‘Re-Born’ B-Body Dana 60

[Cranky]

Yup... I'd be looking for .003-.0035

Rule of thumb, .001 per inch of diameter

Alternate rule of thumb: 0.0005" / 1.000" of diameter for a heavy press fit. For 3.0000" OD DOM TUBING = 0.0015" interference. But different shops/millwrights have their own preferences and opinions and methodology.
BOB RENTON

In this application I'd probably shoot for .001 especially if it's going to be welded.

 

[Nxcoupe]

Agreed, you are pressing into cast iron which is very brittle. I'd go less interference and get a good solid plug weld as well as peripheral weld on tubes to housing. Make sure you get the cast iron very hot when welding it, if you didn't already know.

 

[Cranky]

Agreed, you are pressing into cast iron which is very brittle. I'd go less interference and get a good solid plug weld as well as peripheral weld on tubes to housing. Make sure you get the cast iron very hot when welding it, if you didn't already know.

Well, it's not plain grey cast iron..... https://www.sciencedirect.com/topics/engineering/nodular-iron

 

[Fran Blacker]

I'm in the .003 group. Freeze tubes warm the housing and they'll almost fall in, maybe they will.

 

[Nxcoupe]

Yeah, there's a small difference but it is not steel, that was my point. Have at it, I'm interested to see how it turns out.

 

[ignition1]

Plan to make a .002” cut and bring it down to a .003” interference, then a quick sand. I’ll see how the day plans out to get this done, thanks for all the input

 

[ignition1]

Re-cut tubes to +.003” over inner diameter of housing, pressed in and finished last 1/2” or so with sealer, gonna check straightness of tubes before welding to the housing ;)

 

[ignition1]

Finally got around to plug welding the housing & welding the tubes to the housing. Tubes were cut at e-body width with Mopar perches @ 7 degree pinion up from level perches. Next to weld on the re-used housing ends.

 

[ignition1]

Tacked and making the root pass

 

[ignition1]

Housing is DONE and ready for powdercoat!! Thank you for the input from the members who chimed in.

…still need to drill & tap the vent bolt

 

[Cranky]

Hey, looks like my blocks and your welds look more purdy than mine. I just don't weld enough these days to keep in shape.....

 

[Runcharger]

That looks great. Nice to see one saved.

 

[ignition1]

‘Super Track Pak’ OEM 1968 4.10 gear set and PowrLok Sure Grip 35 spline. Replacing with new clutches.

 

[ignition1]

Carrier is back together… one step closer!! Just waiting for the housing to be powder coated.

 

[ignition1]

POWDERCOATED and power washed, time to start the assembly…

 

[ignition1]

10 fitments later… we have a rough pattern. 5 more tries and then good pinion nut torque at 250 ft/lbs AND pinion bearing preload at 30in/lbs.

 

[Nxcoupe]

10 fitments later… we have a rough pattern. 5 more tries and then good pinion nut torque at 250 ft/lbs AND pinion bearing preload at 30in/lbs.

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Looks good to me! How much was it to powder coat the housing? That looks amazing.

 

[qkcuda]

Very nice work!

 

[RemCharger]

So which ujoint size yoke is that? And what splines on the pinion?

 

[ignition1]

Looks good to me! How much was it to powder coat the housing? That looks amazing.

I sent a bunch of parts down to get coated, but I think the sand blasting and semi black powder coat for the housing and backing plates I’m guessing were around $2-300 of the bill.