with a cut off wheel and re welded. However, once upon a time when I was a fireman I was at the fire house doing some welding and caught my Levi coat on fire while I was happily welding away. Started getting smoky inside the hood so I raised it to see what was going on. I had flames in my face. Patted out the flames to the laughter of my fellow firefighter. He was thinking of calling in a man fire and a full response
    It's good to have friends that care......

  3. #33
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    Default Re: My Dana44 Axle Build

    Next thing to do was install the axle shafts and start thinking about brakes. While the 11" drum brakes would have been an upgrade, the WJ rear discs are so much better. So I got some new drums and pads and got some front and rear calipers and brackets from the pick and pull for 60 for all four. Then I had to have the discs bored out to accept the larger bolt pattern and hub size.
    Attached Thumbnails Attached Thumbnails IMG_1916_zpsl5dqnuuh.jpg  
    230 hp 4.3L Chevy
    Built 4L60E with manual lockout
    Atlas 4 speed
    Griffin radiator
    On board air
    Warn 9.5ti on custom bumper
    7.5" RE front and bastard pack rear on custom long arms
    30 gal gas tank
    lockers
    And a bunch of other stuff

  4. #34
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    Default Re: My Dana44 Axle Build

    next thing to do is make a couple of custom caliper brackets. I couldn't use the WJ backing plate because it has a different bolt pattern on the tube and is made out of, wait for it .............................................. plastic. Looks more like distributer cap material, but I just can't weld on it. So, a couple of custom brackets and I am good to go. I don't need the stock parking brake, I have one on the rear output of the Atlas
    Attached Thumbnails Attached Thumbnails IMG_1910_zpswqiz8tb5.jpg  
    230 hp 4.3L Chevy
    Built 4L60E with manual lockout
    Atlas 4 speed
    Griffin radiator
    On board air
    Warn 9.5ti on custom bumper
    7.5" RE front and bastard pack rear on custom long arms
    30 gal gas tank
    lockers
    And a bunch of other stuff

  5. #35
    Join Date
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    Default Re: My Dana44 Axle Build

    Got the brackets welded on and calipers attached, tried on a wheel and it fits much better than the aluminum wheels on the XJ. also welded on the spring pads in the correct position since I cannot afford the suspension links of choice right now
    Attached Thumbnails Attached Thumbnails IMG_2064.jpg   IMG_2061.jpg  

    230 hp 4.3L Chevy
    Built 4L60E with manual lockout
    Atlas 4 speed
    Griffin radiator
    On board air
    Warn 9.5ti on custom bumper
    7.5" RE front and bastard pack rear on custom long arms
    30 gal gas tank
    lockers
    And a bunch of other stuff

  6. #36
    denverd1's Avatar
    denverd1 is offline Level: Uber Jeep Cherokee Trailer Queen
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    Default Re: My Dana44 Axle Build

    looks good! keeping your leaves for now?
    Wheelin' East Texas in a RED XJ

    RED 98 XJ with 4.5" lift, ZJ steering, front and rear locked on 33's
    Cobra CB, SYE, bumpers, 10K winch, lights
    ,___________
    //___l__,\____\,00_
    l_--- \___l---[]lllllll[]|
    (o)_)--(o)_)--(o)_)

  7. #37
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    Default Re: My Dana44 Axle Build

    Yes for now, unless my business takes off, then the sky will be the limit
    230 hp 4.3L Chevy
    Built 4L60E with manual lockout
    Atlas 4 speed
    Griffin radiator
    On board air
    Warn 9.5ti on custom bumper
    7.5" RE front and bastard pack rear on custom long arms
    30 gal gas tank
    lockers
    And a bunch of other stuff

  8. #38
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    Default Re: My Dana44 Axle Build

    Quote Originally Posted by denverd1 View Post
    looks good! keeping your leaves for now?
    Looks like your getting some work done, keep it going.
    is that a Linde welder in the background ? I had a Linde 300 for a long time, sold it to a friend (he doesn't know to use it) who thought he was going to learn to weld. Miss that machine, should buy it backClick image for larger version. 

