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Thread: Custom Front Diff

  1. #51
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    Re: Custom Front Diff

    Quote Originally Posted by 4speedfunk View Post
    Ah yes...shades of Digger's D44 rig. Pretty.

    A Ford IFS Dana 44 with an extension tube on the drivers-side? What the plan to control the twist? Maybe weld a mounting ear to the snout?
    Took a lot more machining than that design so we could avoid the custom really short CV shaft but it's necessary as I am not willing to compromise on having a awkward short c.v with a ton of plunge just to fit it in there. Really want to be able to use cheap off the shelf cvs.

    As for controlling the pinion, just a U-bolt is fine right????😁 jk can't tell all our secrets

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    Re: Custom Front Diff

    Haha...yes, I always thought Digger's u-bolt mount left a lot to be desired. Totally agree about using off-the-shelf half-shafts. I think the cover mounted bracket is okay and the ten cover bolts can handle the stress...but on a stock stamped cover? You should grab a 1/4" plate cover off eBay...cheap & bulletproof.
    Also...the high pinion is probably very tight against the oil pan. Do you plan to use this with a Rancho?
    It's probably a tad late but, if you run into a brick wall...try a Corvette D44 IRS pumpkin. It's very compact, low pinion, and already has seals and mounting bosses cast into it. True it is aluminum but, it's easily double to triple the strength of the stock AAM-7.
    Great job so far...looking forward to seeing it in place.

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    Re: Custom Front Diff

    Quote Originally Posted by 4speedfunk View Post
    Haha...yes, I always thought Digger's u-bolt mount left a lot to be desired. Totally agree about using off-the-shelf half-shafts. I think the cover mounted bracket is okay and the ten cover bolts can handle the stress...but on a stock stamped cover? You should grab a 1/4" plate cover off eBay...cheap & bulletproof.
    Also...the high pinion is probably very tight against the oil pan. Do you plan to use this with a Rancho?
    It's probably a tad late but, if you run into a brick wall...try a Corvette D44 IRS pumpkin. It's very compact, low pinion, and already has seals and mounting bosses cast into it. True it is aluminum but, it's easily double to triple the strength of the stock AAM-7.
    Great job so far...looking forward to seeing it in place.
    We will definitely put this through hell testing before we bring to market. It is currently installed and fits our H3 that is stock height NO Rancho. We are only running a 1" bodylift and 37s. The shop that is going to be putting this into production for us is very confident in the cover they picked but if there are any issues we will switch to a 1/4" cover. I really do not want to ever run an aluminum housing diff in any offroad vehicle again (the aam in S10, H3, 1500, 2500 are all aluminum junk we have had issues with) We plan on building two versions of an H3 over the next year and a half and both would destroy even an aluminum dana 44.

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    Re: Custom Front Diff

    Everyone else is thinkin it, i'm just sayin it!!
    -2008 H3 Alpha -RIP
    -2009 H3 Alpha/Adv

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    Re: Custom Front Diff

    Quote Originally Posted by cgalpha08 View Post
    Everyone else is thinkin it, i'm just sayin it!!
    Post#46 has a teaser photo
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    Re: Custom Front Diff

    Proof it fits!


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    Re: Custom Front Diff

    Quote Originally Posted by atvspeed4 View Post
    Proof it fits!

    Awesome! Can't wait to see how it holds up

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    Re: Custom Front Diff

    Quote Originally Posted by MUTAINT View Post
    Post#46 has a teaser photo
    I know lol I was looking for the fit photo haha

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    Re: Custom Front Diff

    Looks like it belongs there, can't wait to see test results and production availability😄


    Joe

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    Re: Custom Front Diff

    How much clearance am I going to lose? Looks like a lot at the angle that photo was taken.
    Last edited by MUTAINT; 09-24-2016 at 08:12 PM.
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    Re: Custom Front Diff

    From that angle it looks like the Diff sits a bit lower and could enable a bit more torsion lift if the ball joints had more travel. Is that rig torsion cranked at all or truly "stock" height? A modified skid would help protect the pumpkin if it does hang a bit lower.

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    Custom Front Diff

    Losing some ground clearance is a small price to pay, compared the added strength and most of all...THE ABILITY TO REGEAR.
    Having had a Dana 44 and 37"s installed for years, I can honestly say the regear is by far the biggest single improvement. It's not why I originally did my swap but over time, it has proven to be the best part of the upgrade. Running big tires with stock gearing is just plain annoying. I forget sometimes but, then I drive a stock-geared H3, and I'm immediately reminded how big tires destroy the driveability.

