Tough Front End for the Mitsi (suzolla)

[suzolla]

Hi,
Thought I would do a build thread for my front axle to go in the front of my Mitsi ex Trials Truck.
Need to build a new one as the existing one is custom width so not so easy to put Longfield Super set in and make other improvements.
So Parts List is
Center part of Hilux rear diff housing shaved to give more ground clearance
Hilux front Knuckle ball ends strengthened
3” NB Sch 40 pipe for the axle tubes
Some 12mm thick steel discs to make it easier to keep it straight when welding.
60 Series Landcruiser Longfield 30 Spline Super set, 60 series is 50mm wider than Hilux.
Longfield drive flanges.
ARB Locker
Trailgear 6 shooter knuckles and steering arms.
IFS hub swap to give another 60mm of width
Twin calipers to give independent brakes.
Initailly will use steering box to steer but thinking about going to Hydro Steer, still in 2 minds as will primarily be bush truck with some winch challenge and club trials.

Also as part of the mods going to change the front suspension. did have radius arms and panard, going to have 3 link and panard for better flex, reuse the 12" shocks for the front, will be using coils with air bags on top for reliable suspension but also able to raise and lower height.

Got all the bits, just need to get it done.

Already started on the axle build and removed the old axle and suspension, just need to sort out posting of photos and keep building.

Cheers
Tim

[tomsoffroad]

Wheres the pix? You know us 4wders cant really read

[suzolla]

Hi, yes I know photos are the preferred means of conveying information.
Have now worked out how to do it.
Apologies of the first lot of photos taken with the phone.
Will keep updating this post as progress is made.

Right the starting point before it all started.

Note that photos will not be in chronological order initially.







Most of the bits required to build the front axle housing, just the long side tube is missing, for those of you that are observant you will notice that 4 of the discs have the hole off center, tubes will be set high relative to the axle shafts.



Cutting the ends off the donor housing



Now have the middle bit I need and 2 surplus ends



Machining mandrel



Machining the center part of diff housing





Shaving ( chopping ) the bottom of the diff housing





Machining the knuckle ends true ready for welding on discs.



Discs machined and test fitted to knuckles prior to welding them on



Plates welded to the knuckles and machined true



Making the off set axle tubes



Long and short tubes finished



Shaved and strengthened diff housing





Milling the flange flat



Machinining the face on each end of the center section.



After machining the faces flat, boring the hole that will have the oil seal fitted so that the diff oil does not go up the axle tubes when on an angle.



Picture of axle seal that wil be fitted to inboard end in hole bored above, left seal, and outer axle seal, right seal.



Inboard axle seal fitted to axle, will just need to polish the axle a bit.



Welding axle tubes to center section, TIG root run then MIG to follow



Axle tubes welded to center section, now setting up to weld on the knuckle ends at the correct angle







Moving forward in time, haven't got any photos at the moment of the overall finished assembly, will do when I pull it out.

Photo inside shaved housing with counter sunk unbrako set screws fitted instead of studs to hold the diff head.

https://lh3.googleusercontent.com/-3JDiM_kBVSQ/UKIpFHBYHyI/AAAAAAAAAPs/Pc5aCdnFXHM/s512/DSC00875.JPG?gl=NZ

https://lh3.googleusercontent.com/-trDuwql-Qko/UKIpGOGQTgI/AAAAAAAAAP0/vzGjon0Hi7k/s512/DSC00876.JPG?gl=NZ

View of recess were inboard oil seal will be fitted to keep oil in diff head when on angles.

https://lh5.googleusercontent.com/-KPEzs8q89y8/UKIpEPpm_GI/AAAAAAAAAPk/YaAKbFoKmUs/s512/DSC00874.JPG?gl=NZ

Outboard and inboard axle seals

https://lh4.googleusercontent.com/-b7iRi2q93Jk/UKIpMybKVOI/AAAAAAAAAQw/LpuQs7a2yts/s512/DSC00883.JPG?gl=NZ

60 series Longfields polished for the seals ready to be fitted.

https://lh3.googleusercontent.com/-Y8BsggPNxUs/UKIpRWkvIWI/AAAAAAAAARE/trBW3H1qeFY/s512/DSC00886.JPG?gl=NZ

Inboard axle seal fitted

https://lh3.googleusercontent.com/-InKl5gTztz8/UKIpT7YNHLI/AAAAAAAAARc/EoQhbQXOMVo/s512/DSC00889.JPG?gl=NZ

Outboard axles seal fitted and knuckles clearance to take Longfield CV's

https://lh3.googleusercontent.com/-TslKCq1Z310/UKIpVvPKCPI/AAAAAAAAARs/mDfvKi0mqDM/s512/DSC00891.JPG?gl=NZ

Axle has been finished and had its first run (Woodhill 24hr) with no problems, will take some more photos of the finshed assembly when I next pull it out to fit the coilovers that I am going to fit.

Cheers
Tim

[suzolla]

Made a bit more progress, have added a few photos
Cheers
Tim

[turoa]

How come you're gonna run twin calipers? Why not just run with the one set?

[tomsoffroad]

Nice work Tim

[suzolla]

How come you're gonna run twin calipers? Why not just run with the one set?

I guess partly because I can as the knuckles have the lugs for 2 sets and also means that they do not interfer with the main braking system.
Cheers
Tim

[rokhound]

That is very