We were able to source partial 3D models for both of our axles from websites such as GrabCAD in the form of STEP files. We brought the step files into Inventor and made a few minor alterations to make the models accurate to our exact donor parts. Next we began modeling axle trusses and suspension brackets as necessary to adapt the axles to our suspension systems.
The 14 bolt had to have all of the old brackets cut off of it so that the truss would fit. Here is the axle all cleaned up and ready for the truss.
The front axle is a Dana 60 from a late model Ford F-350. This axle also had to be stripped of all it’s original brackets to make room to work. Here is Jason grinding off the old brackets.
Brakes
For the brakes, we did not want to reinvent the wheel. We are using slightly upgraded calipers and rotors from the OEM ones originally found on the axles. The OEM brakes haven’t had any issues stopping a full size diesel truck on 40s so they are more than adequate to stop a tube frame with 37s. For the brake lines we are using hard line along the axle trusses, trailing arms, and frame. To connect these separate lines we will use steel braded cables so they will bend when the axle flexes. We are also using two separate master cylinders because of two reasons. The first being reliability. With two master cylinders, both have to go out in order to lose all of your brakes. If one goes out you still have the other to limp back to camp. The other reason is the front needs more braking force than the rear for better handling. So we can get the next size up for the front brakes and the fine tuning will come from a balance bar that’s built into the pedal assembly.