Dana 35 Axle Truss Complete...For now?

admin

As many know, the Dana 35 is not the best axle out there to say the least. Since I cannot afford a new axle to swap in, I decided to make a truss for as cheap as I could.  For about $20 it should strengthen up the axle enough to prevent excess bending.On the front of the axle, its 1.5" square tubing, .125 wall (1/8") Welded to the carrier and to the tubes. The idea behind that is for going up a hill it would help with strength.  For the bottom triangular supports, its .25" steel (1/4"), with full beads everywhere it connects. They are sexy  Too bad its all painted so you cant see them... should have snapped some pics earlier :/ The idea behind that is for regular use that part of the truss will help. I also ran beads around the axle tubes to the pumpkin.I will probably do the same triangular design on my front dana 30, and I will probably work on some diff skids for front and rear, or start shopping around.Pics:I'm 21 and learningAvid 4wd enthusiastASE Master tech (Automotive), mechanic/fabricator by trade
Reply:One pic says a thousand words...What you said is not what you meant...or perhaps you DID mean what you typed...who knows?I was wondering how someone would go about making a 'truss' for an axle...Then I saw your pic of an axle HOUSING...Missing one word makes all the difference, don't ya think?WeldingWeb forum--now more sophomoric banter than anything else!
Reply:You added some extra weight to that boat anchor.  Outta' work real good (as an anchor)Kidding aside.  keeping the D35 from bending will go a long way to help it survive a little abuse.  Keep your tires under 33" and avoid putting a locker in that axle and it will last a bit longer.I wouldn't worry to much about your D30 housing.  The shafts will break long before anything else.  Again if you can avoid locking it, it will take quite a bit of abuse.Also, keep the tires on the ground.  Jumping with those axles will break them very quickly (ask me how I know!)
Reply:There are upgraded inner shafts that are quite a lot stronger, Not dana 44 strong, but close.True lockers put a lot of stress on things, but not having lockers puts a lot of stress on things too when you get stuck in places you could have crawled out of with lockers. Trouble is lockers just let you push the limits more.That Dana 35 on a Jeep.  Edit, just read your sig, guess it is. I have a lifted XJ with Dana 35 rear that could use the same, Offroading was fun back when gas was cheep. Now I hardly even drive my jeep.Lincoln PT185 TIGLincoln 175 MIGLincoln 240 amp AC StickLind Needle Arc plasma welderPlasma cutter, soon???
Reply:Originally Posted by 69 chevyOne pic says a thousand words...What you said is not what you meant...or perhaps you DID mean what you typed...who knows?I was wondering how someone would go about making a 'truss' for an axle...Then I saw your pic of an axle HOUSING...Missing one word makes all the difference, don't ya think?
Reply:What´s the square tubing in the differential housing for? Seems its just potruding from there but kinda new with these stuff...My Babies: HF Drill pressHF Pipe Bender3   4.5" Black and Decker angle grindersLincoln Electric PROMIG 175that´s it!
Reply:Originally Posted by elvergonWhat´s the square tubing in the differential housing for? Seems its just potruding from there but kinda new with these stuff...
Reply:I drive an xj not a zj but not to much difference. Looks good except more cross section to plow sand. I'm lucky i have the Crystler 8.25. I wouldn't be worried about bigger tires. It's not the strongest axle but when in 4 wheel the 4.0 has lots of torque but not enough to break axle shafts under halfway hard offroading. Your right it's a jeep it's unstoppable. --Gol'