I have been working on building this axle for about 6 months.... the real delay is the fact that I'm really cheap and I have to wait on my dad to do the machine work (for free). so far I have $150 into this axle and I only have to cut down 1 axle shaft.
heres what has happened so far:
1. I bought a high pinion d-44 housing for $50
2. I had the tubes cut off at the housing and the housing bored out on a horizontal mill to the outside diameter of a tj d-30
3. I pressed the tubes out of a tj d-30 I got from a "put this in for me and keep the old one" deal.
4. I ground the inner knuckles off the d-30 tubes..more on this later
5. I had to cut 2 3/4" off the long side d-30 tube. i figure that must be because of the width difference between the d-30 and d-44 housing.
6. I pressed the tubes into the housing, set the angles, set the width, checked spring perches and welded it tight.
7. I torched the tj inner knuckle apartand welded the part that holds the ball joint to the axle housing for the upper control arm mount. this involved LOTS of measuring and patience with the angle finder as this mount has several angles to it.
then I painted the whole works so it wouldnt rust... I dont wanna hear about the color.. its all I had..
it looks like this now.