THE BUILD
The Frog is currently undergoing a major build up. I've been waiting to do this for several years and it's finally happening! I'm installing a 3/4ton Dana 44 front axle and a GM 14 bolt rear axle, both with 5.13 gears and Detroit lockers. The Dana 44 has flat top knuckles so I'm building my own crossover steering for better steering geometry and rock clearance. The 14 bolt has gotten a disk brake conversion courtesy of 4x4 Land in Topeka KS. I'm doing this SOA(Spring-over-axle) with my current Black Diamond 3" lift springs. While I'm at it I've decided to build my own twin stick set up for my Dana 300 transfer case. It'll be riding on 36x12.50x15 Super Swamper TSL bias-ply tires(or maybe larger)off-road and HUMVEE tires on the street(it won't see much street use). I'll be posting pics and descrips as the build progresses.
One of the best ways to accomodate for a fullwidth Chevy Dana 44 is to move the spring hangers outboard of the frame rails. The the hangers need to be moved out 2" per side. The main mount is made out of 3"x3"x3/8" angle iron with the ends angled for a strong mount to the frame. The gussets are made out of 1/4" flat plate.
Here's a finished mount, for both cosmetics and strength I covered it with 1/8" diamond plate. By tying all 3 of the pieces together, and using triangles when possible, you end up with a virtually unbreakable hanger mount that looks good.
Here's the D44 ready to go in. Get a good look, it'll never look this good again;^) The knuckles are at the machinist's getting drilled and tapped for my hi-steer conversion.
I installed the D44 and got curious as to how tall it's going to be on 36's. I mocked up the front after some measuring and this was the result!