SeriousOffroad

I'd cut it off and start over.

PocketsEmpty

First of all, beautiful work getting that thing straightened out. That started out as a fairly crappy hand you were dealt, but you played it anyhow. Good job.

Secondly...I'll have to agree with Serious. I wouldn't even call that half-assed, more like quarter-assed, if that....Good luck! No updates on the D30? Maybe make it a 30-spline?

eggdashure

Thank you. Took a lot of effort to keep at it. Now that it almost done, I'm glad I stuck with it.

If I start cutting that brace, I will probably just leave it off. What do you guys think? Am I better to leave it as is, or chop it off?

PocketsEmpty

Depends on your wheeling style and what tires and such you're going to be running...chances are you'll be just fine without it.

eggdashure

I think I'll just chop it off, this thing already weighs a ton...might as well try to limit the excess (not to mention ugly) weight. Plus, it may interfere with my exhaust. I'd rather not modify that anymore than I already have.

PocketsEmpty

Get the grinder ready, haha

eggdashure

I gotta give props to my little $15 angle grinder from Harbor Freight, I've beat the tar out of that little thing and it keeps going.

If that brace is anything like the rest of this guys work, should release pretty easily. His welds did not penetrate very deep at all.

eggdashure

Note to self...tack weld better than you did tonight!

So after an hour of tweaking and prodding, I finally had everything where I wanted it and tack welded up the perches. As I was lowering the axle down to pull it out...the axle tilted to one side and fell off the jack. On the way down, the edge of the jack knocked off the perch. Then the other side did the same thing.

I laughed at myself for a bit...but it wasn't a haha laugh. It was like at the end of a cartoon when the character starts laughing hysterically just before running away.

Serves me right for doing it alone...no one around to help right now.

I'll pick it back up tomorrow, but here are a couple pics where I set the pinion angle.





15 degree's was the sweet spot.

Barrelmaker

Subbing, going to be putting am 8.8 in mine, once i save a few more $$ to do it right.

eggdashure

Well, I finally got the drive to get back out and work on finishing the axle.

Everything is welded up now:





I need to drill out, grind out just a little of the spring perch so the U-Bolt can fit through just like the old system. Hoping that won't compromise the perch at all...but I highly doubt it. Very stout all around. Putting the U-Bolt through here should also keep the nut from ever spinning off. My god those things were tough to get tight! I had one wrench in my hitch with cheater bar on another wrench on the other end.

A couple more shots:





So what's left?

Run the brake lines, I'll attach the soft lines to the spring perches and run the hardline across the axle.

Attach the Spicer (Going to Lowe's now for bolts)

Hook it all up to the Jeep.

Bleed the brakes. Fill up the diff.

Drop it in and check/pray for clearances all around. Looked good before. Still worried about the shocks being too long though...

Remove the front drive shaft (left in for added safety so the Jeep didn't roll around).

Profit!!!

eggdashure

Finished off the brake lines tonight and bolted 'er up to the Jeep. Of course, SURPRISE!!! Wrong bolt size...3/8th's = too small to bolt up the spicer to the 8.8. So back to the store tomorrow.

Tomorrow: Bleed the brakes, bolt up the spicer and rear drive shaft, attach the wheels...DONE!

PocketsEmpty

You really think it's gonna be that easy?

Keeping the brace I take it?

eggdashure

Of course!!!

Not...

Brakes continued bleeding after I bled them. Surprise!!! Leak in the drivers side soft line.

Yea, keeping the pointless piece of metal going across the pumpkin, or as you call it "brace". It fits and I ended up being lazy.



You can see the claw marks on the floor where the 8.25 was trying its hardest not to be pulled.

Everything is done, just have to get a new soft line for the drivers side and re-bleed. Project for tomorrow night though.

Oh...and for anyone who attempts this conversion, it's ok that the drivers side sits lower than the passenger when you jack it up at the pumpkin. Remember the 8.8 is not centered like the old axle. Yes, I panicked a little before I realized what was going on.

Ready for the 8.8 to be done. I will have to take a break and build up funds before I move on to the D30. That needs quite a bit of work too. Ball joints, carrier (need to shim it, check patterns and get a new bearing installed), hubs, bushings, but at least there is no welding and measuring involved on this one.

jmu427

How did you handle the e-brake cables? Did your current shocks work out?

eggdashure

E-Brake...is not completely handled yet. But, the plan is to use the setup I had on my 8.25. I basically got some really small u-bolts and looped the cable through it.



It fit's around the connection point fine and when tightened, it's close enough on all sides to avoid slipping off. The cable does not seem affected at all.

The Shocks work, I need to finish off the brake mess tonight and then tomorrow I'll probably pull out the camper and see if I bottom out or not. I tried to get the shocks as outbound as I could for maximum length...but it looks like I only have 2ish inches of up travel at rest. Once the weight of the camper drops down...may only have an inch. I have a home-made bar pin setup on top. I might be able to do away with that and gain another half inch. We shall see.