Toyota eLocker retrofit - assistance needed

[clfrnacwby]

I am retrofitting my front '85 front axle to accept an eLocker. I have removed everything from the housing - axles, existing 3rd, etc. so it's ready to be modified. I would rather not experiment on this housing so I could use some assistance from some of you more experience fabricators - especially someone who has done this before. Here's what's required.

1. I have an eLocker gasket and new studs coming on Monday. The gasket will work as a template - the housing needs to be notched to fit the eLocker.
2. After the housing is notched, the mounting surface area will be lacking for the 3rd so a bit of welding/grinding needs to happen to get some of it back.
3. New studs need to be added to the housing. This will require drilling and tapping - I hear a drill press and some way to hold the axle level will make this go easier. I have the correct sized drill bit and tap on order from Low Range, but they are backordered right now...should be here soon.

Here's a nice write-up of what's required to mod a rear axle - there's quite a bit of overlap with what's required on the front axle. I'll just have a couple of extra clearance issues with the ubolts/leaf springs to work out once I get the axle back under the rig.

http://sonoransteel.com/phong/retrofit_electric_locker.html

I'll monitor this thread, you can PM me, or text/call 376.1191 (801).

Thanks,

Andrew

 

[sixstringsteve]

What part do you need help with? I've done this on 3 different axles, and they all leaked, so you probably don't want me there helping.

If I remember correctly, the front axle is trickier to do because the spring perch is right there and it gets close to getting in the way.

I had a really tough time drilling the hole on a drill press, so I just used a regular drill and got better results.

 

[clfrnacwby]

Thanks Steve. Yes, the front axle requires a bit more work than the rear. Specifically, there are a couple of bolts on the outside that will interfere with the springs. I already have plans to replace those with low-profile allen head bolts.

Specifically what I need help with, is drilling and tapping the new holes and the welding to build up a couple of sections for better gasket coverage.

 

[sixstringsteve]

cool. I'd be happy to help with that. Do you want to do it at my place or yours?

 

[clfrnacwby]

I can bring it by your place. Do you have an 8mm drill bit and tap? If not, I'll have to wait until mine comes in. I'll call you this week.

 

[sixstringsteve]

I think I have 2 sitting around but I need to find them first.

 

[ricsrx]

I have a center punch that fits the bolt hole diameter of housing for marking the new holes that will be drilled, and tapped,

If you all need any help, lmk

 

[sixstringsteve]

Andrew, do you happen to have any extra welding gas? Mine's starting to run low. It's at about 1000 psi, but I'm not sure when it dies. I'll try to get it swapped out at lunch today, but if you had a spare tank I wouldn't have to.

 

[clfrnacwby]

I don't, sorry. My welder is just setup with flux cored wire right now.

 

[sixstringsteve]

allright, i'll try to get my tank swapped out at lunch.

 

[clfrnacwby]

Steve is a fab wizard. We got the axle all welded, drilled, and tapped last night. Then, going above and beyond, he helped me get it cleaned up and the elocker third installed. It's ready to install back into my rig.

Thanks again, Steve.

 

[sixstringsteve]

I wouldn't go so far as to say wizard, but I'm glad I could help.

 

[Kevin B.]

Osumsauce!