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Project Panel Replacement

certifiablejeep said:
2 nuts fully threaded on and then whack N/S/E/W on the nuts with a BFH.
it then starts to crack the seat.
Put in a small shim/wedge and repeat... then step up to larger pieces and eventually it works itself off.
Click to expand...

Happens to me every time i strip one down although i just use a nylon hammer and beat ten bells out of the thing to free it off.
No damage to the stub shaft just have to watch out for bits of nylon flying around 😁
 
Definitely had a workout with this guy... it did not want to come off.
I have never had to replace/take one off before, so wasn't sure... I snuck up on it, but this thing was welded on 6 ways from Sunday.
Got it off and rough ground it down and am almost at where the axle tube was snug up against the steel.

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Will clean it up more and repair it... the spring pin definitely wallowed out the center hole, but even with the minimum clean up, it sits pretty snug against the axle.

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I have to get the other one off and then can start to work on the actual axles and cleaning them up... hopefully they go faster.

cb
 
Got the other one off... different approach, took longer, but saved more of it... either way, these are fine to use.
I will have to repair a few things and add a little more material when welding, but all in all, this is what they look like if anyone was ever wondering.

cb

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Trying a new setup to work on axles... perfect height, stability seems OK... but not something I would want small children around.
Need to get the spring perches off, as well as the drums, they are really on there.

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Cut tubes underneath, need to repair these as well.

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Side shot of the madness... lots of things pulled apart and just waiting on the arrival of the frame.

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cb
 
I had to pack up a few things to ship out last night, but forgot to post the cleaned up axle on both sides... next repair where the PO cut the spring perches off, grind them down and get them ready for axle assembly. I won't weld them until the drivetrain is in place, but I can get them at least ready for the frame.

Then the front axle.

I love that these are 3.54 1986 axles, but there was a lot of work here to put them back to stock.

cb

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The side shot of the madness picture hits home.........There's a lot going on in that shop! I still marvel at how much you get accomplished in such a short amount of time. Be well and stay safe - no falling motors/trannys!
 
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Took a break from the project to get the bosses Jeep fixed up.
Fuel pump was making a lot of noise and it wouldn't start intermittently (Howell Injection setup 258).
New pump and filter and good to go!

cb
 
Cleaning up the tubes for welding

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Not much I can do except for clean them up, weld in the cracks and then smooth it out... the perches will be installed there over this fix and welded again, so hoping for the best... didn't realize how mangled these were when I got them. They should be fine once all the work is done.

cb
 
Cleaned up the axles for the most part... I missed one small area after grinding them down.

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New perches are in and they are larger/taller

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Also, they don't have the provision on the rear for the brake line retainer.

So, I think I have to cut them down a bit as technically being taller (this is upside down), they will actually lower the Jeep, not raise it... so I think some modification are coming to get it more like stock.

You can't find the stock stuff anymore for the D44 rear, so I will just have to make it work and get it as close as I can...

cb
 
How it started, how it was, and where it has gotten to.

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I can't leave well enough alone... I wanted more of a stock look and wanted the rear brake line retainer to be in the stock-ish location... so away we went.

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They came out pretty good, can't complain.
Took longer, but they at least now don't look like a big eyesore.

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They are pretty close to fitting where they need to be... just a little fine tuning on the grinding.

cb
 
Now that the rear axle is done, moving onto the front.

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Have to remove the SOA modifications on this as well and go back to SUA.

Not sure if everyone knows, but on a 1986 front axle, the hubs are thicker where the drag link / tie rod go.

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Front view

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TBR (To be removed/relocated)

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Tried to get a shot of the gouging that was done, but the light had other plans:

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It is the same, if not worse, than the rear.

cb
 
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