Narrowing a Differential For My Turbo 5.3 LS S10 (how to) | 8.8 Ford Rear End Rebuild #1

This time on SPPTV Rob begins rebuilding the Ford Explorer 8.8 Diff he plans to use in his 7875 Turbocharged LS S10. The stock s10 rear end has 3:73 gears and a posi, but it would have been likely to fail from the amount of power the new setup will be making. Follow along as Rob takes this Rear end from junkyard level to mint!
Shout out to Butcher Bro's for lending Rob the jig! Besides that, no special tools are needed. Besides a welder if you consider that specialty. It is a fairly simple process, but it is important to measure everything accurately and take your time.
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[@FreedomInc]

You should use c-channel and clamp your work inside the c-channel. Put to good tacs,turn 90 degrees and 2 more tacs. Then weld it in quarters opposing each other.

[@SPPTVarmy]

Why would i do that when i had a rear end jig? But that is a good way to do it without a jig

[@FreedomInc]

@@SPPTVarmy because it costs nothing because usually 8 inches of angle iron or c-channel is just laying around. Sp it costs nothing. It ensures your work stays exactly where it should be. There is no second guessing. The jig relys on the centerline it falls in which may not actually be the centerline of the rear end. And example is if something is bent,the centerline wouldnt be rights. Using the c-clamos and c-channel that costs nothing because they are already laying there,ensure it is all true from the outside of the tube at the point you are working which will give you a true centerline. Once you tack it in 4 places then weld in opposing quarters,you then measure from the axle housing to the end of the tube in 4 places to ensure correct fitment. There reality is there ks 100 ways to do everything. The most inexpensive,less complicated way is usually the best. I cut down an 8.8 with nothing but a marker, measuring tape, masking tape, a grinder with some cutoff wheels , 2- 8 inch pieces of channel, 2 clamps, and 2 jack stands and an everlast tig welder I added the comment to inform someone that no fancy tools are needed to do any of this stuff. Especially guys or girls comming in get intimidated by all the extra stuff. Be sure to weld the tubes to the main housing also.

[@tavorislevy5476]

SweatPantsPosseTV where can I buy a rearend jig

[@FreedomInc]

@@tavorislevy5476 why spend the money when you can make one for next to nothing? I explained how.

[@fivestar8337]

With an alignment bar couldnt you have welded on 9 inch ends? Gotta buy axles anyways. Explorer brakes will bolt right on to big bearing Torino ends.

[@robertsimons8680]

I just shorten a s10 rear for my trike where do you order your axles from thinks

[@aaronroberts3848]

Duuuu I don't know how to use a chop saw duuuuu ! Just use a God dame band saw !

[@SPPTVarmy]

Got one to give me duuuuuh

[@Gmullin12]

Quick alignment technique is to take a straightedge and make a line on the top and side of the axle so its clocked exactly like factory

[@edward-x3s6f]

Is this as strong as a Ford 9 inch ?

[@SPPTVarmy]

Lots of guys go fast with them, they are plenty strong.

[@billprudencio8450]

Flip the chop saw around and you would have no problems.

[@OCALLARM]

Im still involved in making solid beam axles. The runout in the tubes is the reason you saw the cut parts not lining up. It's ok, every axle tube has some runout from the manufacturing of them. The bracket welding and the swaging process both put runout in thr tubes before the axle is ever installed in the vehicle.

[@FreedomInc]

Before making your cuts,you should habe taken a grinder with a cutoff wheel and horizontally cut a line in the rear end. that would habe ensured your end plate alignments were perfect with no guess work.

[@Squeekybeeky385]

When you order the axles how do you get the Chevy bolt pattern with the 8.8 spline at the s10 length?

[@tylertucker4478]

Could you not just leave it wider and just let tires stick out or make it up in back spacing? And move the saddles to align rear end in the truck?

[@SPPTVarmy]

Yes, many people do it that way.

[@a.j.dominicfrancis4514]

Good job brother

[@mlone7]

you could have made your cuts further inward on the housing and then took a couple of pieces of angle iron on 180 degrees from each other and put C clamps on them to align the axles as well as your bar/jig setup.

[@seando87]

Where did you get your truing bar? Im gona me attempting an 8.8/3rd gen camaro build this winter and would like to have one.

[@SPPTVarmy]

I borrowed it from a friend, not sure where he got it.

[@ezelk1337]

Great job on the narrowing of the rear end. I wondered how people did that. Very well done. Really like all of your videos.

[@Gmullin12]

Make 2 straight lines across the cut section so alignment is easier

[@Paulster2]

To ensure the ends stay clocked correctly on the tubes, just draw a straight line all the way down the tube over the spot where you cut the piece out ... you'll then be able to line it up easy and correctly without worry.

[@blindabinda1234]

Paulster2 I bought this digital angle gauge. Thing works awesome. You just pick a spot say on the pumpkin of the axle then check the difference on the ends and if it's say 12 degrees you cut them off then reweld them at 12 degrees from your benchmark. It works great for roll cages or any angle you have to transfer or mimic.

