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-   -   How to: Vacuum Disco Elimination, Axle Tube Sleeve Fix, ubolt eliminator - 56K beware (http://www.jeepforum.com/forum/f12/how-vacuum-disco-elimination-axle-tube-sleeve-fix-ubolt-eliminator-56k-beware-793813/)

Joe Dillard 06-08-2009 06:48 PM

How to: Vacuum Disco Elimination, Axle Tube Sleeve Fix, ubolt eliminator - 56K beware
 
Last year while wheelin’ in Colorado with some friends, I developed a serious crack underneath my passenger side SOA perch. The problem didn’t surface till the next day while I was in Moab doing a relatively easy trail. All the sudden my front axle started making some interesting noises, and looked as if I had balljoint issues at first glance. So Randy (Rock_Worm) and I got out to take a look. Next thing I know, Randy say’s something to the effect – hey Joe, I think I’ve found the problem”. :laugh:

Anyway, we did a trail repair & then towed it back to our campsite in Moab. The following day, Randy, Larry & I welded it back up as a temporary fix so that we could continue wheelin’ for the next week. It has held up fine ever since & has several other trail runs on it – but I wanted a more permanent fix. So, this is where my “Disco Elimination & Axle Tube Sleeve Fix and ubolt eliminator” begins.

Here’s what the initial crack looked like:

Face of the axle tube:

http://www.fototime.com/422CD210A759037/standard.jpg

View from underneath:

http://www.fototime.com/D188D22864FE795/standard.jpg

View from the back:

http://www.fototime.com/F9B0E7457D508B0/standard.jpg

So, back at my campsite, I borrowed a friend of mine’s Lincoln MIG welder and we cleaned up the crack and welded it back as best we could.

My friend Larry, from WA, helping do some welding:

http://www.fototime.com/E701122C1CE5142/standard.jpg

Beginnings of the repair:

http://www.fototime.com/020D0970DA31F00/standard.jpg

Okay, now that I’ve explained how my troubles started – here’s what I’ve done as a more permanent fix. Yea, it’s a HPD30 and some may say; “why polish it?” This fix cost me a grand total of ~$30.00 for the 3”x.250” DOM, including hardware. I already had everything else laying around my garage.

I had a pair of perches, so I got some 3”x.250” DOM and started doing some measuring.

http://www.fototime.com/546016C6DFB0612/standard.jpg
I secured the Jeep on jack stands & pulled my tire, then started to remove the Warn hubs:

http://www.fototime.com/2FBB1B4622D5E55/standard.jpg
http://www.fototime.com/D34A47C85196707/standard.jpg

Then I removed the Warn spindle & Vanco calipers and rotor:

http://www.fototime.com/B3EDBACEAE8C063/standard.jpg

Joe Dillard 06-08-2009 06:49 PM

Next was to remove the Warn passenger side axle shaft:

http://www.fototime.com/8E0EC9288409BF1/standard.jpg

Remove the steering links from my MORE steering bracket:

http://www.fototime.com/CB86BC11D037425/standard.jpg

Remove & tape up the axle breather & ARB fitting:

http://www.fototime.com/7BCADFCBA2BB76E/standard.jpg

Then the drive shaft and secure it out of the way:

http://www.fototime.com/619779F1B7ABE8A/standard.jpg

Next up was to remove the ubolts & spring plates:

http://www.fototime.com/1CF66D069551953/standard.jpg

HPD30 removed. You’ll notice I didn’t bother removing the brake rotor, hub spindle etc from the driver side since there was no need.

http://www.fototime.com/24C89D8D6E286DC/standard.jpg

Now it’s time to start chopping up the disco housing & completely remove it so I could sleeve the tube with the DOM.

I opened up the vacuum disco block-off plate and stuffed a rag in it so that debris wouldn’t enter the tube as I cut portions of the tube off:

http://www.fototime.com/AB77DF9B1BF2A15/standard.jpg

As you’ll notice here – I cut off the tube close to the axle perch so I could take advantage of as much of the axle tube as possible when I sleeve it.

http://www.fototime.com/73877CAE797B57A/standard.jpg

Here’s the outer portion of it that I’ll reuse. Notice how I marked the tube so that when I reattach it – my caster should be correct:

http://www.fototime.com/7F7ECA0DB976EAE/standard.jpg

Next up, I opened up the disco housing block-off plate & move my rag to the inside of where I’d be making my second cut.

http://www.fototime.com/E6E0EE0E6168E77/standard.jpg

Vacuum disco gone:

http://www.fototime.com/EF7EDA74681EBE0/standard.jpg

Joe Dillard 06-08-2009 06:51 PM

No, Iím not a dentist :D there are some deburring tools I use to help remove those nasty/pesky burrs after cutting:

http://www.fototime.com/925EB0FF46077AB/standard.jpg

Then I removed the old RE axle tube shock mount:

http://www.fototime.com/C7E601B5313441B/standard.jpg

Cleaned up the axle tubes with a flap disc:

http://www.fototime.com/8B99BACF2754694/standard.jpg
http://www.fototime.com/47EF8AE8E41305F/standard.jpg

