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post #1 of (permalink) Old 02-03-2007, 09:48 PM Thread Starter
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Welding on new hangers/perches/outboard brackets?

Hey All,

I started this project about 3 years ago, and then got buisy with a bunch of crap and never completed the project. I am trying to swap out the stock axles from my 79 cj5 for a dana 44 from a waggy, and an AMC20HD from a full size cherokee.

After letting the project sit for 3 years I have forgotten must of the details about what to keep in mind. So if anyone has anything they can help with it would be much appreciated. My buddy the welding master is coming out tommarrow to weld on the perches hangers and outboard brackets. Is their anything I need to keep in mind when laying this out?

The back should be simple I think? Bolt in the new axle, use angle finder to set diff and tcase angle the same and weld the perches in place? Should the angle be exactly the same?

As for the fron, seems slightly more difficult, I had some sweet outboard brackets fabd up which I will weld to the frame, then clamp on the hangers and weld them in place. I guess just measure 10 times then weld once, to make sure it is all square and in the right place?

any advice or recomendations will be much appreciated.

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post #2 of (permalink) Old 02-03-2007, 10:48 PM
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Re: Welding on new hangers/perches/outboard brackets?

On the rear shaft if you are sing a CV style make it about (2) degrees lower rather than pointed directly at the T-case.

If it is a non CV shaft, the angles should be parallel.

On that 20 I'd look at the factory plug welds and maybe grind them out and reweld them. Might also add a couple of 1" stitch welds at the tube and housing.

My Waggy 20 had some pretty poor plug welds and they broke out (looked like they exploded) and the tube rotated some.
First time I've seen it happen on one of the FSJ 20s.

Other than that, just measure a lot and make sure everything is straight before welding it in.

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post #3 of (permalink) Old 02-04-2007, 05:36 AM
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Re: Welding on new hangers/perches/outboard bracke

If you're going to use the same rear driveshaft, you're right - just make sure the angles stay the same.
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post #4 of (permalink) Old 02-04-2007, 10:30 AM
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Re: Welding on new hangers/perches/outboard bracke

When I did my SOA I only bolted down the front axle then took it to an alignment shop to set the proper caster before I welded the front perches.

For the back...if you are not doing a CV driveshaft...good luck getting the angle right....I would 'highly' recommend going with a CV ds...then the rear axle becomes easy....just point the pumpkin to the xfer case.

When I installed the CV ds, the first thing that came to mind was "why didn't I do that sooner". I had tried everything...xfer case lowering...shims....I could get the vibs out for normal driving...but the moment you accelerated...you got vibs....do the CV...trust me on that one.
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post #5 of (permalink) Old 02-05-2007, 10:48 PM
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Re: Welding on new hangers/perches/outboard brackets?

Another thing to remember is shackle angles, i like mine at about a 45* angle, they seem to work the best that way. Shackle angles make a huge differance in ride and flex.
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