Installing Dana 60 1 Ton Axle Swap Truss

[@05glisedan]

Impressive. Very nice work.... I'm still learning to weld. Looking to do a little work on my baby d30.... Maybe one day I'll join the big leagues. Looking forward to the next episode..

[@aireddown813]

Thanks Joe Man! I had a lot of fun on my Dana 30 in my CJ. Broke that sucker a few times. Haha, but it’s a great start.

[@ThePaulv12]

It's not that hard to weld well for the home handyman. Look deep into the puddle and place your mask close to the weld on some practice steel. Really look right inside the weld as you're executing it and keep it moving, moving the puddle over the work pieces then move foreword, repeat. Read a chart of welding faults (just Google it) and how to correct them and within a week your welds will be fine if you practice just 2 hours a night for 7 nights. In fact practice the faults to duplicate them so you can directly see what causes them, then make the corrections and see how the weld shape and quality changes. It is 90% preparation - which means cleanliness, properly clamped, some well placed weld tacs. It's really not that hard welding mild steel. An home arc welder will do a spectacularly good job. Just don't buy a cheap one. Buy a mid priced one up to about 180amp. Resist buying a high amp cheap or mid price high amp. Thing to look out for is duty cycle. That is the time the unit is rated to weld vs time to cool. A mid price 160-180amp arc (say $350-$500) with a true 40/60 or 30/70 (40% weld to 60% cool) duty cycle is far superior to a 200amp 10/90 sub $200 unit. What is hard, is all the theory and experience required to be a professional welder. It takes years of time and experience. My son is completing a welding apprenticeship and he is really good, but I asked him to weld a steel plate onto the bottom of my oil pan (removed from the car) as I can't do it at home as I have no 3 phase power here and I could tell he was unsure of himself. He's used to welding inch thick structural steel and then it being X-Rayed LOL. The weld was just OK by my standards but I could tell for a first attempt at light gauge he was going to be a good welder. Welding a bit of scrap 1/8" steel plate onto a sump had him worried as he hadn't ever welded such light gauge steel.

[@immelting9834]

Glad someone is doing a Durango. I have a Dodge Nitro on one tons front and back. 37's

[@aireddown813]

Now that I gotta see!!! Are you on IG or anything?

[@immelting9834]

@@aireddown813 No, I don't do any social media. However , starting in December I'm going to be building another rig. I have a perfect condition Dodge nitro I got from Texas ( I'm in the outer Chicago area) with a blown engine. I have a set of jk Rubicon axles for it and I'm probably going with a jk take out motor. It'll be on 33's maybe 35's and a family friendly light trail/gravel/ fire road rig. I'll be starting a channel to document the build ; and I'll have to do a walk around on the Nitros and drop a link for ya when I get it going.

[@aireddown813]

@@immelting9834 I’ll be on the lookout for that. Sounds awesome

[@northwestoff-roadopportuni7176]

I sure hope mine turns out even half that quality lol excellent work and thank you for sure each step and tips!

[@ICanThrive]

Awesome job, like your attention to detail. If you want super clean welds welding cast iron to steel, use Royal 44-30 mig wire, the beads are just as clean as welding regular steel, same shielding gas, you won't use anything else after you try it for the first time, excellent welds.

[@aireddown813]

Thanks for the compliment. And thanks for the suggestion. I will give that wire a shot.

[@TheClintmeister]

I was taking welding classes (6G) in the summer. I got one of those open back welding jackets (Great Northern, Atwoods, Tractor Supply). A small fan away from welding but on the body helps too. Dam nice welds there.

[@TheClintmeister]

You need to make YOURSELF a t-shirt, "I create AXLE Porn"!

[@aireddown813]

@@TheClintmeister thanks my friend! I’m no expert, and I hope they hold forever. As soon as my channel hits 10K subs, KZbin will let me sell merch. Then I can make some cool t shirts. Haha.