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  9. #39
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    Default Re: My Dana44 Axle Build

    Quote Originally Posted by 4.3LXJ View Post
    Got the brackets welded on and calipers attached, tried on a wheel and it fits much better than the aluminum wheels on the XJ. also welded on the spring pads in the correct position since I cannot afford the suspension links of choice right now
    there we go...wrong post before...
    Looks like your getting some work done, keep it going.
    is that a Linde welder in the background ? I had a Linde 300 for a long time, sold it to a friend (he doesn't know to use it) who thought he was going to learn to weld. I should buy it back.Click image for larger version. 

Name:	linde.jpg 
Views:	24 
Size:	26.9 KB 
ID:	14389
    Last edited by bugsjeep; 02-28-2018 at 03:47 AM.

  10. #40
    Join Date
    Sep 2009
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    Chico, CA
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    Default Re: My Dana44 Axle Build

    The color was right, but it is an L-Tec Migmaster 250. Nice welder, but can't buy parts locally. When I bought it there was a couple of dealers in the area
    230 hp 4.3L Chevy
    Built 4L60E with manual lockout
    Atlas 4 speed
    Griffin radiator
    On board air
    Warn 9.5ti on custom bumper
    7.5" RE front and bastard pack rear on custom long arms
    30 gal gas tank
    lockers
    And a bunch of other stuff

  11. #41
    Join Date
    Sep 2009
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    Chico, CA
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    Default Re: My Dana44 Axle Build

    Next part of the project is brake lines for those fancy brakes I put on. I bought some brake line and started bending. But you first have to be able to tie them down. So I made these little clamps. This one will accommodate a 3/16 and 14" line
    Attached Thumbnails Attached Thumbnails IMG_2065.jpg  
    230 hp 4.3L Chevy
    Built 4L60E with manual lockout
    Atlas 4 speed
    Griffin radiator
    On board air
    Warn 9.5ti on custom bumper
    7.5" RE front and bastard pack rear on custom long arms
    30 gal gas tank
    lockers
    And a bunch of other stuff

  12. #42
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    Default Re: My Dana44 Axle Build

    To use them, you just tack the lower part to the axle housing somewhere. Shown here is the brake line and new breather line.
    Attached Thumbnails Attached Thumbnails IMG_2067.jpg   IMG_2068.jpg  

    230 hp 4.3L Chevy
    Built 4L60E with manual lockout
    Atlas 4 speed
    Griffin radiator
    On board air
    Warn 9.5ti on custom bumper
    7.5" RE front and bastard pack rear on custom long arms
    30 gal gas tank
    lockers
    And a bunch of other stuff

  13. #43
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    Default Re: My Dana44 Axle Build

    Here is the finished brake line installation. Instead of having the rubber brake hose come off the housing, it will come off the top of the truss. This allows me to have a shorter brake line bouncing around there when running leaf springs and when I go to coils, the hard line will come down the top link which will keep the brake hose completely out of harms way
    Attached Thumbnails Attached Thumbnails IMG_2072.jpg  
    230 hp 4.3L Chevy
    Built 4L60E with manual lockout
    Atlas 4 speed
    Griffin radiator
    On board air
    Warn 9.5ti on custom bumper
    7.5" RE front and bastard pack rear on custom long arms
    30 gal gas tank
    lockers
    And a bunch of other stuff

  14. #44
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    Jun 2009
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    Sandy Level VA
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    Default Re: My Dana44 Axle Build

    Tell you what I'm going to ship you my 9 inch I need you weld on new perches and shock mounts for my my and then I'll ship you the front d44 for you to finish
    91 aw4 Dana 30 and 8.8 with 4.56s, 6in rough country long arm kit, hd offroad shackle relocation, 33s, Va fan full width front bumper, brown dog poly motor mount to go with a fresh long block.

  15. #45
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    Default Re: My Dana44 Axle Build

    Ha Ha That is a long trip to the left coast Finney. I have a D44 I am working on too
    Last edited by 4.3LXJ; 03-01-2018 at 09:54 AM.
    230 hp 4.3L Chevy
    Built 4L60E with manual lockout
    Atlas 4 speed
    Griffin radiator
    On board air
    Warn 9.5ti on custom bumper
    7.5" RE front and bastard pack rear on custom long arms
    30 gal gas tank
    lockers
    And a bunch of other stuff

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