This is part 4 of our Ultimate Adventure Jeep build. Yes, we took a brand-new ’12 Jeep Wrangler, built it once on 35s, then cut it in half and are building it a second time (read all about it in the Aug.-Oct. ’12 issues). Love it or hate it, this Jeep will get you thinking outside the box. We decided that a Jeep with front and rear steering axles (in our case, Spidertrax Spider-9s) should be able to weave its way through tight twisty trails with relative ease. And as you can read in our UA coverage, it did (page 50). Last month we showed you how the HazzardFabWorx gang grafted the front framerails of a junkyard JK onto the back of our pristine 3,000-mile orange Wrangler. On top of that we started adding the fenders, grille, and rear hood for an out-of-this-world–looking Jeep with a trunk. We call it the Off-Roadster. This month is all about axles and how to make them go together. The Spidertrax axles, True Hi-9 centersections, and some really cool shafts that we stuffed under this Jeep are drool worthy, both on the trail and on the shop floor. Read on and check back in next month, when we button up this wild ride. The axles of our Ultimate Adventure Jeep started in a fabrication shop in Colorado. At Spidertrax headquarters the 31/2-inch by 1/4-inch wall tubes were welded into the fabricated centersection.The axles of our Ultimate Adventure Jeep started in a fabrication shop in Colorado. At Spi The 1/4-inch-thick fabricated centersection is welded inside and out. The front mounting surface for the third members is made of hefty 3/8-inch plate and then machined, drilled, and tapped for mounting bolts.The 1/4-inch-thick fabricated centersection is welded inside and out. The front mounting s Spidertrax offers Spider-9 housings in both centered and offset designs, but the centered housing has plenty of tubing length for most any application. The housings are designed for optimal ground clearance, more than any other off-the-shelf 9-inch housing, and they weigh just 60 pounds.Spidertrax offers Spider-9 housings in both centered and offset designs, but the centered Spidertrax offers a downloadable Excel worksheet to determine the length of axleshafts you need to order and how to cut and build your housing at home for a desired overall width and pinion offset. We decided to mimic our front JK housing pinion offset, but enlarge the overall width of all the axles to 70 inches.Spidertrax offers a downloadable Excel worksheet to determine the length of axleshafts you Once we determined how much to cut off each axletube we took them to McKay Manufacturing in Spokane and had the tubes cut in the shop’s horizontal band saw. McKay is a world-renowned leader in high-tech machining, so our Jeep axle project was a simple job for them.Once we determined how much to cut off each axletube we took them to McKay Manufacturing i With the tubes cut to length, we returned to Hazzard Fabworx to install the knuckles. First we sanded the ends of the axletubes for a smooth finish and clean metal to weld to.With the tubes cut to length, we returned to Hazzard Fabworx to install the knuckles. Firs Next we set the third member mounting surface at zero degrees vertical using a digital angle finder from Summit Racing Equipment. With this at zero, we can then determine knuckle caster angle.Next we set the third member mounting surface at zero degrees vertical using a digital ang We tapped the Pro-Series 60 inner knuckle on just slightly to get it started and then made a mark perpendicular to the axle C on the tube and a corresponding mark on the C. This will give us a reference point should we need to turn the knuckle slightly for caster.We tapped the Pro-Series 60 inner knuckle on just slightly to get it started and then made Next we began tapping the inner chromoly knuckle C onto the tube with a dead-blow hammer. The C has a long section of tube to center itself on the axlehousing tube.Next we began tapping the inner chromoly knuckle C onto the tube with a dead-blow hammer. While installing the C we constantly checked the caster with Summit’s Intercomp digital angle finder. We opted for 8.5 degrees of positive caster (leaning toward the rear of the Jeep) on the front axle. This allowed us to roll up the pinion slightly if need be and still have adequate caster. On the rear steering axle we set the caster at zero with a zero-degree pinion angle, as we will not be using rear steer at speed so caster is less important.While installing the C we constantly checked the caster with Summit’s Intercomp digital an Luke Shuman of Hazzard welded the axle Cs to the axletubes. The Spidertrax fabricated housing also allows ease of adding all the other suspension brackets, as they can be welded anywhere on the housing.Luke Shuman of Hazzard welded the axle Cs to the axletubes. The Spidertrax fabricated hous The rear axle uses a three-link-with-track-bar–style suspension. This uses a single upper link that is attached to a mount welded at the top of the differential housing.The rear axle uses a three-link-with-track-bar–style suspension. This uses a single upper The front axle uses Synergy JK axle mounts to duplicate the stock axle mounting style. This allowed us to reuse all of the Zone Off-road Products parts of the front 4-inch long-arm suspension.The front axle uses Synergy JK axle mounts to duplicate the stock axle mounting style. Thi Once all the mounts are installed we assembled the outer knuckles. First the spherical bearings are pressed in and held in place with snap rings.Once all the mounts are installed we assembled the outer knuckles. First the spherical