[@bruizer28]

Dude. Not sure if you are an actual welder, but whether you are or not, good job. Your welds look good and your being hard on yourself with the NiCor. Looks solid. Much respect and look forward to the Durango build. I have done two SAS dakotas and I love this foundation. Doing a SAS Titan now

[@aireddown813]

Thanks so much! That means a lot to me seriously. No I’m not a pro welder, just a self taught garage welder. Dang man you’re the SAS king. Any pro tips on the dodge platform?

[@bruizer28]

You had me at “DURANGO”

[@aireddown813]

Haha. Hell yeah!

[@williamcorbin4275]

You're work is money...$

[@PowerTankOfficial]

A little prep goes a long way!

[@thatmand4542]

Man those are some beautiful welds man :D keep it man

[@aireddown813]

Thanks my friend!

[@dylanschuler2761]

great job. doing the same truss. where did you get you nicore wire. and what brand/ thanks for you videos.

[@aireddown813]

Thank you! It’s blue demon brand. You can buy a 2 lb roll from eBay. It’s called ENiFe-Cl. Let’s see if this link actually works. www.ebay.com/itm/303690185500

[@luiscruz-no3ib]

That looks like a great job

[@aireddown813]

Thanks my friend!

[@2birddogsandawolfdog945]

They make flap disc sander wheels for 4 1/2" grinders. Clears paint off way better than wire wheels. And for no rust, do little pisser welds to seal up the seams. Tacking should be done AFTER pre heating, otherwise the tacks just crack. Next time!!! 😜 Spent way too many years in steel industry.

[@mattgipe84]

Awesome work man! I’m planning a 60/14 or 60/80 combo for my JKU one of these days. Gonna start with a truss and c gusset on my 30 with 37s first though.

[@aireddown813]

Ooooo 60/14 or 80 is so dope on those 4 doors. Good call on the gussets. Don’t want any smiling 😬

[@leslieschyving6487]

Glad you found a use for the weed burner since it’s too scary to use on weeds in the Nevada desert! Nice video!

[@aireddown813]

I agree. That thing is way too hardcore. A 100% of burning your house down.

[@fogstain]

The weed burner really does the trick. its perfect. I did the same

[@aireddown813]

@@fogstain Such a game changer for sure. Thanks for the Sub my friend 👊

[@peterhatch1583]

Where do I buy that truss please and thks for the video plus I like the last song on your video who is he??

[@aireddown813]

Thanks! The song is “New Old Town Blues” from Bo the Drifter. And Artec should have that truss online. I know they were redoing a ton of trusses to their bent designs, so they may have phased this one out.

[@TheNobodyZone]

I would have left the gaps so there was more contact on the welds.

[@MrRickstar321]

I’m planning on doing the swap in my TJ, every vid I’ve seen on YT cuts that 2” off between the diff and yoke, just curious why you didn’t and what effect that will have on mounting if going to coil overs out as close to the wheel ends as I can? Is it a weaker connection there if you don’t cut it out?

[@aireddown813]

I had a plan from the start to cut the short side tube and add 4”. Something I didn’t articulate well in the video. I’ve since done that, and I have enough room for shock mounts. If someone isn’t widening their axle, I’d say cut the casting like you describe.

[@pointblankyt9878]

Great content awesome welds thank you for the video and input on welding it’s going to help me in the near future

[@aireddown813]

Thank you! I’m glad these videos are helping people out :)

[@genoory5090]

Beautiful welds & the cosmetics of the whole axle😍....Hey,whatever happened to the durango you was working on?

[@aireddown813]

@@genoory5090 thank you. The Durango is sitting in the shop waiting. I’ll get back to it someday.

[@genoory5090]

@@aireddown813 Okay. Awesome👌🏻. Looking forward to it

[@ericvinson8889]

Hey can you tell me what back spacing you went with on your wheels to clear the steering etc.?

