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Cheap'ish 609 axle builds


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So… the project starts to draw to a close as the pile of parts is getting smaller !

We have currently on order :

Front & rear braided brake hoses

Last fitting for the hydroboost lines

4 limit straps & tabs to weld on the front shock towers
 

To order still :

Front inner custom 35 spline axle shafts

4 Bilstein 12” shocks

Front brake pads

Front axle shaft u-joints

New fluids….

Will need to have the drive shafts adjusted & rebalanced but that’ll be the last thing once it’s all back on the ground.

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On 7/15/2022 at 12:22 AM, steve200TDi said:

Nice Diff holder! It makes working on it so much easier.

Loving the project so far. Now it's nearing completion, have a list of events/places to use it at?

Steve

Thanks, not many events to go to here…. but we do have ~350k of forest access roads used for industrial & logging operations. A lot of the ones around where we live are in/out due to the steep mountain terrain but if I head north you can put together days of driving where you’ll never see a paved road.

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On 7/15/2022 at 12:22 AM, steve200TDi said:

Nice Diff holder! It makes working on it so much easier.

Loving the project so far. Now it's nearing completion, have a list of events/places to use it at?

Steve

Going to be heading out here… follow the power line cut (on the right) for the next 100km or so… just taken from my front lawn.

Also, have sold the 14” shocks, so can get the new 12’s on order now 😀

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On 7/18/2022 at 12:13 AM, steve200TDi said:

Very nice outlook and look at all that space. You're obviously not over looked or hemmed in!

Steve

 

We’re fortunate we purchased our 1/4 acre lot at the time we did, one a few doors down sold in the last 3 months for $500k cad, about 323k pounds. Neighbor has there place listed for $2.65m… that’s just insane 🤪

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Installed then front 3rd over the weekend, after cycling the suspension decided that I wasn’t happy with the clearance to the sump at full stuff for the larger pinion yoke. So, zip, zip and it lost the corner… am wondering if painters tape will hold the oil in 🤔

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So, have decided whilst we’re down this rabbit hole I might as well upgrade the rear drive shaft to 1350 u-joints from the (similar to LR sized) 1310’s I was running. One of the guys on Pirate modified his LT230 many years ago using modified Ford 9” pinion yokes and I already have the disc brake conversion and a 1350 yoke for the axle….

As I’m already using a Rakeway carrier bearing to get the front drive shaft over the cross member I’ll be leaving that with the 1310 joints. If it becomes an issue I’ll have to change it all out to either 1330 or 1350’s but that’ll require a complete new carrier bearing unit and that’s not in the budget for now. I have included the front yoke conversation pic for info. That’s just a quick machine to match the LR seal diameter & trim the threaded shaft for joint clearance.

So, here we go….

 

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  • 2 weeks later...

Finally got the order of limit straps… after installing the fronts had a change of plan for the upper mounting point… now I need some 12” ones. Tested the drive shaft for binding at full droop & stuff, will be needing to use the Tom Woods high angle joint on the steady bearing end for definite.

To add insult to injury… the courier has lost my order of new Bilstein shocks 😡

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Rear shocks & limit straps installed, checked the drive line angles and we have 18 degrees in total. So, a pair of 1350 HD Spicer Life joints will work just fine. Just got to finish off the t’case yoke, then we can get a new rear drive shaft built up. Decided to keep the beefy going and use a TMR HD kit that’s been machined to use 2” x 1/4” wall DOM tube.

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  • 1 month later...

Finally got the rear t’case yoke back from the machine shop… there so busy with logging equipment repairs before winter hits, small ‘hobby’ jobs get pushed to the back of the line. No worries, people gotta make a living.

Had the LR flange shrunk fit onto the 9” yoke, finished it with a TIG fused joint on the t’case side. Needed to cut a relief for the 7/16” nuts on the back side to hold the X-Eng disk in place, the socket cap bolts needed to be turned down a bit to clear the flange boss.

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  • 3 weeks later...

Got back on the truck now the preparations for winter are all done. Stroked out then rear suspension to full droop (now I have the limit straps installed) to measure the drive shaft length, checked at ride height and it falls about mid stroke on the slip joint.

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Front limit straps installed, added a 1/2” nut to the bottom of the front shock mount and they give me 95% full stroke. Brake lines all connected up & bled… next to finalize the link lengths, adjust the steering & start the tidy up jobs…. So close to being complete 😀

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