bea The shim washer spacers that go between the bearing and the knuckle are what center the knuckle on the bearing. various shims are included in order to get a tight fit.The shim washer spacers that go between the bearing and the knuckle are what center the kn We start with the top 7/8-inch bolt. This drops into the knuckle, through the shim washer, through the spherical bearing, and though another shoulder washer before the nut is installed. No greasy bearing to install.We start with the top 7/8-inch bolt. This drops into the knuckle, through the shim washer, The lower shim washer is installed and the knuckle knocked into place. The knuckle should be tight but still able to be turned by hand. The lower bolt, like the upper, keys into the knuckles so it is unlikely to back off and loosen.The lower shim washer is installed and the knuckle knocked into place. The knuckle should Inside the axlehousing we installed triple O-ring and dual seal axle seals. We added silicone to the O-ring side, and there is a set screw to hold the seals in place. These are used in both front and rear axle applications.Inside the axlehousing we installed triple O-ring and dual seal axle seals. We added silic Rather than using silicone we opted for a reusable LubeLocker gasket between the housing and third member. These make removing and servicing the differential clean and easy.Rather than using silicone we opted for a reusable LubeLocker gasket between the housing a For ground clearance and strength we had to go with the True Hi-9 centersections. These differentials use proprietary high-pinion gearsets. The front diff is a 5.38 Hi-9 (left) while the rear is the burly 5.40 Mega Hi-9 (right).For ground clearance and strength we had to go with the True Hi-9 centersections. These di The Hi-9 and Mega Hi-9 put the pinion 21/4 inches above the centerline of the axletube. This is greater than a high-pinion Dana 60 or Dana 44 by an inch! Plus the Hi-9s offer load bolts and three pinion bearings for redundant insurance against gear deflection.The Hi-9 and Mega Hi-9 put the pinion 21/4 inches above the centerline of the axletube. Th Though many high-pinion differentials are not recommended as rear axle applications, the Mega Hi-9 was designed as a rear axle. Note the huge gear teeth on the ring gear for additional strength. Both third members use Yukon Grizzly full-time lockers as well as Yukon bearing kits, bearing supports, and pinion yokes.Though many high-pinion differentials are not recommended as rear axle applications, the M The Hi-9 differentials and Spider-9 axles once installed kept our Tom Wood’s driveshafts tucked nice and safe up within the chassis. These same differentials are found in many competitive 4x4s, including the buggy driven by Erik Miller that won this year’s abusive King of the Hammers race (“Throttle Down Crown,” July ’12).The Hi-9 differentials and Spider-9 axles once installed kept our Tom Wood’s driveshafts t The axleshafts built for us by Spidertrax are made of 4340 chromoly shafts with 300M yokes. Within these we installed CTM 60 joints also made of 300M. All parts are heat-treated, built to order, and very unlikely to break in a lightweight Jeep like ours.The axleshafts built for us by Spidertrax are made of 4340 chromoly shafts with 300M yokes One final note on the Tru Hi-9s: Proper break-in and lubrication are imperative for longevity. The axles must be filled with 85-140 nonsynthetic hypoid oil, and they must be filled to the bottom of the oil fill plug on the third member, not necessarily the one on the fabricated housing. The axles also need to be run at light load up to 500 miles with constant cooling in order to break in the gears, at which time the oil should be replaced.One final note on the Tru Hi-9s: Proper break-in and lubrication are imperative for longev We are running out of space this month, but we have to point out the new Ultimate Unit Bearings designed and built exclusively through Spidertrax. These unit bearings are easy to install, eliminate the need for a drive flange with their splined body, and are a trouble-free, clean, and simple alternative to rebuildable bearings and hubs. We’ll tell you more about them and the trick brakes, steering, and suspension next month.We are running out of space this month, but we have to point out the new Ultimate Unit Bea SOURCES Tom Wood's Custom Driveshafts 2147 N. Rulon White Boulevard Suite #103 Ogden UT 84404 801-737-0757 www.4xshaft.com Synergy Suspension 870 Industrial Way San Luis Obispo CA 93401 1-805-242-0397 http://www.synergysuspension.com Summit Racing 800-230-3030 http://www.summitracing.com Yukon Gear & Axle 10411 Airport Road Everett WA 98204 866-631-0196 www.ringpinion.com Spidertrax Off-Road 7510 Hygiene Road Longmont CO 80503 800-286-0898 www.spidertrax.com Bubba Rope 310 W Melody Lane Casselberry FL 32707 N/A www.bubbarope.com Nitto Tire 6021 Katella Avenue Suite 250 Cypress CA 90630 877-565-8448 www.nittotire.com Off-Road Power Products 866-379-8685 http://www.offroadpowerproducts.com Warn Industries 12900 S.E. Capps Road Clackamas OR 97015 800-910-1122 www.warn.com Jeep N/A AK 877-426-5337 www.jeep.com Gen Right 4535 Runway St Simi Valley CA 93063 805-584-8635 www.genright.com Zone Offroad Products 888-998-ZONE Hazzard Fabworx 509-995-1176 Lube Locker www.lubelocker.com True Hi-9 218-236-8864 www.truehi9.com Off Road Design 970-945-7777 offroaddesign.com/ CTM Racing N/A AK 760-450-0006 www.ctmracing.com By Fred Williams Enjoyed this Post? Subscribe to our RSS Feed, or use your favorite social media to recommend us to friends and colleagues!