[@aireddown813]

The wheels I’m running are 20x10 with 3.5” backspacing, and there’s plenty of room for the steering.

[@ryannelson2211]

I was hoping you would check with the string device to see if it stayed straight after the truss was welded on

[@aireddown813]

I didn’t even think about it! Missed opportunity. Sorry man.

[@ryannelson2211]

@@aireddown813 I had the benefit of watching back to back

[@joshy0369]

Awesomeness

[@ExploringStillConnected]

Looking good! Can't wait to see you start cutting into the Durango! And I hate welding to cast, so yea, your beads look great👍

[@aireddown813]

Thanks my friend! I started designing the link brackets for the frame side of the Durango, so not too much longer and I should be elbows deep in the swap!

[@CommanDOH-JKU]

Should have it it with two coats of Weld through Primer instead of the paint. Less worry about stripping the paint where you're going to weld.

[@bobbysmith4726]

No matter how much I feel like I wire wheel my axle housing I can’t seem to get it to come out as clean or as nice and shiny as yours, and not just the tubes but the Cs and the knuckles as well. Did you just use wire wheels and a lot of elbow grease or am I missing something? 😂

[@aireddown813]

I have many secrets! First, I use anti spatter spray (Pam 🤣). Next, I chisel the spatter balls I do get off with a hammer and a screwdriver. Next I use a sanding pad on a die grinder to smooth out any blemishes. Then I wire wheel to finish it off.

[@Hillbillyable1]

I used oven cleaner to degunk and then wire wheeled it. Finished with Corroseal (rust converter) then painted it.

[@morganheberling]

a work of art bruh

[@Dallas-Rife-UDX-347-Tennessee]

By the way , try welding in the mid 90’s temperatures here in middle Tennessee with the 90 % plus humidity,, I did it for a living for over 5 years . You don’t sweat , you leak like a busted water pipe ! I don’t miss those days

[@aireddown813]

Hard pass! That sounds terrible 🥵

[@sshyshy6097]

God damn im very impressed with you very disappointed in the product for needing that much modification

[@aireddown813]

Haha. Thanks. It's one of those things I bet most people just weld it on as is and usually don't have an issue. I can't afford to do it twice, so it better be nice.

[@matty86suk]

Toatally awesome and beautiful!!

[@aireddown813]

Thank you sir! You are much too kind.

[@nitrofish1974]

Nice work 👏 what is that rear out of ? Just asking

[@aireddown813]

Thank you! The rear is from a 2004 F250 Superduty. The front and the rear are from the same truck actually.

[@moejr14]

What is the difference between 2005 + and 99-04 Dana 60?

[@genestarwind4610]

Call me extremely ignorant. Are Dana 60s bending alot? Seem like a heavy axle. I know off road is a lot of twisting but to bend a Dana 60 must take impact to justify this must more weight and metal.

[@aireddown813]

I think your logic is right on track. These are only bending under extreme circumstances. For example, mine was bent because the truck I got it from was in a front end collision that ripped the leaf spring off the truck. When it comes to welding though, it doesn’t matter how much metal there is, if you heat it up enough, it will warp.

[@Dallas-Rife-UDX-347-Tennessee]

I’m enjoying catching up on some videos . Nice work . I’m really liking the music in this video . Who is the singing this song ? @ 10:20 ?

[@aireddown813]

Thanks for watching my friend! Artist: Bo the Drifter Song Title: New Old Town Blues I found this guy on the epidemic sound platform for copyright free music for KZbin videos.

[@courtneychappell8801]

America 🇺🇸

[@bradleybrowning5971]

Are you mounting coil overs? If so could you tell me which brackets you are using please? Nice video 👍

[@aireddown813]

Thanks for the compliment! I will be mounting ORI struts, and I’ll likely be making the mounts custom so I can really dial the fitment in. But I was very close to buying the truss mounted shock tabs from Artec. They are the ones that mount on the corner of the truss where it bends down to the axle tube.

