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10.5" sterling shave

Printed From: Rocket City Rock Crawlers
Category: General
Forum Name: General 4x4 Discussion
Forum Description: Tech Talk
URL: http://www.rocketcityrockcrawlers.com/forum/forum_posts.asp?TID=12508
Printed Date: 28 March 2024 at 4:05pm
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Topic: 10.5" sterling shave
Posted By: 83K10
Subject: 10.5" sterling shave
Date Posted: 04 November 2018 at 7:50am
We had a customer at our shop want us to install a ballistic fab shave kit on his 10.5" sterling axle destined to go in his JK. 

I started by turning down the ring gear to 10" in our lathe.

https://flic.kr/p/29DmAoQ" rel="nofollow"> https://flic.kr/p/29DmAoQ" rel="nofollow - Sterling 10.5 ring gear being turned down for shave kit. by https://www.flickr.com/photos/45086110@N05/" rel="nofollow - Griffin93 , on Flickr

Next, we setup the axle in our CNC mill. We didn't have a fixture for holding the axle but we made it work using some V blocks and clamps. 

https://flic.kr/p/2ckwon1" rel="nofollow"> https://flic.kr/p/2ckwon1" rel="nofollow - Sterling 10.5 setup in our cnc mill. by https://www.flickr.com/photos/45086110@N05/" rel="nofollow - Griffin93 , on Flickr

Machining it down. 

https://flic.kr/p/2biUftU" rel="nofollow"> https://flic.kr/p/2biUftU" rel="nofollow - Machining away the bottom of a 10.5 sterling for a shave kit. by https://www.flickr.com/photos/45086110@N05/" rel="nofollow - Griffin93 , on Flickr

Testing the fit while it's still setup in our mill. 

https://flic.kr/p/2biUrFd" rel="nofollow"> https://flic.kr/p/2biUrFd" rel="nofollow - Test fit the shave kit. Measurements in ballistics directions are perfect. by https://www.flickr.com/photos/45086110@N05/" rel="nofollow - Griffin93 , on Flickr

While we were machining stuff, we turned down the back of the hubs and pressed on these abs rings. 

https://flic.kr/p/29Dmuto" rel="nofollow"> https://flic.kr/p/29Dmuto" rel="nofollow - Sterling 10.5 hubs machined for jk tone rings. by https://www.flickr.com/photos/45086110@N05/" rel="nofollow - Griffin93 , on Flickr



Replies:
Posted By: 83K10
Date Posted: 04 November 2018 at 7:58am
We welded this plate on the bottom. Special precautions had to be taken as the housing is cast iron. We used 0.045 Ni55 welding wire with 90/10 gas mix for spray transfer. We pre heated the housing to 250 degrees. Between each pass we used a knotted wire wheel on a grinder to clean up the weld area as the casting was very dirty. We also used a needle scaler to stress relieve the weld area between passes. Once the welding was finished, we stuff a welding blanket inside the diff and wrapped another one around it. This allowed it to cool down really slow. 

https://flic.kr/p/2cu7Xiq" rel="nofollow"> https://flic.kr/p/2cu7Xiq" rel="nofollow - 2018-10-31_07-43-41 by https://www.flickr.com/photos/45086110@N05/" rel="nofollow - Griffin93 , on Flickr

https://flic.kr/p/QqHLih" rel="nofollow"> https://flic.kr/p/QqHLih" rel="nofollow - 2018-10-31_07-43-09 by https://www.flickr.com/photos/45086110@N05/" rel="nofollow - Griffin93 , on Flickr

https://flic.kr/p/2baM4Ni" rel="nofollow"> https://flic.kr/p/2baM4Ni" rel="nofollow - 2018-10-31_07-43-19 by https://www.flickr.com/photos/45086110@N05/" rel="nofollow - Griffin93 , on Flickr


Posted By: 50Willys
Date Posted: 04 November 2018 at 8:16pm
Good job John!!


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Bob S.

'96 Cherokee, 4.0L w/Auto Trans & locked D44s

'99 Dodge 2500 CTD Tow Rig


Posted By: alabamatoy
Date Posted: 05 November 2018 at 7:06am
Wow, very nice.  Not many 4X4 clubs have members with this sort of skills and capabilities.


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"If you didnt buy your 1st gen 4Runner new, then YOU are a newbie!!"

BRC Life Member


Posted By: dontoy
Date Posted: 07 November 2018 at 8:52am
Nice work John you got mad skills!

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1985 ToyBuggy w/TBI GM4.3/TH350, Marlin doubler, 4.88's, locked front & rear, 37" TSL SXII, and other stuff.


Posted By: trevordavis0521
Date Posted: 08 November 2018 at 9:37am
Pretty cool John!


Posted By: CJ7OX
Date Posted: 02 January 2019 at 6:59am
Nice work, John!

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~Sean
Some people spend an entire lifetime wondering if they made a difference in the world. But the U.S. ARMED FORCES don't have that problem. -Reagan

MOLON LABE
85ish CJ-7/06 CTD



Posted By: 83K10
Date Posted: 03 January 2019 at 7:33am
Thanks guys. I hope you guy enjoyed see the pictures of doing this. I'll try to share more stuff like this in the future. 



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