Cheaper Than Therapy: A Build Thread

[sprdv1]

You'll be good with those gears, no worries. It'll run out good.

All good on the gear set up run it. Pinion is a .0005” too deep. Would rather have that than the opposite. When you load it with torque it will be perfect.

5.43’s are pretty deep but will work for sure. Have 4.56’s and would like 4.88’s but not enough to change. The only reason for 4.88’s is it needs a bit more at interstate speeds other wise it is perfect. I’m not super deep with the tcase either with a 3.0, fits my driving style and gives wheel speed when I need it. More gearing off-road to me just feels like your not allowing the drivetrain to work for you, like the engine never gets a load or can lug when it finds traction and hang on to it. Just my opinions and thoughts.

if they say it's so, it's so... great set of minds right there

 

[marjama]

if they say it's so, it's so... great set of minds right there

My thoughts exactly! ;D

 

[sprdv1]

My thoughts exactly! ;D

lol,

weather is getting nice now so almost time to cruise topless and get out enjoy some fresh air

 

[marjama]

Update number 1 from the weekend:

Finally managed to wrap up both the front and rear 3rd members, minus the ARB bulkhead kits. I was missing some pieces, so I ordered a pair of the newer 6mm black hose kits. I think both qualify as vintage these days - both of the nodular center sections are stamped 2006 and I've had the ARB's on the shelf for 10 years. Hope they still work!

Copper line routing inspired by this link:

https://www.pirate4x4.com/threads/9-arb-seal-housing-installation.791990/

I also drilled all of the ARP ring gear bolt heads for lock wire. I spent too much time reading about RD99 failures, and basically attempted to trump them all. So, I suppose I'm not done after all...still need to safety wire them all. But...closer!

(Side note...why the heck are those pinion studs so freaking long?! Are there really pinion supports out there that are 3/4" thick?! I'm runnin' em anyway.)

 

[marjama]

Update number 2 from the weekend:

Finally got some additional brake parts in and mocked up the system. The red part is from one of our 3D printers at work...just an ABS prototype. Good thing I made it - I figured out that my front disc model was totally wrong! The revised version will mount the caliper level and will be thicker where the radial adapter mounts. I was going to build radial mount adapters from scratch, but this configuration was easier to get rolling...and I need to get rolling. Literally.

Also a quick pic of the Wilwood electronic parking brake that finally showed up. They are pretty huge! This was expected, but I thought I'd throw in a side by side comparison of the 4 piston caliper and the monster EPB motor. I won't be able to mount the parking brake straight up or it will run into the coilover! Off to the shop to figure out how to mount the rear...

 

[nvrstuk]

Those Wilwood calipers are huge! Stopping power there!

Things are looking good. Nice to be making progress that you can SEE! way cool Marcus.

 

[Yeller]

Good call on the safety wire. One thing is a promise on a front 9”, the ring gear bolts will work loose. Looking good! One step at a time

 

[marjama]

Those Wilwood calipers are huge! Stopping power there!

Things are looking good. Nice to be making progress that you can SEE! way cool Marcus.

Yeah, the Wilwood's do look pretty big...but I heard that is what the kids are doing these days. My buddy's kid is always talking about getting a "BBK" on his VW Jetta

The actual piston area is reasonable. Fronts are ø1.88/ø1.75, so 5.18 sq in total area. The GM metric calipers I was running were 5.94 sq in.

Have I told you guys how much joy I get out of recycling the box a part came in? It's just about as satisfying as crossing off something on the whiteboard as 'done'! (If only I could stop collecting parts for all of the other projects I have going on...ha!)

Good call on the safety wire. One thing is a promise on a front 9”, the ring gear bolts will work loose. Looking good! One step at a time

Thanks Steve! I was going to try to share some links to all of the ARB 'fixes' I found, but apparently I didn't bookmark them. The competition version with locking fasteners didn't exist when I bought these RD99's, but I probably wouldn't have sprung for them anyway. I'd really rather not have the ring gear come loose. That seems like it'd be bad

 

[Yeller]

I've never understood why they come loose on the front virtually every time without mechanical retention, locktite is not enough. Rarely is it an issue on the rear, I've seen it but rare enough I feel comfortable not worrying about it, on everything but racers. ARP does make drilled bolts for it but they are spendy, over $80 for a set of bolts, worth it though to save the damage they can cause.

 

[marjama]

I've never understood why they come loose on the front virtually every time without mechanical retention, locktite is not enough. Rarely is it an issue on the rear, I've seen it but rare enough I feel comfortable not worrying about it, on everything but racers. ARP does make drilled bolts for it but they are spendy, over $80 for a set of bolts, worth it though to save the damage they can cause.

It is an odd phenomena...I assume it is from some form of mechanical precession (effectively the bolt 'wobbling' its way out). I remember read that in the 'old days' cars had left handed threads on one side of the car due to this issue, but the need was eliminated with the tapered seat. Can't say I've ever run into left handed wheel threads!

