I added inner sleeves, & will add in the C gussets when ball joint time rolls around. Anyway I have these gussets waiting to go on,
http://www.synergysuspension.com/Syn...t-p-21273.html
Inner sleeve was 2" .120 wall dom. Add 3 rousette welds front, 2 top, and 3 back on the long side. Stub side got 1 front, top & back of the tubing &
welded the ends of course. My upper control arm mount is boxed in & Currie mini skids welded on!
I would look at boxing in the upper control arm mount & getting mini skids for you control arm backets as those will usually go first

I'm on 31's, steelies & its a expo rig so I figured with all the weight & such added, it was a good idea..if only for insurance of it not breaking lol.

 

And how much time and money have you spent on your D30 so far? Just curious

 

$16 for the currie mini skids, 1/8th plate I had lying around for the upper mount & its 100% boxed it...no space anywhere, it wraps all the way up! 30 for the piece of 2" DOM and 72 for the outter C gussets which are purely overkill & only bought because I liked the looks. I could of made my own but truely liked how the Synergy ones boxed everything in!
I have about 125 tops into my D30 & over half that went into the outter C gussets cause I liked the looks Probably cost some about 150 to do it all at full prices, most people spend like 90 on a diff cover they will bearly use...so everyone has an agurement thats right in their mind!


I will only ever run 33's as this is an expo rig & at that it'd be a 235/85 or a 33x10.5. For what I'm doing my axle setup is perfect & won't bend or break, its stronger & more durable than it was from the factory! Preferably I think the stuff I've done is super cheap and should be done if you plan to keep your D30. For someone like me, never going over 35's, its perfect!
I honestly rebuilt the entire diff when all this took place, new bearings & seals! Now all I need is Alloy tube seals and I'll be done with it.


My c8.25 is a 29spline..cost me 116 from pick & part. A d44 would cost me about 400. I rebuilt my whole diff, added Zj disks & a simple 1.5" .120 wall mini truss, also welded the tubes to the 3rd member. And I will be cutting and raising my shock mounts shortly! I did all this for just under 400
Again not needed but I had the 1.5" laying here so I did it. And again its stronger and overkill than I need which is what you want when you 150+ miles in the desert. I added maybe a total of 40lbs to the entire jeep to know that its going to hold up to abuse if needed!

 

Wow.

 

If I were to go 35's..I would honestly look for tons! I would never go 44/9" because you will still break it just the same! Its not a huge upgrade! Most running that setup are on chromos...so if I were going that route, I would pick up a 14bff & a D60 and go to town & I would do it leaf sprung honestly


But for what I'm doing my **** works, and cost me almost nothing..I got a c8.25 29spline, which is about equal to a d44 other than being a c-clip..wish I would of done a 8.8 now but oh well. Maybe in the future!
I rebuilt the c8.25 & added disks and Kj ebrake cables which cost me 70 alone lol..for less than I could get a decent d44.

 

Hey, if you want to gusset the C's, go ahead. It won't hurt anything to add em, and the peace of mind is well worth the $40. That said, realistically, you would bend the axle tube before the C's anyway so really what is needed is a full axle gusset kit. Tire size aside, you say you do beach blasting mostly and I've seen guys "smile" their front axles with stock tires at the dunes so I would definitely gusset the axle!

 

JK dana 30 axles are made from ductile steel. It is brittle and they need to be reinforced.
Older Dana 30s are cast steel. They don't need gussets...

 

On 31's you will most likely bend the housing before the C's! I would just plate the upper CA mount & run mini skids & be done..if your gonna do more than wait and save like 200-250.

Get alloy axle seals, 2" .120 dom tube, outter C gussets, mini skids & a small peice of metal for the upper Ca mount and do it all..never worry again!

 

wow what. I'm getting tired of you and you're a disrespectful mod.

 

OP, for your intended use i would says the C gussets are a little over kill, but it wouldn't hurt anything to put them on. i plan to do C gussets, because i have 1/4" plate at my disposal and because i would like to beat on my jeep and not have to worry about the inner Cs bending. i've witnessed them bend, and it pretty much means you would have to get a new housing. i think making the gussets is cheap insurance.

 

ive got a friend with a 99 xj that was 100% stock when he bought it and the c's were already bent, i ordered gussets for my xj the other day and plan on doing the inner tube sleves soon. just my 2 cents worth

 

Smiled the front axle, ouch that sucks. Im thinking of doing the axle tube sleeves considering the "not so bad" price from quadratec. And along with the C gussets. OVerkill? Maybe, but in a Jeeps case, stronger is better. Agree?

 

Not overkill at all ive seen so many of these bent wish just 31's and mild offroading and seen some jeeps bone stock with bent c's so i would say its a great thing to do for what little it costs