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    Re: Custom Front Diff

    I'm already dragging the skid on obstacles with 37s. Just didn't want to lose that clearance.
    "I'd rather be lost on Drummond Island than found on the Mainland!"
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    Re: Custom Front Diff

    We just hit 800 mile on the new diff. Our goal is 3000 miles on the road and several technical offroad trips before these make it to market but it should happen pretty quickly. We have a few things that will need to be tweaked but all in all its going great.
    Last edited by atvspeed4; 10-18-2016 at 03:48 PM.

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    Re: Custom Front Diff

    Well we have 1750 miles on the diff and one off-road trip all of which it performed amazing especially with the front air locker!
    In regards to the loss of ground clearance there are three options:
    #1 Run the 0.75" spacers in the kit
    #2 Notch the skid just where diff comes in contact (will be close to flush with bottom of skid plate
    #3 We will make a 1/4" plate skid which will fit up tight to the diff and should be almost no loss of ground clearance.

    This weekend we are going on an amazing off-road adventure almost 4 hrs from shop so we will see how it holds up!

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    Re: Custom Front Diff

    Thanks for the updates.


    I like option #3. Thick skid plate!
    "I'd rather be lost on Drummond Island than found on the Mainland!"
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    Re: Custom Front Diff

    May be I missed it.

    If the centerline of the IB CV joint lover that the OE differential? If so, How much?
    This could be a great middle solution for my truck and its WAAAAY out of wack front end.
    Carl
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    Re: Custom Front Diff

    I need to double check the final amount but I believe it is 0.75" drop

  24. #69
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    Re: Custom Front Diff

    better than nothing, and not that bad in the big picture either. Good stuff.
    Carl
    2006 H3 - with a bunch o stuff
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    Re: Custom Front Diff

    We had a great trip this weekend exploring Vermont and some really cool caves!

    1119161729c.jpg

    The front dana 44 ifs diff with air locker performed amazing even when my girlfriend was driving and caught some serious air with the front tires on a full throttle steep hill climb.

    Ryan driving H3.jpg

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    Re: Custom Front Diff

    Quote Originally Posted by atvspeed4 View Post
    We had a great trip this weekend exploring Vermont and some really cool caves!

    1119161729c.jpg

    The front dana 44 ifs diff with air locker performed amazing even when my girlfriend was driving and caught some serious air with the front tires on a full throttle steep hill climb.

    Ryan driving H3.jpg
    Saw your vid on instagram, awesome cave pic man, I would to get a pic of my rig in there.
    "yours may go fast but mine goes everywhere"




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    Re: Custom Front Diff

    Where in Vermont was that cave picture taken?

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    Re: Custom Front Diff

    Quote Originally Posted by IRONHORSE1 View Post
    x2, after checking them out they really don't look like there's any H3 to them, even the grill looks off a bit. Now the Rod Hall stock class Alpha's on the other hand....a bad ass race modded truck in the hands of a bad assed Baja 1000 legend!
    Rod Hall's race H3 is an I5 ( stock class) not an Alpha , his son raced the Alpha . The 2 don't race in the same class. At one time the Hall race team had an H1 , H3 I5 and H3 Alpha . Nicest people you will ever meet . Rod's H3 did a great job in Baja !

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    Re: Custom Front Diff

    *Update* on our last run there was a steep hill climb with foot tall ledges and loose soil. The only way up was front air locker engaged and full throttle with the 37s bouncing on the way up. Halfway up the hill at full throttle the truck hit a ledge and went four wheel airborne. While this made for a great picture, when we landed it sheared one of the bolts on our pinion mount due to the torque on the diff at impact. We are in the process of installing a new design to solve this.

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    Re: Custom Front Diff

    Just got the diff reinstalled and the truck back together Friday but after a short drive the battery/ alternator went... Hope to have the new one installed this week and plan on another wheeling test trip again soon.

    We really would like to get these to market around March if testing goes smoothly.

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    Re: Custom Front Diff

    Exciting news! We will hopefully be putting these up for sale in few weeks.