I bought fasteners for the ARB's from Gearworks and drilled them myself: https://gearworksinc.com/product/716-ring-gear-bolt/

Spendy at ~$53/set, but I figured it was cheap insurance. I couldn't find anyone else who made them in the length that fit the ARB setup. I think I only broke one drill bit off during the process, and it came out easily. That's a record for me! If I could have found them pre-drilled I'd have likely paid extra for it to be done - it's a tedious process and I didn't have any extra bolts!

(I'm pretty sure for my use I could have gotten away with red loctite and never have had an issue, but I really don't want to run into issues down the road!)

 

[nvrstuk]

I had my D44 ARB bolts come loose a couple decades ago too. Heard a "CLUNK" in the front when doing a TTC Competition... thought it was going to be the cause of the end of our team's day but a few minutes later I blew a pinion out of my 9" rear end... so I saved the front end but... lol

This is when I went to the rear end that I thought was tough enough to last me forever... TRUHI9... we all know how that worked out too.

Anybody found an issue with them backing out of the D60 front? I figured I drain the oil often enough that I'd catch any that might be backing out. ????

 

[Yeller]

Far less issue with a D60, seen it but pretty rare. I think it has to do with harmonics and ujoint oscillation in the axle shafts, just my theory. I do know harmonics are vastly different between a 9", D44 and D60. I think the OD of the ring gear bolts is a big factor.

 

[marjama]

Just a quick update...seems like life has gotten busy lately with spring springing and a quick work trip all the way across the country. I did manage to bust out another 'prototype' for the rear brake mount. I didn't take many pics though.

Clearance between the wheel and the components look pretty good. No issues there. You can see how far the electronic parking brake (EPB) motor sticks out - it's pretty significant! I think my current plan is to move the brake caliper to the front of the axle, and have the EPB to the rear, clocked up as far as I can get it without getting into the shock. This should leave me more clearance for the rear sway bar (which has yet to be figured out, but is intended to be installed forward of the rear axle). Or, I can find a way to have the rear sway bar installed at the back. This might be preferred since the link & tire would offer more protection to the EPB if I leave it in this configuration. 10 lbs of stuff in a 5 lb bag!

 

[nvrstuk]

Sounds like things are getting a bit "tight" in your package Marcus!

I can feel your pain...

 

[marjama]

Sounds like things are getting a bit "tight" in your package Marcus!

I can feel your pain...

Ha! I think that's a pretty fair thing to say for all early Bronco owners ;D

 

[sprdv1]

Ha! I think that's a pretty fair thing to say for all early Bronco owners ;D

LOL, amen to that..

 

[marjama]

Overland Trailer...distractions!

Man...you know you haven't been posting updates when your thread has been pushed all the way to the 4th page!

I'm still here and kicking, but sidetracked on an "overland trailer" build that will probably turn out pretty similar in concept to what the guys at Turtleback Trailers make. Trying to get it done before camping season shows up! Here's an image of the base frame after it was tacked up. (This pic makes me cringe a bit...what a mess in the background! I like the trailer sitting on 37's though!)

It's Bronco related. For one, it is wearing the Bronco's wheels and tires...and I plan to pull it behind the Bronco if I ever get it done! Also, the Bronco is in the background ;D

 

[subjb1]

Man...you know you haven't been posting updates when your thread has been pushed all the way to the 4th page!

I'm still here and kicking, but sidetracked on an "overland trailer" build that will probably turn out pretty similar in concept to what the guys at Turtleback Trailers make. Trying to get it done before camping season shows up! Here's an image of the base frame after it was tacked up. (This pic makes me cringe a bit...what a mess in the background! I like the trailer sitting on 37's though!)

It's Bronco related. For one, it is wearing the Bronco's wheels and tires...and I plan to pull it behind the Bronco if I ever get it done! Also, the Bronco is in the background ;D

I’ve been following this build for a while. Now I really want to see what you’re gohunt to do with that trailer. Do you have another thread on that build?


Sent from my iPhone using Tapatalk

 

[sprdv1]

Man...you know you haven't been posting updates when your thread has been pushed all the way to the 4th page!

I'm still here and kicking, but sidetracked on an "overland trailer" build that will probably turn out pretty similar in concept to what the guys at Turtleback Trailers make. Trying to get it done before camping season shows up! Here's an image of the base frame after it was tacked up. (This pic makes me cringe a bit...what a mess in the background! I like the trailer sitting on 37's though!)

It's Bronco related. For one, it is wearing the Bronco's wheels and tires...and I plan to pull it behind the Bronco if I ever get it done! Also, the Bronco is in the background ;D

Long as you catch up and give us pics all good...

Keep plugging along

 

[marjama]

I’ve been following this build for a while. Now I really want to see what you’re gohunt to do with that trailer. Do you have another thread on that build?


Sent from my iPhone using Tapatalk

I don't have a build thread yet, but I've thought about it - I will let you know! Hard to keep up on taking pics and posting with everything going on, but we'll see. Should be a cool trailer when it's done (I hope!).