I'm sorry for the lag guys. Quite a bit of views on this thread, so obviously there's some interest. Weeks are busy, time is short, I've got plenty of updates for ya though.
Let's start with the condition of the axles that came in it. D30/d35 c-clip, both caked with a 1/4 of dirt & engine oil..oh yes she leaks like crazy. Front brakes had 3/16-1/4" deep grooves from god knows what. 1 rotor almost worn through. The rear was metal on metal and leaking diff fluid (wheel seal). It also had a total of 4 broken wheel studs between both sides in the rear.
I knew I wanted to regear to 3.55s anyway for a poor mans regear. Turns out I had a perfectly good d35c (non c-clip) with 3.55s in the shed. Nice thing I got it for free & its practically new. Brakes, seals, and track lock rebuild
& no more c-clip action.
This axle got a 1.5" .188 mild truss. Plated in with 1/8" plate. We also welded the tubes on it for reassurance. It was on hand & cheap & easy to do for the extra reassurance. On 235s and a factory track lock I doubt we'll brake it.
The front was a craigslist find. 40 bucks for a complete ready to run , caliper to caliper d30 non disco high pinion with 3.55s. I couldn't believe it, thought it would be junk. Turned out to be in amazing condition, front brakes within a couple hundred miles and brand new hubs. Bushings were toast but those were on the list of replacements anyway.
This axle got some fab action as well. 1.5" .188 wall mild truss with 1/8" plate. 1/4" outter c gussets, boxed upper control arm mount and 1/4" control arm mini skids & a trimmed track bar bracket to prevent binding at droop. Oh and some custom shock mounting copied over from the jeepspeed guys.
The axle also received a set of big joint 760 shafts & a lockrite. The stock small joint shafts are now spares.
I sold the d30 with 3.07s, with the small joint shafts for 125 & the old D35 got me its scrap weight. So far I'm into the axles for a portion of the locker cost..yes a portion. Basically bought it & the upgraded axles & what not for just over 100 bucks. Deeper gears, brand new brakes, 760 shafts, locker & LSD & a spare set of shafts for the d30.. Not to shabby ehh?
Went from, 3.07s & 215s 1900rpm cruise at 65mph to 235s & 3.55s for a 2150rpm cruise at 65mph...cheap mans regear that works perfect when you stick to 235s or 30s.
don't you love simple, small & cheap builds? Souls bump me a bit in mileage as well.
A few pics of the fab work.... Looks normal right? Look closer just past the knuckle where the brake mounts...........aww some for of shock mount.
Now "double take". Custom lower shock mount, plated/boxed it all in with 1/8" for strength. You can also spy the c gussets in this picture. Sorry for the slit... Those are ruffstuff mounts, 1/4" thick and they rock! So much nicer than using tabs. We put a thick socket on the axle bolt, set ruffstuff mount on socket and tacked it. Removed socket and fully welded it in. Popped the socket back on and it works perfect, can get the bolt in and out without a struggle. Only issue Is you must remove the shock before you can remove the arm/bolt which isn't to big of a deal for me. The pros outweigh the single con by far!
Obviously it's got a long shock in there. Jks stud adapters up top with 11" travel Bilstien 5100s. You can also spy the 2" extended bump stops. At full bump, metal to metal I've got 3/4" shaft showing. At full droop I've got 10" shaft shocking. It's exactly .8 before full extension. Full droop is currently limited by the stock arms binding on the mounts which will not change. It stops the drop and it works perfectly every time! I intent to keep the stock arms 100%..remember "double take grocery getter". Stock looking but very surprising...will probably add in a set of wj arms when I find a good set..extra security with them being boxed in. Just nicer over all since she'll be on stock stuff forever...no real need to go bigger.
The lift has been changed from the original 3" setup. It was rough riding according to the other half and it needed an adjustable track bar & lowers to work properly. It's now rocking a OME 934 (v8 zj coil) with a extra 5/8" isolator for a total of 2.5" up front. In the rear its a stock HD replacement pack with a ranger main leaf added & the overload replaced with a stock xj 3rd for a bit extra weight carrying capacity. Works very & quite soft. Sits level at 2.5" above stock as well. Going to add a mj shackle I have laying here to bump it up a wee bit once the springs settle, it will also help rear flex. Its got 3" extended bumps but they don't hit at all...going to hash this out in the next few weeks so they are actual doing their job.
The rear shocks I have are Bilstein 4600 series off of a grand cherokee. I used my stock rear sway bar mount as a bpe which drops the shock mount down 1". The zj shocks are also 1.25" longer than stock, so it worked out perfectly for my lift! I'm getting good at this budget building cherokee stuff huh?
She gets her crown HD steering on this week as well. Just install a new crown replacement stock track bar.. Again keeping this stock and simple & cheap. As well as very effective offroad for what it is.