    **These will only be available for NON-Rancho applications for now until we install rancho lift kit on our shop truck and revise the mounts**

    Specs:
    High pinion Dana 44
    Alloy flanged axle shafts
    Any gear ratio down to 5.38
    Locker choice: Yukon air locker, truetrac, elocker
    Uses off the shelf OBS k1500 CV shafts (Much bigger than stock and inexpensive)
    Fully bolt in
    3-4 week lead time

    *Requires:
    -Outfitter design steering rack mounts (will not clear other brand mounts) if you have one of our first gen mounts we will include core for top clamp that needs to be swapped
    -Outfitter design crossmember bushings and need to be swapped.

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    Re: Custom Front Diff

    Can you leave the factory steering rack mounts in without any clearance issues?
    2009 H3T alpha offroad
    2007 H3 -sold

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    Re: Custom Front Diff

    Quote Originally Posted by justin94tt View Post
    Can you leave the factory steering rack mounts in without any clearance issues?
    Yes but I absolutely would not run stock mounts! Especially with front locker

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    Re: Custom Front Diff

    Quote Originally Posted by justin94tt View Post
    Can you leave the factory steering rack mounts in without any clearance issues?
    If someone where going to put an entirely new front differential in a vehicle for strength/reliability at a very substantial cost. I would think that they would want to upgrade the steering mounting points knowing the OEM bracket is a weak point while the front differential is out of the rig. Seems like someone would want to take care of all of the weak points of their H3/H3T front end at one time for a nominal extra fee.
    Last edited by MUTAINT; 03-07-2017 at 09:38 AM.
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    Re: Outfitter Design HP Dana 44 IFS bolt in front diff

    What's the ballpark price on this?

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    Re: Outfitter Design HP Dana 44 IFS bolt in front diff

    Quote Originally Posted by ClickClickBoom View Post
    What's the ballpark price on this?

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    ~$3,300 for fully built diff with gears of your choice and truetrac. That INCLUDES shipping. Just and gear oil, bolt in and go.

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    Re: Custom Front Diff

    Awesome!

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    Re: Custom Front Diff

    IMPORTANT UPDATE TIME!

    IT FITS ALPHAS! Finally got a chance to test fit in my personal alpha and it fits perfect. I am waiting for a truetrac and 4.10 gears to come in and they can finish setting up the diff for my alpha.

    We are waiting for our cnc plasma table to be delivered end of January so we can start cutting brackets and then can finally start selling these!

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    Re: Custom Front Diff

    4.10? are you planning on running 35s or 37s?
    "I'd rather be lost on Drummond Island than found on the Mainland!"
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    Re: Custom Front Diff

    Quote Originally Posted by MUTAINT View Post
    4.10? are you planning on running 35s or 37s?
    Not sure yet. Its going to be my girlfriends DD now since I bought the 2006 adventure manual last week to DD.

    Either way I dont want to go with 4.56 as I have a 6L80 and custom Tcase adapter sitting on the shelf and a custom harness for a VVT 6.0L to swap into the alpha on its way.

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    Re: Custom Front Diff

    Quote Originally Posted by MUTAINT View Post
    4.10? are you planning on running 35s or 37s?
    So what hapened aside for atvspeed4 getting banned???? Never saw a post about making a new front end diff setup and ws getting all excited....

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    Re: Custom Front Diff

    He wasn't banned. That is a mistake that needs to be corrected.
    "I'd rather be lost on Drummond Island than found on the Mainland!"
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    Re: Custom Front Diff

    Quote Originally Posted by zefrum View Post
    So what hapened aside for atvspeed4 getting banned???? Never saw a post about making a new front end diff setup and ws getting all excited....
    Quote Originally Posted by MUTAINT View Post
    He wasn't banned. That is a mistake that needs to be corrected.

    Don't know why or how it happened but it has been corrected.
    There was absolutely NO reason for a ban.
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    Re: Custom Front Diff

    Quote Originally Posted by bunger View Post
    Don't know why or how it happened but it has been corrected.
    There was absolutely NO reason for a ban.

    Thanks for sorting that out! When the Bots took over the site I was banned and as far as I knew up to today I thought the site was still down.

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    Re: Custom Front Diff

    Quote Originally Posted by zefrum View Post
    So what hapened aside for atvspeed4 getting banned???? Never saw a post about making a new front end diff setup and ws getting all excited....
    Still working on the front diff. We had a awesome trip to Moab in March but after pushing it hard on some of the trails we broke one of the 1541h stub shafts in the dana 44 so we have been working on finding a supplier for 4340 alloy shafts which we locked down last week.

