Beefing up a Dana 30/44
 

so, were doing a pretty serious build on a rubicon JK. and part of the build includes adding some beef to the front Dana44 axle, which as you know has the same tubes and outers as a dana 30.

along with regearing to 5.38's we are adding EVO sleeves and EVO outer C bracing. so its pretty much like an internal truss and adds a tremendous amount of stregth to the axles. also adding some LCA mount skids

the kit
http://i12.photobucket.com/albums/a2...f/IMAG0516.jpg

the patient
http://i12.photobucket.com/albums/a2...f/IMAG0510.jpg

started with tearing down the front end. removing the axles shafts and hub assembly.
http://i12.photobucket.com/albums/a2...f/IMAG0514.jpg

then drilling a series of holes into the tubes, i drilled a total of 17 1/2" holes throughout the axle. (not fun btw)
http://i12.photobucket.com/albums/a2...f/IMAG0520.jpg
http://i12.photobucket.com/albums/a2...f/IMAG0519.jpg

then cleaned up around all the holes and the outers, took it all down to bare metal. then inserted the sleeves and started welding up all the plugs in the shaft, and welding the outer gussets and tube ends.
http://i12.photobucket.com/albums/a2...f/IMAG0521.jpg
http://i12.photobucket.com/albums/a2...f/IMAG0012.jpg
http://i12.photobucket.com/albums/a2...f/IMAG0523.jpg
http://i12.photobucket.com/albums/a2...f/IMAG0522.jpg
http://i12.photobucket.com/albums/a2...f/IMAG0015.jpg
http://i12.photobucket.com/albums/a2...f/IMAG0013.jpg
http://i12.photobucket.com/albums/a2...f/IMAG0011.jpg

and done...with the exception of paint
http://i12.photobucket.com/albums/a2...f/IMAG0005.jpg
http://i12.photobucket.com/albums/a2...f/IMAG0007.jpg
http://i12.photobucket.com/albums/a2...f/IMAG0008.jpg

overall, i like it alot. seems extremely beefy and a great upgrade to consider for any dana 30 or jk/tj d44. also comes with new rubber o-rings to seal up the outer end of the shafts, and a grease fitting for the o-ring.

that is awesome. didn't know the outer of the jk d44 were same as d30. seems to kinda defeat the purpose of a bigger axle though. which probably why you did this mod. good upgrade.

very nice. I think all you need to do for an XJ dana 30 is cut down the inner sleeves because its a little narrower then the JK front.

you may not have to, the sleeves end slightly after entering the carrier housing. so you have a little room to play with.

i may do some measurements monday if i dont forget.