Trev1006

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.

Trev1006

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.

Trev1006

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.

Trev1006

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.

brookhart63

Looks good man. That's a cool truss idea

ZoMbIeCuStOmS

looks good nice welds man

Trev1006

Thanks guys.

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.

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?

Trev1006

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?

Trev1006

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.

malibu71

thanks alot man, we will see how it turns out tomorrow afternoon!

That Jeep Guy XJMJ

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.

Trev1006

Well I may throw it in then. Even with my stock drums my rears lock and slide if I stab the brake pedal.

Trev1006

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.