Project Coppertop Axle Swap - Page 2

Coppertop · 12-25-2010, 12:59 PM

The goods are starting to roll in.

Now,I need to get the engine and trans in the white car.Then the axle swap project starts.

Nick

Coppertop · 01-14-2011, 07:54 PM

Had a good day...Got my rear dana 60 stripped and cleaned for the machine shop.Going to have the housing shaved and reamed to fit 35 spline axle shafts.

The rear disc brakes mount and clear the 16 inch wheels I have on hand(still waiting on the new beadlocks)

I decided to upgrade to 35 spline axle shafts.It's amazing the difference in size..

The original 30 spline axle is on the left.

Nick

itbrokeagain · 01-14-2011, 08:03 PM

Who is going to end up doing the axle work for you?

Coppertop · 01-14-2011, 08:17 PM

Quote:

Originally Posted by itbrokeagain

Who is going to end up doing the axle work for you?

Terry -TKH Fab ( the guy you hooked me up with) I wanted to have it there last monday.But the car from hell was still in the garage.

Planning on dropping it off tomorrow.

Nick

gothodgie · 01-14-2011, 10:12 PM

looking good... that is a great up grade on those shafts...

Coppertop · 01-30-2011, 11:03 AM

I'm making progress.Still about two weeks behind schedule.The front truss from T&T Customs install went pretty well.Just a few highlights.
The axle must be stripped of all brackets.

On the driver's side (two and three eights )of the cast spring mount must be removed.A 4 1/2 grinder with a cut off wheel done the job.

The truss required some trimmimg to fit.All done with a hand grinder.

The bottom LCA brackets were welded on after the top was welded in place.

Back to the garage...

Nick

94Dodge Truggy · 01-30-2011, 11:15 AM

Excellent work! Going to be ready for west virginia?

Tool Man · 01-30-2011, 06:57 PM

Quote:

Originally Posted by 94Dodge Truggy

Excellent work! Going to be ready for west virginia?

Looks good

Coppertop · 01-30-2011, 08:14 PM

Quote:

Originally Posted by 94Dodge Truggy

Going to be ready for west virginia?

Yes Sir,I'm planning on it...

Nick

yellowjacket · 01-30-2011, 10:09 PM

Slick...

WrenchMonkey · 01-31-2011, 12:46 AM

Outstanding, man! Great work!

Robert

Coppertop · 01-31-2011, 12:42 PM

Thanks everyone,Picked up my shaved and reamed Dana 60 rear end yesterday from TKH Fab.Terry done a great job..Can't wait to get it under the XJ..

Nick

cincygman · 01-31-2011, 07:32 PM

Looks awesome Nick! If you need some help with the problem car, I got some left over C4.............ahh nevermind

Coppertop · 01-31-2011, 10:39 PM

Quote:

Originally Posted by cincygman

Looks awesome Nick! If you need some help with the problem car, I got some left over C4.............ahh nevermind

Thanks ,Funny you mention C4...I drove it(Ford Taurus) today, only to have a gas line start leaking.It was tempting to strike a match.....

As usual ,I pulled it in the garage and repaired the car from HELL.

Did manage to get the ball joints replaced on the Dana 44.

Nick

Coppertop · 02-25-2011, 07:02 PM

Making progress,rear axle installed.The rear shocks look long,not much travel.

A tad wider

I like the look of the T&T u-bolt eliminators.

Hope to get the front dana 44 installed this weekend.

Nick

gothodgie · 02-25-2011, 07:17 PM

those u bolt eliminater perches look sweet...

Keep up the good work...

93 Krawler · 02-25-2011, 08:33 PM

Quote:

Originally Posted by gothodgie

those u bolt eliminater perches look sweet...

Keep up the good work...

Yeah, they are sweet. That's the way to go.

no mods · 02-25-2011, 10:24 PM

those wheels gonna clear the calipers like you had hoped?

