Brillos Builds

[brillo_76]

So I got the axle housing out. Plasma cut the rear plate off. Then grinding down the ring so that I can weld on the replacement backing plate.

 

[brillo_76]

So when I welded the back plate on. Then filled the housing with motor oil to check for leaks.

 

[brillo_76]

Which I expected, it took me 3 passes of welding to get that plate sealed back onto the housing and having zero seeps... This photo was just before painting, but you can see.. I had to significantly beefing up the welds around to get it sealed.. So if you have seeps.. No biggie, grind down the welds and weld again ...

 

[brillo_76]

Now, this is axle housing lived its life in the rust belt. So I had 8 bolts that just snapped...So now I just drilled a 1/8 hole in each of these bolts... Starting with a 1/16 bit for a pilot. Then jumped up a few more bits to get a larger hole surface inside the bolts. Once that is completed. I use wax crayons to circle around the bolts to use the wax for 2 purposes. When you weld the bolt hole shut the heat will melt the wax down to the threads. Then 2nd is so i don't weld to the other metal next to the bolt. As its always best to get the old bolt out and clean up the threads, then to completely drill it out and re-tap the bolts which mostly you have to jump up a size or 2 to get good threads again.
So here are a few pictures of me doing the sway bar bolts and other bolts.

 

[brillo_76]

Here is the painted axle housing. I am waiting for the breather gasket and axle seals... I am also modifying the 3rd member studs and nuts. Being in the rust belt. I got 45mm x 8mm X1.25 tap bolts with flanged nuts in Stainless Steel. This is so the bolts don't seize. I also put stainless in the rest of the housing for the same reason. I don't have the bolts yet so I don't have a photo of the completed housing with the nickle copper brake lines and the stainless steel nuts on the brake lines too..

 

[Speedy]

I guess I'm surprised that the housing to basically container of oil could rust through. Wow.

 

[GhostRing]

I guess I'm surprised that the housing to basically container of oil could rust through. Wow.

"Weather Wins"

Every time :Cry:

 

[brillo_76]

I guess I'm surprised that the housing to basically container of oil could rust through. Wow.

They rust from the outside in on the housings... The boxed frames go from inside out. Its interesting but what happens. The life in the rust belt. Where you not only fight the chemicals on the roads. You have to fight the freeze thaw ratio that is what gets us here.. That freeze thaw is complete hell on steel with the expansion and contraction of the steel. That really execrates the rot and you throw the salt and melting chemicals in the mix is like using a flame thrower.. Oh well, it what happens in this environment.

 

[brillo_76]

My 45mm X8mm X1.25 tap stainless bolts arrived. Along with the my axle seals, breather and 3rd member gasket. So I pulled the old axle gaskets out and put the tap bolts in and set the gasket on. Now ready to pull the the old axle out so I can start the swap out.

 

[brillo_76]

The Rear axle housing being removed. I should have just used the table. So I did not think that one through. Good thing they are not supper heavy and 2 people can move them.

 

[brillo_76]

Well I got the 3rd member out of the old axle housing. Cleaned up and back into the replacement housing. The 45mm are too long. You can actually use 30 mm Bolts which would make it a lot easier to get the member in. I could
not get the abs out of the old housing which doesn't surprise me at all. So set the axle in and see how the worked. I painted the member and cut the extra off the bolts. Torqued the nuts naturally before painting it all.

 

[brillo_76]

Got the dust shields cut off as there was nothing left of them. Then just painted the outside of the back plates as I wait for the new replacement nuts.
Granted its a lot easier to clean the body panels with the rear axle out Along with the frame.

 

[brillo_76]

I did get the rear axle back in along with the gas tank.

However, for whatever reason. I currently can't add compressed images to my thread. Seems to be a firefox web browser issue. Chrome works so I added the photos.. There is the rear axle and gas tank with skid back in the rig.

 

[brillo_76]

Now I am plating the rest of the frame that needs repaired due to the Rot that the rust belt keeps on giving me. There is an 1/8 plate angle behind the front section. Not much metal there but with the angle in there and welded in it will be stronger now. I didnt grind the welds down or paint it yet.

 

[brillo_76]

Well the Pinon Seal was leaking gear grease.. I wonder why??

 

[brillo_76]

So, because I don't have seal press that will push seals in with shafts in them. This is what happened my first try. Yes, I do make mistakes. Good thing the seals are reasonable.

 

[brillo_76]

So on these styles of seal. If you don't have the seal press like I don't, I used a piece of wood. Taking my time. Just giving it a little tap tap tap... That is definitely a lot better seal installation...

 

[brillo_76]

The Lift gate repair. Looks a lot better then a hole in it.​

 

[brillo_76]

The frame needed repaired the front arches needed metal.. The rear frame is all plated in this rig. So I just rebuilt the front arches. The passenger side first. Then the drivers side​

I expect 5 years or so then I have to replace the frame. Which I have but need swap a few around. Then take one of those other frames and replace this one.

 

[brillo_76]

Last but not least. Was the replacement calipers and rotors.. along with replacement lower ball joints. Those were the old ones with one looking aftermarket and the other original 220K on the clock​