Rearend swap, rebuild, powdercoat project

[Tx Firefighter]

I recently did a thread on my conversion to late model front suspension with rebuild and powdercoat work. I figured since that part of the project is done, I'd start a thread on the rear conversion process. This process will likely take a week or two since parts are so expensive and I have to scrape up the extra coin to buy as I go. I will update the thread as I make progress like I did the front end swap on the earlier thread.

I started with an 80 model 12 bolt rear differential out of a leaf spring truck (obviously, since all 80 models are leaf springs). I am going to completely rebuild this thing and install it into my coil spring equipped 63 truck to get highway gears and 5 lug wheel pattern.

First, I spent some time cutting and grinding all of the leaf spring pads and shock mounts off the donor unit.




Then, I tore the unit completely apart, removing everything from the housing. I will replace all seals and bearings, so no worry about damaging the old units. I need the housing completely bare to degrease it and powdercoat it.






I cleaned all of the internal stuff to evaluate what needs to be replaced and what can be reused.

[Tx Firefighter]

Next, I bought a set of Early Classic Enterprises rear end saddles. These things are just the ticket to put a generic axle into a coil spring truck.

I centered it under the truck and set the pinion angle and tack welded the saddles into place. Then, I removed the whole unit and welded the saddles permanently into place. Not my finest welding, but solid and not going to fail.




Now, I put the housing into the oven to cook it at 500 degrees for an hour. This will bake any remaining grease or oil out of the nooks and crannies.




It's in the oven now, so hopefully later tonight, after it cools enough, I can get it sandblasted and powdercoated. If not tonight, that will be the goal for tomorrow.

After that, a trip to the parts store to buy new pinion and axle seals, carrier, pinion, and axle bearings, and cover gasket.

[ruffrida2005]

Is that a home made oven? and if so do you have a link on how you built it. I know some people that want to build one!

[Tx Firefighter]

My buddy built it in his shop. It's just basic welding and fabricating. There is a lot of information on the net about building them to go by.

[forestb]

I'm Sorry what is the point of the oven? and are those saddles for the 63's and up or will they work on a 62 also?

[Tx Firefighter]

The oven is twofold. One, it bakes off any grease and oil to get the surface ready to accept the powdercoat. Two, it is how you cure powdercoat. You have to hold the part temperature at 400 degrees for 20 minutes to cure the powder. Once it is baked grease free, I will sandblast the housing and apply the powder, then back into the oven again.

The saddles will fit an coil spring rear GM truck.

[daverod]

Just bought me a 71. sub. $300 and it runs. I was holding off because I did'nt know if the rear end would work in my 66. All I have to do is watch you and I have it made. My welding sucks so I think I might let someone else do the welding. Keep up the good work. Wish you were closer I'd let you do powder coating.

[ruffrida2005]

where is Springtown near? I'm in Killeen!

[Tx Firefighter]

Well, good progress in the last few hours. It is now blasted and powdercoated...






Hopefully tomorrow, I can get some bearings and seals and start reassembling it.

[TR65]

Man, Nice work Kevin.

TR

[daverod]

What angle did you set the pinion at?

[slepysal]

very nice work,Tx dig the attention to detail. What did you use to cut the leaf spring perches off?
I am trying to scrapr up some $$$ to have Chief install the 67 rear end into my 60.
Oh and forestb the saddles are the same 60-72, they are just spaced diffrent on the 60-62's
Keep up the good work Tx

[Tx Firefighter]

Originally Posted by daverod

What angle did you set the pinion at?

I did it a way that is hard to explain. I set the original rearend on the bench and made sure the axle saddles were perfectly level. Then, I measured the pinion angle and found it to point up 10 degrees from level. On the new rearend, I just made sure that with the new saddles perfectly level, the pinion pointed up 10 degrees. I don't know what the angle will be once installed, but it will be exactly what the original angle was on the original rearend.

Originally Posted by slepysal

very nice work,Tx dig the attention to detail. What did you use to cut the leaf spring perches off?
I am trying to scrapr up some $$$ to have Chief install the 67 rear end into my 60.
Oh and forestb the saddles are the same 60-72, they are just spaced diffrent on the 60-62's
Keep up the good work Tx

I used a torch to remove a bulk of the original saddles, then a grinder with a flap wheel to buff off the remaining remnants. I had no need to save the saddles for reuse, so I could be pretty crude on removing them.

[padresag]

Originally Posted by slepysal

very nice work,Tx dig the attention to detail. What did you use to cut the leaf spring perches off?
I am trying to scrapr up some $$$ to have Chief install the 67 rear end into my 60.
Oh and forestb the saddles are the same 60-72, they are just spaced diffrent on the 60-62's
Keep up the good work Tx

you can usually take old perches off with a hammer from the underside on one side and it should just peel off at the weld and grind it.
if the perchs are going in at the same angle as the old ones do the one side at a time then you can use 2 straight sticks across the perches and eyeball till the sticks balance out across the housing
ron

[Tx Firefighter]

I went ahead and did one more thing tonight before shutting off the lights. I powdercoated the cover in ultimate chrome. I'm too poor to afford a real chrome cover, so a refurbished original cover will have to do. Bad pictures though. It looks fine in person.

[TexC-10]

You're my hero!

[rustyescott]

damm good work

[joe231]

very nice work...and fast, you seem very efficient

[sams60gmc]

Looks great man. Makes me want to get motivated to go get mine all ready to put in!