Rebuilding 8" Toy Housing?

[99BlackTac]

In the not too distant future, i'm planning on a SAS for my 99 Taco. I recently picked-up a front axle from an 85 runner for the build. I know that this axle falls between 5-6" short of what I need, so I had an idea: Is it somewhat possible to cut the knuckles off and cut the housing apart so i'm left with just the 3rd mounting face essentialy, then add tube to my desired length, then add the knuckles?
Before everyone says, "just buy a diamond axle, or Sky, or whatever," I may end up doing that, but i'm just curious if this is do-able or not. I've got nothing but time to work on it, and materials would be rather cheap. Just looking for thoughts/opinions on it, what I may need to consider, what I haven't considered. I know the hardest part would be keeping it straight the whole time with all the welding, but I can work with that/around that. Let me know what you guys think. I might do it anyways just for the sake of doing it, especially since i've already cut the knuckles off!

[badmoonrising]

its been done but the metal is too thin....i wouldnt want to

[Jomentum]

get a Fj80 housing ?

[99BlackTac]

Originally Posted by badmoonrising

its been done but the metal is too thin....i wouldnt want to

I suppose I could use the housing mounting surface and area around/behind it as a template and kinda start from scratch, using 1/2" plate for mounting the 3rd, then build around it with 1/4" plate. Axle tubes would be in the 5/16"-3/8" range i'm thinking.

Originally Posted by Jomentum

get a Fj80 housing ?

That would be more $ than i'm looking to spend, plus i'd be flipping it, and i'd feel bad flipping an FJ80 front and risk screwing it up.

[88cleve4runner]

could turn into a nice little write up. i say go for it, i've never seen it done. and plus it could give you sometime to brag about when people talk about their bought axle, you can talk about your built axle?

[hunter4runner]

it's do-able you would have to flip it in the process and you would probably mess something up no offense

[NorcalPR]

There's a guy on Pirate IIRC that is a weld on spacer that goes on the short side. You'd need custom made longs for the short side.

[99BlackTac]

Originally Posted by hunter4runner

it's do-able you would have to flip it in the process and you would probably mess something up no offense

Never know till I try, but i'm fairly confident in my fabrication skills if I really take my time on it, set everything up right.

Originally Posted by NorcalPR

There's a guy on Pirate IIRC that is a weld on spacer that goes on the short side. You'd need custom made longs for the short side.

Is this what you're referring too? (Not sure if i'm allowed to site pics right from IH8Mudd, but regardless)



I don't like the idea of adding in spacers like that, i'd rather have one solid piece.

[Hoax 56]

i say build one from scratch, would be pretty cool to see and wouldnt cost very much. but would be hard to get everything right

[hytenor]

sell it and get a D44.
huge waste of time/$, IMO.

[Backwoodsboy]

Originally Posted by hytenor

sell it and get a D44.

huge waste of time/$, IMO.

agreed



and uh you need to flip that axle anyways. that mini truck axles are pass side drop. and tacoma is driverside output on the tcase. so yeah you need to flip it.

[NorcalPR]

Originally Posted by 99BlackTac

Never know till I try, but i'm fairly confident in my fabrication skills if I really take my time on it, set everything up right.

Is this what you're referring too? (Not sure if i'm allowed to site pics right from IH8Mudd, but regardless)



I don't like the idea of adding in spacers like that, i'd rather have one solid piece.

Nothing you can really do since the whole housing is just a top and bottom piece welded together to make the housing.

Best bet is to wait till Dan at Ruffstuff comes out with his housing, or go with a Diamond if you want all Toyota stuff.

[NorcalPR]

Originally Posted by hytenor

sell it and get a D44.
huge waste of time/$, IMO.

x2. I have the flipped housing and I have it because it was cheap and available at the time of getting parts. Worked out in my end. If I were to do it all myself though, I'd just get the right housing and call it a done deal.

[99BlackTac]

Originally Posted by NorcalPR

x2. I have the flipped housing and I have it because it was cheap and available at the time of getting parts. Worked out in my end. If I were to do it all myself though, I'd just get the right housing and call it a done deal.

I'll likely end up doing that, but i'm still going to investigate this possibility a bit further.

[hytenor]

Originally Posted by 99BlackTac

I'll likely end up doing that, but i'm still going to investigate this possibility a bit further.

it has been done...long thread on Pirate in the Tacoma section.

[vegaskurt]

There are a few build threads in the hardcore section on ih8mud. I remember seeing one where they extended an fj40 housing. There were pictures taken of the housing as they welded it that showed how easy it is to warp the entire housing.

If it were me, I'd chop the steering balls off and weld them onto a $400 ruffstuff housing. But if your looking for a project, build a jig and go for it.

[99BlackTac]

Originally Posted by vegaskurt

There are a few build threads in the hardcore section on ih8mud. I remember seeing one where they extended an fj40 housing. There were pictures taken of the housing as they welded it that showed how easy it is to warp the entire housing.

If it were me, I'd chop the steering balls off and weld them onto a $400 ruffstuff housing. But if your looking for a project, build a jig and go for it.

Yeah i've been looking into those housings, plus i've already got the steering balls off.