[@Paulster2]

What I was talking about is, if you put a stripe down the length of tube before you cut, it's VERY easy to align the pieces after you make the cut. If the line is straight before the cut, making it straight after the cut will put the tube in alignment right where it should be. Easy-peasy. The angle finder has its uses, no doubt ... I'm just all in on finding the easiest way to do something, which a Sharpie has covered hands down in this instance.

[@blindabinda1234]

Paulster2 ya I know what your talking about. I'd probably use a sharpie also like your saying but I'd still check the angle just for a piece of mind.

[@FreedomInc]

@@Paulster2 mark what is being cut out. Tale a cutoff wheel and cutback light horizontal line. Simple,fast and guaranteed perfect placement every time.

[@Excentrix54]

NEVER NEVER NEVER USE A CHOP SAW to cut something you want straight

[@ernestomejia110]

some of the comments suggest to weld the tubes to the center section. So, if they're not welded on from the factory, could you take 2 sets of rear ends and slip the tubes out of the center to make one with two long tubes and one with two short tubes? Instead of cutting the long side of one.

[@CharlieBrown-pb9xn]

yes you can

[@PerrybuiltPerformance]

Might be something to think about. I was told by numerous people in the 8.8 world that if I planned on putting power down I also needed to weld the tubes to the housing all the way around. Might be something to do while you have it all apart!

[@8wireracing694]

Hahaha Mike likes the sparks...as long as he doesn't make you guys fight and throw tools around.

[@fordkack9314]

Excellent work, i must say you got skills and balls, i would newer dare to try that

[@MartinMcMartin]

Top marks to the guys trusting you with their alignment jig. Hope you rought them beer

[@BooM-HeadsshoT]

8:57 - 9:03 made me jump cutting that bit out and going right to the chop saw at full rpm haha

[@waynep8007]

This is the best channel on KZbin...!

[@ACELABUTSA]

i thought you had a band saw i just did this and used a band saw it was super easy ... set it and go grab a beer!

[@dubCanuck1]

Nice work as always Rob. And Clayton with the Timmie's-sporting cameo!

[@guidoheeling1179]

Wow, these videos just keep getting better! keep it up guys!

[@xozindustries7451]

Could you get two long axles and cut them and respline them, or will that kill the heat treating?

[@SPPTVarmy]

Ya i think you would have to re heat treat them

[@meangenevstheworld.7773]

Yes you can do it that way. You wouldn't hurt the heat treat by cutting and machining as long as it's its got cutting fluid. That being said the machine work may cost as much as new axles.

[@meangenevstheworld.7773]

@@shaun4bigblocksllc wrong about what ?

[@hectorramirez-pm5in]

What size axles did you end up ordering? I’m going to cut an explorer 8.8 for my 1st gen as well but I want the same size/ placement overall as the stock 7.5 s10 diff because I have a set of rims that are perfect with stock 7.5 and I’m looking to keep it that way

[@SPPTVarmy]

When you go to order axles they should give you a spec sheet to fill in so you get the exact size. My axles are shorter then stock 7.5 length

[@erichnl1]

I saw on a thread a guy ordered from moser and asked to get 1"less than the stock explorer short axle he cut 1"from the short axle tube and 4" from the long (driver) side..

[@hectorramirez-pm5in]

@@erichnl1 and that was to fit stock 7.5 diff specs?

[@erichnl1]

@@hectorramirez-pm5in yes that was for stock size s10 2wd the 4wd are different width

[@PCMrX.9961]

Go to harbor freight and buy a PIPE CUTTER I think I paid $25 to $35 for it. It will cut a good straight cut. I have a 20 by 80 lathe now and it's no problem.

[@HughieGT]

Will you make a video showing how you fab up your four link? Currently upgrading my luv truck.

[@Myvintageiron7512]

I have a question hopefully you can answer if you narrow the long side only on an 8.8 how wide of a tire can you tuck under the S-10 Bed thanks for any light you can shed on this I and doing the same thing but I want a 12" wide tire tucked under my plan is to cut the long side down and use two short side axel's bit I don't know if that's enough for 12" tire Thanks so much by the way your videos are very helpful!!

[@SPPTVarmy]

I dont think a 12 inch wide tire will fit between the frame and outside lip of the wheel opening.

[@Myvintageiron7512]

@@SPPTVarmy O definitely not I forgot to mention we are going to narrow the frame

[@SPPTVarmy]

If you narrow the frame and run the proper offset i would think they would fit

[@CharlieBrown-pb9xn]

It depends on rim backspacing from that point

[@b.c4066]

Too late but why didnt you use a simple ridgid pipe cutter, just like a tubing cutter but much bigger. They can be rented for 25 dollars a day.

[@backyardbuilttrucks1]

Chop saw has deflection in the wheel . . double check for being square. Love the channel.

[@ronringel9132]

I've been waiting for this video... Nice job Rob.

[@marshallnoise3557]

I am surprised you didn't weld the tubes while it was all straightened on there.

[@Brad_James]

Nice info!!!