[@bradleybrowning5971]

@@aireddown813 oh okay! Thank you. I am building a 90 Chevy 1500 with a99-04 60. The truck will have a cummins and I’m trying to figure out about mounting coil overs.

[@aireddown813]

@@bradleybrowning5971 that sounds dope!

[@bradsmith403]

Thought that was a 10am tecate

[@techi3075]

Is the center cast iron or cast steel?

[@aireddown813]

As far as I can tell, it’s cast iron.

[@davefuria5205]

slag you drag, looks good tho

[@aireddown813]

Haha. Thanks. I shouldn’t have been so high and mighty about it, but it’ll do!

[@davefuria5205]

I watched most of the dreadnought build any new progress

[@aireddown813]

@@davefuria5205 I have a new video pretty close to being done. I’m hoping to finish it up in a week or two.

[@ChickenDad]

what wire gauge are you using? .035?

[@aireddown813]

I’m not entirely sure, but knowing me, it was .030” for the mild steel and .035” for the nickel iron wire.

[@runningproblem]

What welder is that?

[@aireddown813]

It’s an old Millermatic 185

[@runningproblem]

@@aireddown813 that’s what I guessed. Looks like 50% wire speed and 50% voltage. It’s fun watching you put all this together. It makes it seem less intimidating for me and I have no idea what I’m doing.

[@aireddown813]

@@runningproblem thanks man! It’s been scary sometimes especially when cutting into the housings. I’m stoked that this is making you feel better about trying it yourself.

[@gordonboylan]

Rim?

[@aireddown813]

KMC Hex beadlocks 20x10 with superduty 8 lug pattern. 3.5” backspacing.

[@TheRealSlowhand]

Apparently, you have a problem with any comment critical of your welds... So rather than leave those comments you reply then delete the comment... Clearly, you're a joke for conducting yourself this way... Maybe that's why you have so few subs because any legitimate fabricator/welder can see you don't know how to weld... So if you don't like the criticism just delete the comment without giving some BS reply before you delete the comment... I had given a thumbs up, but seeing how you conduct yourself I changed it to a thumbs down....

[@aireddown813]

I didn’t delete or flag your comment... so thanks for the assumption. If you were such a great welder, you’d be more interested in helping people better themselves than cutting them down. That proves to me you are the internet troll I’ve been warned to not give the time of day. Thanks for the welding tip, and for dragging your poopy attitude through my channel.

[@TheRealSlowhand]

@@aireddown813 You really are a joke to try and spin this around... My other comment was responded to by YOU, but when I went to respond it was gone... So clearly you did remove it... Someone that self inflates his welding ability with no clue that those "pretty" welds are just that... They're not however quality welds... As for helping youbetter yourself I wouldn't waste my time you have too much of a self inflated belief that your a welder because these welds look pretty... That misplaced ego tells me it's a waste of time to tell you why those welds suck... Lastly, you have a few comments on this video, but not one that is negative... Could it be that you filtered them out like you did my original post... It certainly must be... You do what you like with this response message... I don't need to offer welding lessons since I gain nothing from it but you would have gotten my advice if you asked rather than delete my other comment after you replied...

[@aireddown813]

@@TheRealSlowhand I didn’t delete it. I don’t delete comments. It’s funny how offended you are though. Also, I said “you’re probably right” and “thanks for the tip” yet you say I have a big ego. Meanwhile your ego has you trashing me, and self proclaimed novice welder, for being excited for my progress. You won’t waste your time helping anyone improve, but you’ll waste it being a jackass on my channel. You can’t fathom for one second that I welded the truss cold to stop the housing from warping, which I stated in this video. You clearly can’t be helped. I’m sure you have some last word agenda so I’ll undoubtedly hear from you again, but I really hope not. Go troll someone else’s channel.

[@aireddown813]

@@TheRealSlowhand Look man, I’m sorry I let us go this far. It has me really frustrated. Can we call a truce?