Axle Gussets - JKowners.com : Jeep Wrangler JK Forum
 
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post #1 of 10 Old 06-21-2011, 05:28 PM Thread Starter
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Axle Gussets

Thinking of beefing up the dana 30 up front on my JK. looking at Rusty's axle gussets.

Is it possible to weld the gussets on while the axle is still mounted on the jeep? or is it required to remove the axle and shafts? I doubt there any risk of burning thru, but would the heat of welding mess anything up? Seals bearings etc?

Mike B

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post #2 of 10 Old 06-21-2011, 05:33 PM
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you should be fine, most people just do small sections at a time and even put a wet rag on the welds to cool them down and go back and forth from side to side to letting time for each side to cool down a bit. the gussets are a very smart upgrade
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post #3 of 10 Old 06-21-2011, 05:42 PM
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Yup. Can definitely be done with the axle in place.
Did a set of polys yesterday actually.
Well let me put a disclaimer on that- poly performance and OREs can be done on the jeep- never done a set of rustys.

Just do a little bit at a time and alternate sides/upper/lower too keep as much heat out of the plastic ball joints as possible.
I also use a wet towel on the bjs between passes to help cool them/prevent as much heat soak as possible.


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post #4 of 10 Old 06-21-2011, 05:47 PM
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x2. Welded some Teraflex ones on mine and just had a cool wet rag on the BJs as stated. worked fine.

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post #5 of 10 Old 06-21-2011, 06:13 PM
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Awsome thanks for the tips! Mine are in the mail


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Black 2008 x ,Dana30 Aussie locker,Teraflex C gusset's 2.5 Pro comp coils,Adj Rancho Rs9000's JKS quick disconnects,Jks Adj trackbar, 35.13.50.15 Toyo MT's on 15x8 MB Razors, K&N intake,Superchips, Magnaflow muffler,Optima Red top, Poison spyder ricochet rock rails,Solid diff covers, front Mopar rock bumper chopped, HD D-rings,Xrc 8000 winch, HOGG cut fenders!Bedlined interior, 130 watt kc slimlites
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post #6 of 10 Old 06-21-2011, 08:03 PM
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I bought the teraflex just because there easy to weld in, ive welded both styles.
They get HOT when welding them on be VERY careful not to melt your balljoints...they are plastic if still stock.
I installed poly bj's after welding gussets.
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post #7 of 10 Old 06-21-2011, 11:04 PM
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We use Poly, and they can be welded with the axle housing on the Jeep, but since we are also sleeving our axles, we do it off the Jeep. For $100 more, plus some drilling time, the inner sleeves are WELL worth it...just food for thought!

Nena Barlow

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post #8 of 10 Old 07-15-2011, 03:10 PM
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Do you have any pics of the installed gussets, trying to get an idea of where I would need to beef up my housings.
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post #9 of 10 Old 07-15-2011, 04:03 PM
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Welded mine while on jeep. Just used plenty of water to keep cool!!

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post #10 of 10 Old 07-15-2011, 04:20 PM
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I did my Poly C's and the rest of Rusty's kit while the axle was still under the Jeep.


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