[@tommygunnz7154]

Would bird cages make your life a lot easier? instead of welding them brackets but back on. Then you'd be able to play with pinion angle for more grip.

[@davidconley3610]

Very informative video Rob!

[@eliseorafaelmataramirez5021]

Buen trabajo Gracias por compartir Saludos

[@jerrynova1]

Did you measure for a centered or off set pinion?

[@vidznstuff1]

Where did you source the axles and how much were they (each)?

[@shitbox7413]

Looks really good, nice work as usual Rob. 👍🏻

[@HammerHeadGarage]

Where did you order the axles?

[@dannymarrel3776]

I don't get it. Some are narrowing them some aren't.

[@SPPTVarmy]

Depends on the backspacing of the wheel you’re using

[@overdonecustoms7012]

I’m narrowing a Ford Explorer rear end also and I’m looking for another short side axle would you b interested in selling yours, since you won’t be using it?

[@04pts8k]

did you weld the tubes where they meet the center section for a bit more strength?

[@jlkelly304]

Ah shit, new tunes!

[@rafatrill]

How come u didn't upgrade to 9inch press on bearings ends?

[@hendren244]

Awesome job rob! What is the mesurment of the new axles you ordered ?

[@hendren244]

Crickets...

[@SPPTVarmy]

Sorry, they are 2 inches narrower then a stock s10. I can get you exact measurements if you want

[@hendren244]

Lol its ok man, you don't have to but if you would that would be awesome of you. Are you measuring from the inside of the axle flange or overall ?

[@BLUECFURR]

I saw this video a few on my play list before I watched it, it looked like Steve Erwin about to rassle a crock

[@honestmechanic7974]

Dont know if you went over this or not but why use the ford 8.8?

[@luckautofab4461]

honestmechanic 79 Ford 8.8 is pretty much a copy of a chevy car 12 bolt.. 31 spline axles and come with 3.55 3.73 or 4.10 gears with posi stock.. and there cheap from the local junkyards from 96-01 explorers with disc brakes.. all and all with Rob narrowing it himself and buying new axles he will still probably have less then 800 bucks in it.. cheap upgrade and they will hold twice the power vs a stock s10 diff

[@ChuckBeefOG]

honestmechanic 79 Because it is already narrowed to the right length on one side, half as much work. Ford also has good rearends in those days. Like the guy above me said, they will take more power and more gear options than the weak S10 rear end that can only take about 300hp.

[@SPPTVarmy]

The Sonicstang, Shithorse, and Clayton's Mustang all have 8.8s as well.

[@HaNg_ALL_ThE_tRaItOrS_hiGh]

The 8.8 is stronger than a 9" anyway.

[@cmsracing]

Left handed people unite!

[@garylogan5460]

you going to use stock gears or are they going to be lower ROB? nice job on the truck so far like your videos,keep them coming.

[@novaracer2000]

gary logan im using the 3.73 gears the 8.8came with.

[@_Anthony___]

Would this work the same for a ls3 c10?

[@trapspotcustoms627]

Daughter from work? Who would of ever guessed you had kids lol my kids dont let me get shit done 😂

[@8wireracing694]

What amps are you set at to weld the axle tubes rob...just in case I take a crack at this one day.

[@FreedomInc]

1amp per thousandth is a good starting point. So 1/8th inch material would start at 125amps. It is all in how you weld tho. Usually the faster you can weld it,the better off you are. So run hotter,and move faster is better to cooler and slower. Because the slower you run the more heat goes in the work. I would habe dont this totally different. First before I made my cuts for what was taken out,I would have cut a horizontal line with a cutoff wheel. So no matter what it would be aligned perfectly when it went back together. Then,use c-channel or similar as a fixture. Put two pieces one top and one bottom ckapme it all together and it cant move. 2 good tacks turn it 9p degrees and tack again.GOOD TACKS. then welfare it in opposing quarters so it wouldnt come out of square. And be sure to bevel the tubes and leave a small landing.

[@chadharmon5716]

Y'all enjoying the nice weather up there?

[@SPPTVarmy]

Yup, me and Rob are having a drink outside right now.

[@ChuckBeefOG]

It’s 9am just across the border in Ontario and it’s 27 with humidity. Gunna sweat at work later today.

[@blackmacgyver9965]

I hate when the breaker trips when using my chop saw .

[@canabox7112]

I am a welder. One of my pet peaves is when people call a disk a blade!

[@RAM_C5]

But did you let it cool?

[@heavyweight8854]

Too late now, but you should have bought 9 inch ends. eliminates the c-clip in favour of the floating axle.

[@austindoud273]

heavyweight 88 disc brakes the poor mans c clip eliminator kit

[@novaracer2000]

Exactly, this was cheaper.

[@georgebonney90]

👍

[@1991CALYPSO]

I miss seeing Bendy :(

[@SPPTVarmy]

He's in a upcoming video

[@dragbikedemon]

Fn Clayton! Lol

[@mjminino]

what exit song is that?

[@rickzym6223]

bla..bla..bla.

[@SPPTVarmy]

Bloobity bla