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Junkyard 609 axles

Yep you're correct. The two pucks in the diff align the bar to the carrier bearings, then the two outer pucks align your full float spindles or semifloat cups. There are some vids on youtube that may help you visualize



 
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after reading this they just use a 1.25" bar. would this work regardless of big bearing or small bearing?

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Yeah that example would work. All different third members have carrier bearings in the same position, just have different diameters. So as far as alignment goes they're all the same, you just need the correct pucks for whatever third member you're using for alignment, unless you skip the 3rd member all together like that product.
 
now the next part is getting that fancy spindle alignment tool. the spindles i want to use are from a dana 60 that o bored out by hand to fit 35 spine axles and have zero faith they are drilled in the center so i want to align like OP did from the out side
 
chaplinfj60 said:
now the next part is getting that fancy spindle alignment tool. the spindles i want to use are from a dana 60 that o bored out by hand to fit 35 spine axles and have zero faith they are drilled in the center so i want to align like OP did from the out side
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too weak
Get some 14 bolt ones
 
Ideally you would want 05+ UBs to go in the back.
But if you have to have hubs, 14 bolt hubs is the way to go.
 
Bebop said:
Ideally you would want 05+ UBs to go in the back.
But if you have to have hubs, 14 bolt hubs is the way to go.
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Wrong thread my friend, this one is about building an axle using parts primarily from a junkyard. Ideally I would want portal outers on my axle but that’s just ideal for me.

Also I have a set of 14 bolt spindles here that are not any beefier than the ones I pulled from the 2001 E350 Dana 60 donor. Much different than the Dana 60 rears from the 70’s that came with 30 spline shafts and required boring, those are a waste of time.

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Chaplin,

For alignment you could just use any old crappy drop out 3rd you have laying around, you would just need to have the puck od match the bearing od and the id should match the bar you are using for alignment.

I’m using a 9-3/8 drop out that would use 3.25” bearings and my alignment bar is 1.5”
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Dan said:
Wrong thread my friend, this one is about building an axle using parts primarily from a junkyard. Ideally I would want portal outers on my axle but that’s just ideal for me.

Also I have a set of 14 bolt spindles here that are not any beefier than the ones I pulled from the 2001 E350 Dana 60 donor. Much different than the Dana 60 rears from the 70’s that came with 30 spline shafts and required boring, those are a waste of time.
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All good points.
 
very well two votes against the old dana 60 that bored out. easy enough to source another on Facebook, just saw a dana 70 for 200 bucks not getting it yet. just the first thing i saw
 
so keeping with the junkyard theme if i cut this axle tube at the line roughly and weld it to the ford nine. other than being a shitty dana 60 what will happen. i would plan on bracing and all that jazz. just spit balling ideas here


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That’s essentially what I did, just a little less tube from the 60 on mine.

Basically cut it so that you can keep your brakes from the 60 donor. The only issue is that your tube diameter might not match. That’s mostly an aesthetic thing so a non issue for functionality as long as you get some good welds and bracing like you mentioned.
 
Sean said:
Can I ask why you're cutting up the rear 60 to build a 609 rear axle?
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look close at all the brackets. i bent the bejesus out of it i used the wrong type of truss and with the added power, massive power i may add of the factory LS and 5 to 1 tcase with the magnum engaged... i did a number on it.
i had to make a slide hammer to pull the shafts out......

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chaplinfj60 said:
look close at all the brackets. i bent the bejesus out of it i used the wrong type of truss and with the added power, massive power i may add of the factory LS and 5 to 1 tcase with the magnum engaged... i did a number on it.
i had to make a slide hammer to pull the shafts out......

1717180345834.png

1717180436834.png
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Youch. I didn't look at the axle closely at all. Yeah...totally get why you're doing it then. I thought the housing was good so I questioned what would be gained by going 9" other than quick change/cheap third members....
 
Dan said:
I don’t know about Chaplin but in my shop we don’t ask the ‘W’ question.:flipoff2:
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I hear ya....I just like people asking 'why'....so I can think through my reasoning and hopefully they point out the flaws in my 'logic' if there are any glaring issues.
 
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