Coppertop · 02-26-2011, 11:22 PM

Yep,they cleared when I mocked it up on the bench..The 3.75 backspacing was the key..If I were to do it over again.Would go with 17 inch wheels.

Nick

krawlin85toy · 02-28-2011, 07:15 PM

lookin good.

Coppertop · 03-19-2011, 11:31 AM

Removed the Dana 30 and installed the Rough Country long arm system and the Dana 44 axle last weekend.Some early issues, the trac bar hits the front diff cover truss when the axle cycles upward.Hope to Fab a new bracket and relocate the trac bar bracket forward to solve the problem.The front shock mounts that came with the TnT truss kit won't work.I'm thinkin' bout just welding on some tabs.

I like the way everything mounts up behind the axle increasing ground clearance.

I managed to get one wheel installed.Looks like more fender trimming...

I hope to get all the issues solved and the steering links built this weekend..

Nick

Coppertop · 03-27-2011, 01:36 PM

Another sixteen hour day in the garage yesterday,results in a one mile test drive......... on the jack stands.Yeah, I know why bother.I now know the WJ brake booster and master cylinder upgrade I did a few years ago won't work with the bigger calipers. So,I'm searching for options.

Lookin' at the Dodge truck and /or Durango master cylinder option.Theres a few sitting at You pull.So....off to the savage yard I go.

Hope to have good news by the end of the day.

Nick

Coppertop · 03-28-2011, 12:03 AM

Think I figured it out(Just took most of the day). The afternoon started with a trip to the savage yard.I pulled the brake booster and pedal assy. from a 98 XJ .This will allow me to use a MC from a 1999 Dodge Ram truck.A trip to Advance Auto for the MC with the reservoir(Nothing at You Pull was worth buying) So the plan was to unbolt the old and bolt on the new..Then reallity kicks in(nothing comes easy for me)...:(

Pending mods:
Top pedal assy mounts won't match up
Rewire brake switch
The brake lines will need to be redone (too short)
The new master cylinder won't clear the hood( the cap hits)
Remount my on-board welder control panel so the brake lines will install in the MC

Maybe the good news will come next weekend .

Nick

Coppertop · 03-28-2011, 01:26 PM

Just realized I didn't post up the steering and trac bar info.I made the trac bar with 3/4 Ruff stuff heims and 1.375ODx.188 DOM with a 5/8 mount bolt.
The steering links are 7/8 Ruff Stuff Heims and 1.625ODx.188 DOM with 3/4 Bolts.They are pretty beefy..Can't wait to trail test them.

Looking for fender flare options...:confused:

Nick

WrenchMonkey · 03-28-2011, 04:51 PM

Badass, man. When do you wanna do mine?

You can't just move the TJ flares up?

Robert

Edit: Here's a thought: http://www.naxja.org/forum/showthread.php?t=1045189

12-25-2010, 12:59 PM	#26
Coppertop XJWHEELING Join Date: Nov 2007 Location: Colerain Township Posts: 837	The goods are starting to roll in. Now,I need to get the engine and trans in the white car.Then the axle swap project starts. Nick __________________ Just a 200 dollar cherokee that wouldn't start .. Ten years later same chrome grille ..

01-14-2011, 07:54 PM	#27
Coppertop XJWHEELING Join Date: Nov 2007 Location: Colerain Township Posts: 837	Had a good day...Got my rear dana 60 stripped and cleaned for the machine shop.Going to have the housing shaved and reamed to fit 35 spline axle shafts. The rear disc brakes mount and clear the 16 inch wheels I have on hand(still waiting on the new beadlocks) I decided to upgrade to 35 spline axle shafts.It's amazing the difference in size.. The original 30 spline axle is on the left. Nick __________________ Just a 200 dollar cherokee that wouldn't start .. Ten years later same chrome grille ..

01-14-2011, 08:03 PM	#28
itbrokeagain Just Empty Every Pocket - CORE Member - Join Date: Feb 2007 Location: Amelia Posts: 1,435	Who is going to end up doing the axle work for you? __________________ 91 fj 80 on 37 Nitto Muds with a 10k winch. Cage and sliders coming soon.