Test fit of the new sleeve, perch & rechecking castor with my angle finder:

http://www.fototime.com/BDC1000F6FA5342/standard.jpg

I drilled some holes in the new sleeve so I could plug-weld it in place:

http://www.fototime.com/5EAD1ECC10C4246/standard.jpg

Test fit & checking castor:

http://www.fototime.com/679A12F68E2777E/standard.jpg

Marking the new spring perch for welding:

http://www.fototime.com/FA43A5FC0EB5ADD/standard.jpg

Fabricating new spring plate and ubolt eliminator plate:

http://www.fototime.com/E3B94CF63046E0D/standard.jpg

Joe Dillard 06-08-2009 06:52 PM

Since I did a 1Ē wheelbase stretch some time ago Ė I needed to drill an offset hole in my spring perch so the centerpin has an exit:

http://www.fototime.com/27835817EDDA8E7/standard.jpg

Measure twice Ė drill once ;)

http://www.fototime.com/A1BEA1CF778A951/standard.jpg

Ubolt eliminator test fit:

http://www.fototime.com/655E29DE28A536B/standard.jpg

Plug welds complete & beginnings of the sleeve welded:

http://www.fototime.com/9A288CA58811C37/standard.jpg

Spring perch & ubolt eliminator tact welded & angle rechecked:

http://www.fototime.com/6F583DF0F37D629/standard.jpg

Starting to paint/reassembly & getting ready for final welding:

http://www.fototime.com/9CAF8D22FD040DB/standard.jpg
http://www.fototime.com/B6859207F0FDE23/standard.jpg
http://www.fototime.com/E0647F52F9EA32F/standard.jpg

Perch & new lower shock tabs welded:

http://www.fototime.com/CE5F4EFF68A14E0/standard.jpg

Joe Dillard 06-08-2009 06:53 PM

Nothing ever goes perfectly Ė right? :laugh:

I checked the tube and noticed that the rag I put in it earlier was accidentally left inside. No big deal, I took a broomstick handle & retrieved it:

http://www.fototime.com/7FEE0E6F25EE8DF/standard.jpg

Thatís better. Notice the ARB crosspin:

http://www.fototime.com/4DB91B63CD63C79/standard.jpg

On to the reassembly. Brakes, steering, spindle, shocks, check:

http://www.fototime.com/14444312D47B45F/standard.jpg
http://www.fototime.com/6D327AF0CA62C35/standard.jpg
http://www.fototime.com/2611620AC146C8A/standard.jpg

Drive shaft, breather ARB Ė check:

http://www.fototime.com/B65EC31CCC35F50/standard.jpg
http://www.fototime.com/D1B8DEA3F124913/standard.jpg
http://www.fototime.com/6F4C1D875A7E611/standard.jpg
http://www.fototime.com/A69BDBE5DAB449F/standard.jpg

Joe Dillard 06-08-2009 06:53 PM

Hubs & tires, check:

http://www.fototime.com/C018CFCF15BE2FA/standard.jpg
http://www.fototime.com/6AA7E5F63356B08/standard.jpg

Well, thatís about it. This is just the first fitting. Iíll be changing this design in the future, but you get the idea as to why & how itís done.

ghost183 06-08-2009 07:15 PM

wow joe...


you actually made it look easier than what i thought it would be.. very nice, and clean!!

rustywrangler 06-08-2009 07:39 PM

First class work man. Very nice.

EnFuegoUno 06-08-2009 07:44 PM

Sweet!!!....

bartolo 06-08-2009 08:22 PM

never thought it could be done nice job and very clean

havasu 06-08-2009 08:39 PM

I wish I had half the ambition that you have Joe! Great write up!

Joe Dillard 06-08-2009 08:48 PM

Thanks guys. :)

I must admit - it was time consuming, and I could have done thing better in certain areas. I'll address a few items in the next couple days. EG: paint, better hardware, and a couple other items.

I took it for a test drive today. Other than the need to adjust my drag link, everything seems fine so far.

Brads_nky_yj 06-08-2009 08:54 PM

Bout frikin time Dillard!

RockWoRM 06-08-2009 10:43 PM

I think this shows how a little fab skill and willingness and patience can "get 'er done"! :thumbsup: :thumbsup:

I am currious where ya came up with the u-bolt eleminator idea? Looks cool, though. :)


Pic for nostalgia sake. :D


http://img25.imageshack.us/img25/1695/1001476i.jpg



WRM :cheers:

Joe Dillard 06-08-2009 11:15 PM

That was NOT a "happy camper Kodak moment" for me Randy. :rofl:

It was certainly nice to have you along to assist/advise/pitch in wherever you could. :cheers2: Looking forward to our next run together.

As far as the ubolt eliminator approach I did goes - I thought "what easier way is there than this?" Plus, it's cheap, easy to make, and effective.

I have seen a few designs that are a little bit like mine, but not completely.

What I like alot about it is that it seems I can torque each bolt to specs easier and that the bolts are out of harms way a little better than before.


The time now is 05:03 PM.

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