    We are waiting for a set of new stub shafts to be made for out prototype diff that will allow us to run differerent (larger) off the shelf Cv shafts and as long as those fit and work fine during testing we are all set to start making them.

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  55. #91
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    Re: Custom Front Diff

    I know I know...we are taking too long...

    We are working on version 2 of the HD diff and are switching from c-clip to external bearing retainers so customers do not have two get a different set of shafts if they decide to switch from an air locker to trutrac due to different c-clip spacing requried. Also trying to see if we can fit a Dana 50. Fingers crossed we will be picking up the prototype tonight and going wheeling this weekend in New Hampshire.

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    Re: Custom Front Diff

    Well I have 2 cracked teeth on my 7.6" ring gear and had to purchase a new R&P and bearing kit.
    Wish the D44 IFS would have been done my now.
    I would have just swapped in your diff and 1/2 shafts and been done with the 7.6...
    "I'd rather be lost on Drummond Island than found on the Mainland!"
    Previously owned: Mr. Black H3 Alpha OffRoad, Mr. Orange 08 H3 Alpha, Mr. Blue 08 H3 Alpha OffRoad, Mr. "T" 09 H3T Adventure 5 speed, XXLH3 10 H3 Alpha OffRoad

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    Re: Outfitter Design HP Dana 44 IFS bolt in front diff

    Really sorry, we just refuse to sell something if we are not 100% ready.

    Just barely done in time but just picked up the Dana 50 new diff with bearing retainers. This thing is massive!! Lots of custom machining but definitely worth it.

    diff.jpg
    Last edited by atvspeed4; 10-26-2018 at 03:13 PM.

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    Re: Outfitter Design HP Dana 44 IFS bolt in front diff

    Excellent update... i forget the details on the application what applications this will eventually fit into. Will this drop into a rancho lifted H3?


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    Re: Outfitter Design HP Dana 44 IFS bolt in front diff

    Quote Originally Posted by Jphh20 View Post
    Excellent update... i forget the details on the application what applications this will eventually fit into. Will this drop into a rancho lifted H3?


    Sent from my iPhone using Tapatalk
    As of right now it won't be setup for a drop cradle lift like the rancho or tuff country due to differences in the pinion height/ size

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    Re: Custom Front Diff

    Wow,tuff, that diff seems like.... indestructible whish i had the cash to do an SAS on my rig.Would love to change the T case also and put an 2WD, 4H-4L in.

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    Re: Outfitter Design HP Dana 44 IFS bolt in front diff

    Quote Originally Posted by atvspeed4 View Post
    As of right now it won't be setup for a drop cradle lift like the rancho or tuff country due to differences in the pinion height/ size

    Sent from my Pixel XL using Tapatalk
    Thanks for your prompt response. I have been watching your development on this with excitement. It looks very well designed and fabricated. Do you see a variant that would one day fit the rancho? I have been looking at this solution to run 37s with a beefed up front diff or a SAS. Continue to drop updates and keep us all in excitement.


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    Re: Outfitter Design HP Dana 44 IFS bolt in front diff

    Quote Originally Posted by Jphh20 View Post
    Thanks for your prompt response. I have been watching your development on this with excitement. It looks very well designed and fabricated. Do you see a variant that would one day fit the rancho? I have been looking at this solution to run 37s with a beefed up front diff or a SAS. Continue to drop updates and keep us all in excitement.


    Sent from my iPhone using Tapatalk
    We would love to do one for the rancho but in Massachusetts we cannot get a rancho lifted h3 to pass inspection so its a pain to install the kit, Fab new mounts, check fitment and then take rancho off. We have one of the last new rancho kits ever made sitting in our shop but have not installed because of that. We need to figure out how much the rancho cross member drops where the third pinion bolt mounts. Just haven't had a chance to compare on CAD

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    Re: Custom Front Diff

    So what ever happened to this project?
    You can hop in with me, my friends are all grown up and will not come

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    Re: Custom Front Diff

    "I'd rather be lost on Drummond Island than found on the Mainland!"
    Previously owned: Mr. Black H3 Alpha OffRoad, Mr. Orange 08 H3 Alpha, Mr. Blue 08 H3 Alpha OffRoad, Mr. "T" 09 H3T Adventure 5 speed, XXLH3 10 H3 Alpha OffRoad

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