Waldo's 1 Ton Build Thread
04-14-2015, 08:17 PM
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JK Freak
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Waldo's 1 Ton Build Thread
I have been waiting for this day for years. Somehow my D30 bounced 37's off rocks for two years before it finally bit the dust last weekend. I now have the excuse I needed to get a set of 1 tons under my JKU. After making calls to 40+ scrap yards in the area, I found a D60 and a Sterling 10.5 out of an 08 F250 that I will be using. The plan is to use the Artec Industries Truss/Swap Kits for both front and rear. After those and the new driveshafts show up things will start to get a bit more interesting. Here is a picture of the 1 tons as they were loaded on the trailer. As you can tell, I'll be around the torch and plasma cutter while I wait for brown Santa.
04-14-2015, 08:27 PM
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04-15-2015, 06:54 AM
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JK Junkie
Take it from a guy who spent too many hours cutting cast on the front axle - use a portaband. Cuts like butter. Plasma is a mess on the thick cast (and enough heat to crack it). Cutoff wheels get stuck after you get about 1/4" in. Sawzall is worthless.
When you cut the 2" of cast from the driver side tube, don't run a blade into the plug welds. They're made of some sort of titanium/unicorn semen. Cut around and use an air hammer and it will pop off.
When you cut the 2" of cast from the driver side tube, don't run a blade into the plug welds. They're made of some sort of titanium/unicorn semen. Cut around and use an air hammer and it will pop off.
04-15-2015, 08:11 AM
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JK Freak
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So far, I have $1,260 into the axles (including $100 in core charges) and $840 in the two truss kits (including $100 in shipping.) I have yet to order drive shafts as I haven't gotten it mocked up to measure yet. I have a pretty good feeling that this project will nickle and dime me to death. I'm sure I'll keep finding little things that need to be replaced. The rear is missing a brake caliper and I haven't checked to see if the rotors can be turned or if those will need to be replaced as well. I also haven't made my way to checking the seals or brake lines. As I continue, more pictures will come.
04-15-2015, 10:53 AM
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Take it from a guy who spent too many hours cutting cast on the front axle - use a portaband. Cuts like butter. Plasma is a mess on the thick cast (and enough heat to crack it). Cutoff wheels get stuck after you get about 1/4" in. Sawzall is worthless. When you cut the 2" of cast from the driver side tube, don't run a blade into the plug welds. They're made of some sort of titanium/unicorn semen. Cut around and use an air hammer and it will pop off.
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04-15-2015, 11:08 AM
#8
JK Freak
Unicorn semen is the toughest shit ever www.overlandoff-road.com
04-16-2015, 12:48 PM
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Got my hands on a portaband and agree that it's the way to go. It still took quite a bit of time to get through though. The front D60 came with all of the steering components, arms, and shocks. Everything is off, although, it's rough. Including the trips to the hardware store for new blades, time to search for sockets, and beer breaks, I have about 11 hours into it so far. My back is aching and my knuckles are bloody. The trusses are on their way, I hope to have them by the middle of next week.