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View Full Version : My Ultimate D30 Build (Polishing the Turd)



coverinearth
04-11-2010, 10:12 PM
So i've recently noticed a bent C on the drivers side of my current HP D30 under my YJ. Since the axle is already rather well built in the internal section, I really dont see the point in spending money on it that could be used elsewhere.

So the decision was made to build the ultimate D30 housing and swap my internals over to it.

I found a 91 XJ HP D30 local, complete for rather cheap. ($75)

The plan was at first just to truss and do inner C gussets and then weld my SOA perches on and go.

Then we started tearing into it and since i already run 1 piece chromoly shafts, the vaccuum disconnect is pointless. So the XJ housing also has the UCA mount cast into the vac-disco piece.

After searching the boards and finding Joe Dillards re-sleeve I decided to integrate that into my Ultimate D30 build.

The axle was dropped off friday (4-9-10)
http://img.photobucket.com/albums/v18/cvrnrth/White%20YJ/Polished%20Turd/turdhome1.jpg
http://img.photobucket.com/albums/v18/cvrnrth/White%20YJ/Polished%20Turd/turdhome2.jpg

Immediatly we tore into it getting all the unusable stuff chopped off. (Read, everything!)
http://img.photobucket.com/albums/v18/cvrnrth/White%20YJ/Polished%20Turd/choppinturds1.jpg
http://img.photobucket.com/albums/v18/cvrnrth/White%20YJ/Polished%20Turd/choppinturds2.jpg

Dualing grinders:
http://img.photobucket.com/albums/v18/cvrnrth/White%20YJ/Polished%20Turd/choppinturds3.jpg

The result of a stubborn bracket:
http://img.photobucket.com/albums/v18/cvrnrth/White%20YJ/Polished%20Turd/turdfightsback.jpg

That was the end of day 1. Today Prosonic (Nick) from JeepForum.com came over to help me finish getting it all torn down. Made lots of progress today.

Nick saying hello:
http://img.photobucket.com/albums/v18/cvrnrth/White%20YJ/Polished%20Turd/byebyestockturd.jpg

Yeah, we got carried away holding it on the stands:
http://img.photobucket.com/albums/v18/cvrnrth/White%20YJ/Polished%20Turd/LOLstraps.jpg

This is the way the service manuals tell you to take off the pinion nut right?
http://img.photobucket.com/albums/v18/cvrnrth/White%20YJ/Polished%20Turd/pinionnutremoval2.jpg
http://img.photobucket.com/albums/v18/cvrnrth/White%20YJ/Polished%20Turd/pinionnutremoval1.jpg

Empty:
http://img.photobucket.com/albums/v18/cvrnrth/White%20YJ/Polished%20Turd/emptyturd1.jpg

Evil has taken over:
http://img.photobucket.com/albums/v18/cvrnrth/White%20YJ/Polished%20Turd/emptyturd2.jpg

coverinearth
04-11-2010, 10:12 PM
We continued our destruction (Disassembly)
http://img.photobucket.com/albums/v18/cvrnrth/White%20YJ/Polished%20Turd/dirtyturdy1.jpg
http://img.photobucket.com/albums/v18/cvrnrth/White%20YJ/Polished%20Turd/dirtyturdy2.jpg

Tubes clean:
http://img.photobucket.com/albums/v18/cvrnrth/White%20YJ/Polished%20Turd/cleantubes2.jpg
http://img.photobucket.com/albums/v18/cvrnrth/White%20YJ/Polished%20Turd/cleantubes1.jpg

No turning back now:
http://img.photobucket.com/albums/v18/cvrnrth/White%20YJ/Polished%20Turd/byebyedisco1.jpg
http://img.photobucket.com/albums/v18/cvrnrth/White%20YJ/Polished%20Turd/byebyedisco2.jpg
http://img.photobucket.com/albums/v18/cvrnrth/White%20YJ/Polished%20Turd/byebyedisco3.jpg

O, my.
http://img.photobucket.com/albums/v18/cvrnrth/White%20YJ/Polished%20Turd/osnap1.jpg

Bye bye disco:
http://img.photobucket.com/albums/v18/cvrnrth/White%20YJ/Polished%20Turd/f-offdisco.jpg

Pieces:
http://img.photobucket.com/albums/v18/cvrnrth/White%20YJ/Polished%20Turd/osnap2.jpg
http://img.photobucket.com/albums/v18/cvrnrth/White%20YJ/Polished%20Turd/turdpieces1.jpg
http://img.photobucket.com/albums/v18/cvrnrth/White%20YJ/Polished%20Turd/turdpieces2.jpg

