2008Rubicon If I do gears, do front axles too?

If this worked... Pic is of the "bomb shell kit" - outer sleeve, long tube side. Showing that it isn't knoched for the stabilizer link tab on the axle housing. Was the same on both ends.

Oh-Oh -Oh! it worked the first try! Cool!
*


A trip to the milling machine....

And walla - notched like it needed to have been. Man, it's nice to have the toys to work with. For the record - I am not a machinist, but 2~3 years ago I bought the mill and South Bend lathe and have learned to do "thngs" with them. Have never used or ran any of them before, but am doing ok with them for what I want / need.

Well, my camera skills could stand some improvement....
**



Clamped in place ready to weld. Is to where I am now. Had to "fit" the clam-shell on the other end too.



Short side also fitted, clamped and ready to weld.
**


Ends are Tig Welded....

Looking good!

I believe 90~140 is the recommended gear oil.

Well, work so far.... About ½ welded.

Should I also make a truss from the pumpkin to about ½ way up the upper control arm bracket, and continue from the other side to just under the spring perch? I have some ¼" plate I can cut something out of. And of course some webbing/gussets worked in. What you think? And start at the spring perch on the short side, go over the top, and around control link connection on top of the pumpkin.

If you've got the time, I say, "hell yes, go for it!"

It's looking good.

I can make time. Figured I'd be down for 2 weeks, Hope it's not longer.
**
**

**
**
Something I made some time ago to help me, is working well for this project.
**
Still need to get the rear axle out to take down for the gear change.
**
By the way---- Torque Spec's for anything I need to Torque? (Anything - front or rear - exernal to the pumpkin.) Thanks... Me, Myself, I...

Adding a truss now.

*
Used a profile gauge and cardboard cutouts to get the approximate shape to fit the pumpkin shape to the square tube. I painted the insides after media blasting and welding the speed holes so won't rust from the inside at least. I am using Eastwood Rust Encapsulator paint for all base coats, and will be using the 2k Ceramic Chassis Black for the top coat...

*
From the underside - you can see that the fit is excellent for welding.

*
On the far end... more speed holes.

*
I machined a knoch

*
To fit like this....

*
But didn't like the fit, so welded the knoch back up (focus isn't good...)

*
Ended up lopping off the tab and welding it to the truss...

*
And the Eastwood Paint inside. Will be welding a top plate onto it. Letting the paint dry....

*
This is the other end, and is where I am as of today. All welding on the pumpkin is done a little at a time - an inch at a time usually.

*
All approximate shaping and speed holes were done on the milling machine.


Finished shaping on the 2" belt sander. Started out with a piece of 2" bar stock I had. Chamfered the edges for better weld penetration.
*

So, have been busy. Still need to paint the inside of the inner tube sleeves. Have some Tom Woods Drive Shafts ordered too. Got the hardware, soon as Dana's are back under and jeep weight is on them, will take the measurements and send to them for the correct lengths. Getting the 1350 series - front and back.
*

Dang man, you ain't messing around!

Good work!

man, sure wish i had shop tools like that


I would love to try my hand at all sorts of stuff with a mill and lathe




looking great btw

The final set....

*
The "C" gussets that came with the Bomb-Shell kit was welded on first, then I split and welded the "Poly-Performance" "C" gussets over the top of them - since they went up higher, and also had the lower to add.

*
Shot of the lower "C" gusset.

*

*
*
I bought this truss for the front, but couldn't figure out how to use it. So.... I modified it and added it to the rear axle housing since it was out.

*

Not shown, or installed yet, I have 2 flat bars that bolt to the top, bend 90° down and attach to the two outermost bolts on the diff cover.
*

*

After getting a couple issues fixed, is working well now. Happy with it so far.
*
Along with the 5.38 gears, I also installed "Tom Woods Driveshafts" - 1350 series I think it was. Pic's with new and originals.
*

*

*
Over kill? Did I forget anything? Kitchen sink maybe? Rockwells?
Working on winch mounting now. Have a new thread started there if haven't noticed.... And need to start a new thread on the head liner I'm doing too.... Will this ever end????
*
Some of the threads I've read show the finished result, but not so much on details on how it got there. So, I may post a lot of pics with the "little" things/steps I've done. Hope this helps anyone else considering things I've done. This is my first experience with 4wd. So far, I think I've done ok....