01-14-2011, 10:12 PM	#30
gothodgie Join Date: May 2009 Location: loveland Posts: 843 Images: 49	looking good... that is a great up grade on those shafts... __________________ chris hodges 96 fzj80 3x locked, 4"lift, 37s, homebrew sliders and bumpers,a work in progress 71 fj55, SOA, locked...The jungle bus... retired

01-30-2011, 11:03 AM	#31
Coppertop XJWHEELING Join Date: Nov 2007 Location: Colerain Township Posts: 837	Front Dana 44 Truss Install I'm making progress.Still about two weeks behind schedule.The front truss from T&T Customs install went pretty well.Just a few highlights. The axle must be stripped of all brackets. On the driver's side (two and three eights )of the cast spring mount must be removed.A 4 1/2 grinder with a cut off wheel done the job. The truss required some trimmimg to fit.All done with a hand grinder. The bottom LCA brackets were welded on after the top was welded in place. Back to the garage... Nick __________________ Just a 200 dollar cherokee that wouldn't start .. Ten years later same chrome grille ..

01-30-2011, 11:15 AM	#32
94Dodge Truggy EX-Vice President Join Date: Jan 2007 Location: Fairfield, Ohio Posts: 3,048	Excellent work! Going to be ready for west virginia? __________________

01-30-2011, 10:09 PM	#35
yellowjacket barely breathing Join Date: Mar 2008 Location: alexandria, ky Posts: 889	Slick... __________________ my next rig will be on the trail before zuk 2.0 will

01-31-2011, 12:46 AM	#36
WrenchMonkey Mechanical Animal - CORE Member - - Moderator - Join Date: Feb 2008 Location: Beechmont Posts: 1,883	Outstanding, man! Great work! Robert __________________ DIRTY DEEDS, DONE DIRT CHEAP Whatever doesn't kill you makes you stranger

01-31-2011, 12:42 PM	#37
Coppertop XJWHEELING Join Date: Nov 2007 Location: Colerain Township Posts: 837	Thanks everyone,Picked up my shaved and reamed Dana 60 rear end yesterday from TKH Fab.Terry done a great job..Can't wait to get it under the XJ.. Nick __________________ Just a 200 dollar cherokee that wouldn't start .. Ten years later same chrome grille ..

01-31-2011, 07:32 PM	#38
cincygman Join Date: Nov 2008 Location: Pleasant Run Farms (near Fairfield) Posts: 378	Looks awesome Nick! If you need some help with the problem car, I got some left over C4.............ahh nevermind __________________ Romans 7-8

02-25-2011, 07:02 PM	#40
Coppertop XJWHEELING Join Date: Nov 2007 Location: Colerain Township Posts: 837	Rear Dana 60 installed Making progress,rear axle installed.The rear shocks look long,not much travel. A tad wider I like the look of the T&T u-bolt eliminators. Hope to get the front dana 44 installed this weekend. Nick __________________ Just a 200 dollar cherokee that wouldn't start .. Ten years later same chrome grille ..

02-25-2011, 07:17 PM	#41
gothodgie Join Date: May 2009 Location: loveland Posts: 843 Images: 49	those u bolt eliminater perches look sweet... Keep up the good work... __________________ chris hodges 96 fzj80 3x locked, 4"lift, 37s, homebrew sliders and bumpers,a work in progress 71 fj55, SOA, locked...The jungle bus... retired

02-25-2011, 10:24 PM	#43
no mods Join Date: Aug 2010 Location: blue ash Posts: 89	those wheels gonna clear the calipers like you had hoped?

02-26-2011, 11:22 PM	#44
Coppertop XJWHEELING Join Date: Nov 2007 Location: Colerain Township Posts: 837	Yep,they cleared when I mocked it up on the bench..The 3.75 backspacing was the key..If I were to do it over again.Would go with 17 inch wheels. Nick __________________ Just a 200 dollar cherokee that wouldn't start .. Ten years later same chrome grille ..

