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Cheap'ish 609 axle builds


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5 hours ago, landy_andy said:

Am using new BJ’s for now, realistically if they last 50,000km that’s prob 5yrs+ of use based on we only get 6 months of summer here if we’re lucky.

Was going to stick with 3.50:1 but assembled these tonight..... and measuring the WMS to the top BJ nut flat casting edge is 10”. On the truck the spacer & washer combo are 1.75” thick to give me the 10” of clearance from the WMS to the spring to miss the BJ nut.

So, that means I’ll need to build the axles out to a WMS/WMS of 64.5” to fit the front correctly.

My plan was to build the rear axle, fit it and work on the front next winter.... but.... plans change and I’ll just build both now at the same time. Will save a few bucks on water jet cutting setup as I can combine parts for both in the same thickness of material.

Probably won’t get them on for this summer as I need to spread the cost of the 3rd’s out unless I can find some S/H lockers but those are rare in 35 spline or the worn out.

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What is this car used for/what tyre size are you aiming for?

Daan

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6 hours ago, Daan said:

What is this car used for/what tyre size are you aiming for?

Daan

Not used for a lot at the moment, can’t seem to get it finished.... 😕

I have 35’s on it at present but want to change those out to 36 or 37’s, all depends on if I change the wheels too as finding 15” tires that are not boggers is getting slim pickings now.

Once done...be heading into the mountains, have 350,000km of dirt roads here to go explore then off to Moab 😃

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Got some time to grind off the welds on the inner C’s, slit the stub of axle tube and hammer them out. Quick clean up with the wire wheel and there ready to install onto the new pieces of axle tube.

Also picked up the latest batch of water jet cut parts, assembly jig, spring seats, front & rear brake caliper brackets and the drilling jig for the front Ford spindles to the Dodge unit bearing pattern.

 

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Started to put the assembly jig together at the weekend....then found an oops... 🙄

Replacement should be here later this week.... and I corrected the drawing so when the bend lines are marked on the water jet, it folds up the correct way.

 

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Edited by landy_andy
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  • 2 weeks later...
On 5/15/2020 at 1:07 AM, TobyMellin said:

Looking good :D

 

Me and the Mrs are hoping to get over to BC soon when all this dies down, got some potential job interviews.

 

6 months of summer is better than what we get in the UK!  <_<😂

Where are you planning on moving too ?

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On 5/17/2020 at 4:26 AM, landy_andy said:

Where are you planning on moving too ?

We really want to move to Squamish, but the commute in to Delta every day may be a little long I think. 

We only had a quick stop over last time, so once everything is clear, we will come over for a couple of weeks. 

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On 5/18/2020 at 4:11 AM, TobyMellin said:

We really want to move to Squamish, but the commute in to Delta every day may be a little long I think. 

We only had a quick stop over last time, so once everything is clear, we will come over for a couple of weeks. 

Oh dear... another lower mainlander..... 🤣

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Braved the 30+ degrees heat & burned wire this week. Really happy how this centre section turned out. Only had a small area of porosity in one weld that needed to be ground out & redone.

Few pictures of the assembly process & finished product before it gets a quick clean up with a flap wheel to smooth out the sharp edges.

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So, decided to run the numbers on a centred diff housing rather than offsetting it to align with the front one. Doesn’t work out that much difference, just under 5” due to the offset pinion in the 9” diff.
Time will tell if this is a good move or not.... but for now am getting the rear axle tubes cut & the stubs fitted at the local machine shop. Then time to assemble it.

 

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Edited by landy_andy
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