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View Full Version : Building a HP44 to stock Waggy width (61.5")Posted: Mon Jan 28, 2008 3:11 pm


Wildman
03-24-2008, 23:49
I started this project with a bare housing from a 1976 Ford F150, or at least that is what I was told it was off of. I picked it up off Ebay for $100 and then had to have it shipped from PA to WA.
http://img.photobucket.com/albums/v654/wildman4x4nut/Jeep/IMG00481.jpg
I cut the ends off as close to the inner knuckles/inner C's as I could.
http://img.photobucket.com/albums/v654/wildman4x4nut/Jeep/IMG00485.jpg
Then ground down the welds on the inner C so that I could get the tube that was in them out.
http://img.photobucket.com/albums/v654/wildman4x4nut/Jeep/IMG00484.jpg
Tube thickness isn't in issue.
http://img.photobucket.com/albums/v654/wildman4x4nut/Jeep/IMG00482.jpg
I had done a search on Pirate before I started this project and was able to get some measurements. 1980-84 Waggy shafts are 15.8" short side and 32.12" long side. To make this housing fit those measurements I need to cut tubes down.
http://img.photobucket.com/albums/v654/wildman4x4nut/Jeep/IMG00490.jpg
I took the short side down to a length of 8" and the long side to 24 3/8" from the center of the casting hole on the pumkin to the outside edge of the tube.
We then heated the inner C up in 400 degrees in my buddies oven. (His wife was gone)
It slipped onto the tube no problem.
http://img.photobucket.com/albums/v654/wildman4x4nut/Jeep/IMG00493.jpg
We set the pinion angle to 13 degrees and the caster at 7 degrees.
http://img.photobucket.com/albums/v654/wildman4x4nut/Jeep/IMG00492.jpg
Checked 5 times and welded ONCE.
http://img.photobucket.com/albums/v654/wildman4x4nut/Jeep/IMG00495.jpg
http://img.photobucket.com/albums/v654/wildman4x4nut/Jeep/IMG00500.jpg
Wildman
03-24-2008, 23:51
Then it was time to install the Rubicon Express bracket kit.
Now this is more for a TJ/XJ/ZJ at this point but I figure I should add it.
First is the bridge over the pumkin.
http://img.photobucket.com/albums/v654/wildman4x4nut/Jeep/IMG00502.jpg
http://img.photobucket.com/albums/v654/wildman4x4nut/Jeep/IMG00504.jpg
http://img.photobucket.com/albums/v654/wildman4x4nut/Jeep/IMG00505.jpg
Next is the coil spring brackets/shock mounts.
http://img.photobucket.com/albums/v654/wildman4x4nut/Jeep/IMG00507.jpg
http://img.photobucket.com/albums/v654/wildman4x4nut/Jeep/IMG00508.jpg
Next is the pass side upper control bracket. We trussed it too just for.
http://img.photobucket.com/albums/v654/wildman4x4nut/Jeep/IMG00510.jpg
http://img.photobucket.com/albums/v654/wildman4x4nut/Jeep/IMG00511.jpg
Then it was time for the lower control arm brackets.
http://img.photobucket.com/albums/v654/wildman4x4nut/Jeep/IMG00512.jpg
http://img.photobucket.com/albums/v654/wildman4x4nut/Jeep/IMG00513.jpg
Wildman
03-24-2008, 23:53
Okay here it is all done.
http://img.photobucket.com/albums/v654/wildman4x4nut/Jeep/IMG00515.jpg
http://img.photobucket.com/albums/v654/wildman4x4nut/Jeep/IMG00516.jpg

Then I installed a ARB locker/5.13 gears
http://img.photobucket.com/albums/v654/wildman4x4nut/Jeep/IMG00528.jpg
http://img.photobucket.com/albums/v654/wildman4x4nut/Jeep/IMG00531.jpg
I hope this helps.
korisu56
03-25-2008, 03:54
That looks really good. I especially liked how well you covered the tube trimming. I've heard about people doing it, but had never actually seen it done.
E5EDDIE
03-25-2008, 14:29
Wow, nice work, Chris ya got any buyers remorse looking at this work?
trailsnail
03-26-2008, 01:48
Sweet job. That didn't seem like that much work at all. Makes me wonder.
Devildog
03-26-2008, 20:56
Man nice job.
JeepJohn242
05-24-2008, 12:56
Good work from this pic's.... nice attention to detail, Like the use of the high pinion...Great welds very clean...
gunnersmac
05-24-2008, 13:05
Very nice/clean work...
USMCHarleyJeepGuy
05-24-2008, 18:46
Nice job. Let us know how she feels when she is under your rig.
Wildman
05-27-2008, 00:57
Nice job. Let us know how she feels when she is under your rig.

Been under the rig now for 2 years. It is working great and I have had ZERO issues with it. I just moved up to 38" tires and will see if it can live with the bigger meats.
USMCHarleyJeepGuy
05-27-2008, 09:40
Been under the rig now for 2 years. It is working great and I have had ZERO issues with it. I just moved up to 38" tires and will see if it can live with the bigger meats.

Sweet. The only thing better than hearing of a nice mod is hearing it has turned out to be a nice DURABLE mod.
S/F
Jeff