Mock up for the C gussets:
http://img.photobucket.com/albums/v18/cvrnrth/White%20YJ/Polished%20Turd/beefgusset1.jpg
http://img.photobucket.com/albums/v18/cvrnrth/White%20YJ/Polished%20Turd/beefgusset3.jpg
http://img.photobucket.com/albums/v18/cvrnrth/White%20YJ/Polished%20Turd/beefgusset4.jpg

Tomorrow i'll be picking up some 3" OD, 2 1/2" ID DOM tubing to sleeve the long side tube. Will also be sleeving the shortside. Then welding on the C gussets, as well as a set of BallisticFab Perches.

Then I can begin making the Truss to complete the beef of this Dana30. I know i've left out lots of technical details, but a full write-up can be done if one is wanted.

-Nick

village_idiot
04-11-2010, 10:19 PM
i just saw this on JF, looks like allot of fun/work

oldschoolyotaguy
06-26-2010, 10:56 AM
progress?? slacking?? decide to just buy a toyota and not have to do all this extra work haha??

jeepxj3
06-29-2010, 01:35 AM
Seems like alot of extra work when you could have just picked up a 92-99 XJ front D30.

oldschoolyotaguy
07-05-2010, 11:14 AM
or a found a junkyard 9", and a 60 out of a wrecked truck.... and viola, 609 axle.... and you can keep it 5 lug

JunkJeep
07-13-2010, 07:37 PM
Really, i have a 94', no vac box. straigh axle tubes. Its gonna be a nightmare getting that sleeve and axle perfectly straight so u get no vibes, worn out bearings or binding. Ford 9" arent that great and D60's kill ground clearance. Shoulda just bypassed the vac box w/ straigh axle, block off plate. If u really wanna spend time / money get the dana super 30 31spline chromo kit. Unless your runnin 44" tires, really hard to break. Dont know if anyone told u, axles, and the ball joints are the weak spots on the D30 not the vac box and knuckle attach points.

JunkJeep
07-13-2010, 07:38 PM
Toyota's suck BTW. U can outwheel me? I'll outlast you, Just have to wait till your frame implodes.

JunkJeep
07-13-2010, 07:40 PM
Oh, and accuracy is gonna be a b*tch with all those harbor freight tools!

96greenxjjeep
07-13-2010, 08:16 PM
Really, i have a 94', no vac box. straigh axle tubes. Its gonna be a nightmare getting that sleeve and axle perfectly straight so u get no vibes, worn out bearings or binding. Ford 9" arent that great and D60's kill ground clearance. Shoulda just bypassed the vac box w/ straigh axle, block off plate. If u really wanna spend time / money get the dana super 30 31spline chromo kit. Unless your runnin 44" tires, really hard to break. Dont know if anyone told u, axles, and the ball joints are the weak spots on the D30 not the vac box and knuckle attach points.


apparently you haven't seen him build anything before

Deadman 94 xj
07-13-2010, 08:28 PM
I smell a noob! or a troll. Not sure yet.

ridgerunner97
07-13-2010, 08:29 PM
LIKEWISE! Someone is being a dickhead for no real apparent reason, I bit my tongue in my thread about control arms but this is a recurring theme...

limegreentj
07-13-2010, 08:46 PM
Oh, and accuracy is gonna be a b*tch with all those harbor freight tools!


fail!

i've built A LOT of stuff with HF tools, toyotas dont suck,

just about anyone can build nice stuff with awesome tools, but it takes a real fabricator to build nice stuff with cheap tools

no offense but a lot of people arent gonna be accepting of your critisism when your last (first) six posts were basically knockin everyones ideas

abrzrkr
07-13-2010, 09:25 PM
I call bogus

JunkJeep
07-14-2010, 09:42 PM
I'm sorry, I had a bad day yesterday. Waiting around for parts to come in is frustrating. Not trying to make enemies. I do like your entusiasm, not many people would take on a challenge of doing up a beefy 30 instead of a 44 or 60 swap, i agree that its the way to go. I'm only jealous of how yota's never die, and i cant talk sh#t about cheap tools, have a bunch, they're all made in china or tiwan anyway so why pay a premium for them.

tjblair
07-14-2010, 09:46 PM
Wow, I didn't see that coming. way to redeem yourself:038:

limegreentj
07-14-2010, 09:49 PM
Wow, I didn't see that coming. way to redeem yourself:038:

x2!