10.5" sterling shave |
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83K10
RCRC Club & Business Member Joined: 17 February 2004 Location: Huntsville, AL Status: Offline Points: 3173 |
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Posted: 04 November 2018 at 7:50am |
We had a customer at our shop want us to install a ballistic fab shave kit on his 10.5" sterling axle destined to go in his JK.
I started by turning down the ring gear to 10" in our lathe. Next, we setup the axle in our CNC mill. We didn't have a fixture for holding the axle but we made it work using some V blocks and clamps. Machining it down. Testing the fit while it's still setup in our mill. While we were machining stuff, we turned down the back of the hubs and pressed on these abs rings. |
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83K10
RCRC Club & Business Member Joined: 17 February 2004 Location: Huntsville, AL Status: Offline Points: 3173 |
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We welded this plate on the bottom. Special precautions had to be taken as the housing is cast iron. We used 0.045 Ni55 welding wire with 90/10 gas mix for spray transfer. We pre heated the housing to 250 degrees. Between each pass we used a knotted wire wheel on a grinder to clean up the weld area as the casting was very dirty. We also used a needle scaler to stress relieve the weld area between passes. Once the welding was finished, we stuff a welding blanket inside the diff and wrapped another one around it. This allowed it to cool down really slow.
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50Willys
RCRC Club Member RCRC Vice President Joined: 16 February 2004 Location: Trinity, AL Status: Offline Points: 2910 |
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Good job John!!
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Bob S.
'96 Cherokee, 4.0L w/Auto Trans & locked D44s '99 Dodge 2500 CTD Tow Rig |
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alabamatoy
Admin Group I dont work here anymore... Joined: 16 February 2004 Location: Signal Mountain Status: Offline Points: 9367 |
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Wow, very nice. Not many 4X4 clubs have members with this sort of skills and capabilities.
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"If you didnt buy your 1st gen 4Runner new, then YOU are a newbie!!"
BRC Life Member |
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dontoy
RCRC Club Member Hail HURTS...aske me how I know! Joined: 16 May 2004 Location: Athens, Limestone County Status: Offline Points: 889 |
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Nice work John you got mad skills!
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1985 ToyBuggy w/TBI GM4.3/TH350, Marlin doubler, 4.88's, locked front & rear, 37" TSL SXII, and other stuff.
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trevordavis0521
Newbie Joined: 30 March 2015 Location: Huntsville, AL Status: Offline Points: 24 |
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Pretty cool John!
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CJ7OX
RCRC Club Member Joined: 17 February 2004 Location: United States Status: Offline Points: 1869 |
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Nice work, John!
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~Sean
Some people spend an entire lifetime wondering if they made a difference in the world. But the U.S. ARMED FORCES don't have that problem. -Reagan MOLON LABE 85ish CJ-7/06 CTD |
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83K10
RCRC Club & Business Member Joined: 17 February 2004 Location: Huntsville, AL Status: Offline Points: 3173 |
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Thanks guys. I hope you guy enjoyed see the pictures of doing this. I'll try to share more stuff like this in the future.
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