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Old 02-23-2012, 07:31 AM   #1
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Default 8.8 beef up.

Well I picked up an 8.8 out of an exploder a week or so ago and I thought I would post up some of the stuff I fabbed for it. I know the 8.8 is a popular swap, so here are some goodies you may want to make for yours. I started by stripping all the old brackets, the brake line was rusty, so that went too. This baby has 4.10 gears and Trac loc, I only paid a hundred bucks for it.
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Old 02-23-2012, 07:37 AM   #2
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Went to work fabricating a truss and welding the tubes. I gutted the axle before I did this, I diddnt go into detail on that. I wanted to keep it strictly what fab was done. I have more details in my build thread. The truss is just 2" structural tube. When I weld the casting, I dont do anything fancy. Warm it up a little, if its hot out I will skip this step. Weld it then let it cool. Ive welded alot of cast, never a crack.
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Old 02-23-2012, 07:41 AM   #3
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Next was a ss diff cover. 5/16 for the ring, 1/4 for the rest. I used 5/16 for the ring so after I weld it all up I can have extra to machine flat so it doesn't leak.
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Old 02-23-2012, 07:45 AM   #4
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Then we get to the u bolt eliminators, these I just started, but ill have em done soon, may mount the axle Saturday. But I still need to make shock mounts. Those pads are 2 x 4 box steel I radiused to fit the 3.25" axle tube.
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Old 02-23-2012, 12:36 PM   #5
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Looks good man. That's a cool truss idea
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Old 02-23-2012, 06:51 PM   #6
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looks good nice welds man
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Old 02-23-2012, 07:04 PM   #7
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Thanks guys.
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Old 02-23-2012, 11:39 PM   #8
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looks good. out of curiosity, how hot do you heat the cast and are you just welding it with a mig? i plan on finally getting around to welding my 8.8 saturday and would like your input.
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Old 02-24-2012, 12:58 AM   #9
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Excellent Job Keep it up. I'm running an 8.8 in my MJ as well. Did you plan on picking up an adjustable proportioning valve for the brakes?
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~http://www.cherokeeforum.com/f46/my-...doing-d-19146/

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~http://www.cherokeeforum.com/f46/198...e-path-167502/

1987 Jeep comanche- 4cyl cheap dd fixer upper
~http://www.cherokeeforum.com/f46/198...-2-4x4-181856/
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Old 02-24-2012, 05:36 AM   #10
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Quote:
Originally Posted by That Jeep Guy XJMJ
Excellent Job Keep it up. I'm running an 8.8 in my MJ as well. Did you plan on picking up an adjustable proportioning valve for the brakes?
Im going to try it as is with the breaks. I having I diddnt use for the nova, so I can put it in if I need it. Did you use one?
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'95 yj
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Old 02-24-2012, 06:16 AM   #11
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Quote:
Originally Posted by malibu71
looks good. out of curiosity, how hot do you heat the cast and are you just welding it with a mig? i plan on finally getting around to welding my 8.8 saturday and would like your input.
First thing is, it needs to be very very clean. Yes I used a mig. A Lincoln weld pak10. Only runs off 110, but its a beast. Next step is to groove out where the tube and housing come together with a cut off wheel. Not too deep, maybe 3/16 at most. You are just trying to get a nice clean area to lay the weld. Then grind all the metal around it clean. I like to weld my ground clamp to the tube, it makes a good ground and its just easier. Set the axle on jackstands, so it can be rotated easily. Now heat the cast with a rosebud torch tip, not too much. You will see all the moisture dry up and then go a little more. Some guys get it hot, not me. Then I weld it with the welder real hot, rotating it with my knee as I weld. I weld it hot with a 110, with a 220 I would prolly run the voltage around 22 on my Miller.
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Old 02-24-2012, 08:16 AM   #12
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Quote:
Originally Posted by Trev1006 View Post
First thing is, it needs to be very very clean. Yes I used a mig. A Lincoln weld pak10. Only runs off 110, but its a beast. Next step is to groove out where the tube and housing come together with a cut off wheel. Not too deep, maybe 3/16 at most. You are just trying to get a nice clean area to lay the weld. Then grind all the metal around it clean. I like to weld my ground clamp to the tube, it makes a good ground and its just easier. Set the axle on jackstands, so it can be rotated easily. Now heat the cast with a rosebud torch tip, not too much. You will see all the moisture dry up and then go a little more. Some guys get it hot, not me. Then I weld it with the welder real hot, rotating it with my knee as I weld. I weld it hot with a 110, with a 220 I would prolly run the voltage around 22 on my Miller.
thanks alot man, we will see how it turns out tomorrow afternoon!
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Old 02-24-2012, 08:59 AM   #13
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Quote:
Originally Posted by Trev1006 View Post
Im going to try it as is with the breaks. I having I diddnt use for the nova, so I can put it in if I need it. Did you use one?
for mine no... only beacause i don't daily drive it. However if i was planning on driving it allllllll the time i would put one in... the rears for me only really lock up when i slam the break pedal. Mostly when i'm driving in the snow, or on a dirt road is when i will actually notice the rear locking before the fronts.
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I bumble bees!
Having the most capable rig is the battle...... Being a better driver is the War!

1987 jeep comanche-10" lift long arms
~http://www.cherokeeforum.com/f46/my-...doing-d-19146/

1986 jeep comanche- bone stock 2wd to 4wd H.O
~http://www.cherokeeforum.com/f46/198...e-path-167502/

1987 Jeep comanche- 4cyl cheap dd fixer upper
~http://www.cherokeeforum.com/f46/198...-2-4x4-181856/
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Old 02-24-2012, 09:07 AM   #14
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Well I may throw it in then. Even with my stock drums my rears lock and slide if I stab the brake pedal.
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6.5" tereflex short arm, 33"BFG MT's ,10k warn, rollbar, oba

'95 yj
450 horse sbc.....always broke...
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Old 02-24-2012, 09:12 AM   #15
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Quote:
Originally Posted by malibu71

thanks alot man, we will see how it turns out tomorrow afternoon!
Try to keep it at such am angle that you are welding down hill all the time. Your welds will come out alot nicer. Remember to not just hold the wire right in the crack. For this I did about a 3/8" side to side motion while also keeping my weld puddle pushed up so I doesn't drip or sag. I like to keep the handle of the gun below the weld pointing the tip up. Then just roll the axle and repeat, always welding down.
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'95 yj
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Old 02-24-2012, 09:12 AM
 
 
 
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