02-28-2011, 07:15 PM	#45
krawlin85toy Join Date: May 2007 Location: Hamilton Posts: 265 Images: 76	lookin good.

03-19-2011, 11:31 AM	#46
Coppertop XJWHEELING Join Date: Nov 2007 Location: Colerain Township Posts: 837	Front Dana 44 install Removed the Dana 30 and installed the Rough Country long arm system and the Dana 44 axle last weekend.Some early issues, the trac bar hits the front diff cover truss when the axle cycles upward.Hope to Fab a new bracket and relocate the trac bar bracket forward to solve the problem.The front shock mounts that came with the TnT truss kit won't work.I'm thinkin' bout just welding on some tabs. I like the way everything mounts up behind the axle increasing ground clearance. I managed to get one wheel installed.Looks like more fender trimming... I hope to get all the issues solved and the steering links built this weekend.. Nick __________________ Just a 200 dollar cherokee that wouldn't start .. Ten years later same chrome grille ..

03-27-2011, 01:36 PM	#47
Coppertop XJWHEELING Join Date: Nov 2007 Location: Colerain Township Posts: 837	Another sixteen hour day in the garage yesterday,results in a one mile test drive......... on the jack stands.Yeah, I know why bother.I now know the WJ brake booster and master cylinder upgrade I did a few years ago won't work with the bigger calipers. So,I'm searching for options. Lookin' at the Dodge truck and /or Durango master cylinder option.Theres a few sitting at You pull.So....off to the savage yard I go. Hope to have good news by the end of the day. Nick __________________ Just a 200 dollar cherokee that wouldn't start .. Ten years later same chrome grille ..

03-28-2011, 12:03 AM	#48
Coppertop XJWHEELING Join Date: Nov 2007 Location: Colerain Township Posts: 837	Think I figured it out(Just took most of the day). The afternoon started with a trip to the savage yard.I pulled the brake booster and pedal assy. from a 98 XJ .This will allow me to use a MC from a 1999 Dodge Ram truck.A trip to Advance Auto for the MC with the reservoir(Nothing at You Pull was worth buying) So the plan was to unbolt the old and bolt on the new..Then reallity kicks in(nothing comes easy for me)...:( Pending mods: Top pedal assy mounts won't match up Rewire brake switch The brake lines will need to be redone (too short) The new master cylinder won't clear the hood( the cap hits) Remount my on-board welder control panel so the brake lines will install in the MC Maybe the good news will come next weekend . Nick __________________ Just a 200 dollar cherokee that wouldn't start .. Ten years later same chrome grille ..

03-28-2011, 01:26 PM	#49
Coppertop XJWHEELING Join Date: Nov 2007 Location: Colerain Township Posts: 837	Steering links and trac bar set-up Just realized I didn't post up the steering and trac bar info.I made the trac bar with 3/4 Ruff stuff heims and 1.375ODx.188 DOM with a 5/8 mount bolt. The steering links are 7/8 Ruff Stuff Heims and 1.625ODx.188 DOM with 3/4 Bolts.They are pretty beefy..Can't wait to trail test them. Looking for fender flare options...:confused: Nick __________________ Just a 200 dollar cherokee that wouldn't start .. Ten years later same chrome grille ..

03-28-2011, 04:51 PM	#50
WrenchMonkey Mechanical Animal - CORE Member - - Moderator - Join Date: Feb 2008 Location: Beechmont Posts: 1,883	Badass, man. When do you wanna do mine? You can't just move the TJ flares up? Robert Edit: Here's a thought: http://www.naxja.org/forum/showthread.php?t=1045189 __________________ DIRTY DEEDS, DONE DIRT CHEAP Whatever doesn't kill you makes you stranger Last edited by WrenchMonkey; 03-28-2011 at 10:50 PM.

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