How to: Vacuum Disco Elimination, Axle Tube Sleeve Fix, ubolt eliminator - 56K beware - JeepForum.com
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Unread 06-08-2009, 07:48 PM   #1
Joe Dillard
Electric Chair Operator
1991 YJ Wrangler 
 
Join Date: May 2004
Location: King George, VA
Posts: 12,459
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”.

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:



View from underneath:



View from the back:



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:



Beginnings of the repair:



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.


I secured the Jeep on jack stands & pulled my tire, then started to remove the Warn hubs:




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



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Unread 06-08-2009, 07:49 PM   #2
Joe Dillard
Electric Chair Operator
1991 YJ Wrangler 
 
Join Date: May 2004
Location: King George, VA
Posts: 12,459
Next was to remove the Warn passenger side axle shaft:



Remove the steering links from my MORE steering bracket:



Remove & tape up the axle breather & ARB fitting:



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



Next up was to remove the ubolts & spring plates:



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.



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:



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.



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:



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.



Vacuum disco gone:

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Unread 06-08-2009, 07:51 PM   #3
Joe Dillard
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1991 YJ Wrangler 
 
Join Date: May 2004
Location: King George, VA
Posts: 12,459
No, I’m not a dentist there are some deburring tools I use to help remove those nasty/pesky burrs after cutting:



Then I removed the old RE axle tube shock mount:



Cleaned up the axle tubes with a flap disc:




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



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



Test fit & checking castor:



Marking the new spring perch for welding:



Fabricating new spring plate and ubolt eliminator plate:

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Unread 06-08-2009, 07:52 PM   #4
Joe Dillard
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1991 YJ Wrangler 
 
Join Date: May 2004
Location: King George, VA
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Since I did a 1” wheelbase stretch some time ago – I needed to drill an offset hole in my spring perch so the centerpin has an exit:



Measure twice – drill once



Ubolt eliminator test fit:



Plug welds complete & beginnings of the sleeve welded:



Spring perch & ubolt eliminator tact welded & angle rechecked:



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





Perch & new lower shock tabs welded:

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Unread 06-08-2009, 07:53 PM   #5
Joe Dillard
Electric Chair Operator
1991 YJ Wrangler 
 
Join Date: May 2004
Location: King George, VA
Posts: 12,459
Nothing ever goes perfectly – right?

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:



That’s better. Notice the ARB crosspin:



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





Drive shaft, breather ARB – check:




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Unread 06-08-2009, 07:53 PM   #6
Joe Dillard
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1991 YJ Wrangler 
 
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Location: King George, VA
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Hubs & tires, check:




Well, that’s about it. This is just the first fitting. I’ll be changing this design in the future, but you get the idea as to why & how it’s done.
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Unread 06-08-2009, 08:15 PM   #7
ghost183
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wow joe...


you actually made it look easier than what i thought it would be.. very nice, and clean!!
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Unread 06-08-2009, 08:39 PM   #8
rustywrangler
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First class work man. Very nice.
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Unread 06-08-2009, 08:44 PM   #9
EnFuegoUno
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Sweet!!!....
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Unread 06-08-2009, 09:22 PM   #10
bartolo
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never thought it could be done nice job and very clean
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Unread 06-08-2009, 09:39 PM   #11
havasu
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I wish I had half the ambition that you have Joe! Great write up!
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Unread 06-08-2009, 09:48 PM   #12
Joe Dillard
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1991 YJ Wrangler 
 
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Location: King George, VA
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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.
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Unread 06-08-2009, 09:54 PM   #13
Brads_nky_yj
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Bout frikin time Dillard!
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Unread 06-08-2009, 11:43 PM   #14
RockWoRM
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I think this shows how a little fab skill and willingness and patience can "get 'er done"!

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


Pic for nostalgia sake.






WRM
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Unread 06-09-2009, 12:15 AM   #15
Joe Dillard
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1991 YJ Wrangler 
 
Join Date: May 2004
Location: King George, VA
Posts: 12,459
That was NOT a "happy camper Kodak moment" for me Randy.

It was certainly nice to have you along to assist/advise/pitch in wherever you could. 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.
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