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10.5" sterling shave

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83K10 View Drop Down
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Joined: 17 February 2004
Location: Huntsville, AL
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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 View Drop Down
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Joined: 17 February 2004
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Post Options Post Options   Thanks (0) Thanks(0)   Quote 83K10 Quote  Post ReplyReply Direct Link To This Post Posted: 04 November 2018 at 7:58am
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 View Drop Down
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Joined: 16 February 2004
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Post Options Post Options   Thanks (0) Thanks(0)   Quote 50Willys Quote  Post ReplyReply Direct Link To This Post Posted: 04 November 2018 at 8:16pm
Good job John!!
Bob S.

'96 Cherokee, 4.0L w/Auto Trans & locked D44s

'99 Dodge 2500 CTD Tow Rig
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alabamatoy View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote alabamatoy Quote  Post ReplyReply Direct Link To This Post Posted: 05 November 2018 at 7:06am
Wow, very nice.  Not many 4X4 clubs have members with this sort of skills and capabilities.
"If you didnt buy your 1st gen 4Runner new, then YOU are a newbie!!"

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dontoy View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote dontoy Quote  Post ReplyReply Direct Link To This Post Posted: 07 November 2018 at 8:52am
Nice work John you got mad skills!
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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Post Options Post Options   Thanks (0) Thanks(0)   Quote trevordavis0521 Quote  Post ReplyReply Direct Link To This Post Posted: 08 November 2018 at 9:37am
Pretty cool John!
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