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View Full Version : Dana 35c tube thickness?



SuicideTireZJ
05-02-2006, 10:15 PM
Honestly, I searched multiple forums as well as google for this, but I couldn't find what I was looking for. My question is how thick are the axle tubes on a D35c?

I was thinking about an axle swap and the obvious pain is what to do about brackets. I, being the budding bootyfabber, came up with the idea of cutting the whole axle tube in half and just welding the part of the tube with all the brackets on it to the new axle. This probably won't work for the LCA brackets, but the UCA's, coil perches, shock mounts, hell, even the brake line attachments will all be MUCH easier to line up than cutting off each bracket individually and figuring out how to line everything back up.

Obviously I will gain about an inch of lift depending on how I cut the tube, but that's no biggie. I just thought this might be a decent way to save on time, money, etc. I'd imagine I'd just tack the two pieces together after adjusting the caster and making sure everything was lined up, and having a welding shop (or someone with more skillz than me) stitch the two pieces together, and weld whatever other tabs not on the cut to the axle as well. Is this a horrible idea, or one of sheer brilliance?

Here's an amazing MSPaint interpretation of what I'm trying to do (everything is pretty much approximate):

http://i19.photobucket.com/albums/b179/ZJBuilder/swapidea.jpg

LouisianaZJ
05-02-2006, 10:21 PM
i guess it could work

i think the tubes are 3/16" or so...

DJJordache
05-02-2006, 10:41 PM
thats pretty ghetto:poke: i am probably gonna go the route of 3x3x.25 square box and cut it with a 3.25 hole saw for the control arm brackets
heres the info:
http://4x4help.com/axle/axletube.htm

nate
05-03-2006, 12:45 AM
D35 tubes should be 1/4", same as most D44s.

ELLLLLIOTTTTT
05-04-2006, 01:10 AM
I'm thinking the tubes are 3/16" as well. I know 8.8 tubes are 1/4" and they are definatley thicker than the D35.

rob92xj
05-04-2006, 02:39 AM
They are 3/16's which is why the bend as easy as they do.

nate
05-04-2006, 12:41 PM
Maybe it is 3/16". I had a book with all the Dana axle specs, but I don't know where it when

EMTimZJ
05-04-2006, 01:37 PM
Man you guys are newbitrons.:booya:

http://www.cj7jeep.com/info/axle/images/tube_thickness.gif

http://members.cox.net/quanno/ford88.html
http://home.earthlink.net/~jetmanjay/id6.html

-These say that 8.8's are 0.25" wall as well. Some even 0.188"

-Tim

J B
05-04-2006, 02:54 PM
Even if they are the same thinckness, the 8.8 tubes are considerably bigger, making it much less prone to bending.

nate
05-04-2006, 06:34 PM
I was right :D

DJJordache
05-04-2006, 07:56 PM
I posted that same info at the top first so I want my cookie!:D

okzj
05-09-2006, 08:41 AM
NEGATIVE!!!!

Don't do it, man. Yes, it would be a lot easier, but you need to do it right the first time. If those welds fail, you're gonna be plowing the field with your pinion (best case) or watching your axle outrun you (worst case). The brackets need to be radiused for the new axletube and welded all the way around. That way, EACH BRACKET will have 1/4 of the weld length that the WHOLE TUBE HALF would have otherwise. It's a great idea as far as the mechanics go, but just welding pieces of the old axletube on is a bad, bad idea. If you are wanting more CA separation, build a truss. It will be much easier to do correctly.

Sorry to kill your idea, but I don't want anyone getting killed or worse: you screwing up a perfectly good ZJ.