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[turbohf]

so I'm looking to pickup a Ford Explorer 8.8" rear end for my Nova project.

the housing has an offset differential with longer axle on one side. then I'll buy an extra short side to throw in he newly narrowed housing.

question is have any of you done this before? is his something I should be attempting myself? or should I just be paying someone to do it?

http://www.blueovalfanatics.com/forum/showthread.php?p=40538
http://www.streetsource.com/Groups/8/Topic/64390
http://www.garagejournal.com/forum/showthread.php?t=46025  lots of special tooling used on this one.

I seen another one I can't find now, but he had made a sleeve to put inside the cut axle tube. is that needed? I have found several now that make no mention of an internal support sleeve. and all the ford 9" just have ends welded on.

this isn't a full on drag car. not a heavy car. but is a car that will see lots of road miles. and make more power than is needed for the street.

[HiProfile]

The weakest part will be just outside the welds (HAZ), so a sleeve could potentially help add strength. The question becomes where is strength needed? The twisting forces will be between the pumpkin and the suspension mounts, which is inboard of those welds. Considering 99% of rearend failures are from diff, gear, or axles breaking I wouldn't worry much about tube strength. Alignment is probably more important.

[ratcityrex]

This is how I would do it. Get 2 short axles, use a large pipe cutter (most rental places carry them) and cut the desired amount that you need gone out. Then bevel both sides of housing. Get some steel tubing to sleeve the inside of the houseing. Drill a hole on each side of the housing to tac weld in your sleeve after you've clamped it down with 3 pieces of angle iron and a few hose clamps to hold it all together. Slide your short axle in and then tac weld your sleve, then tac weld your housing together and then rotate your axle to make sure there is no binding. If all is well then weld it up and let it rip. I belive your over thinking all this.

[Random Hero]

Thats exactly how i did it before i got my jig. angle iron and all!.

you can also grind and drill out the welds on the center chunk, pull out the tubes, shorten, reinstall and weld. that is the best way.

[turbohf]

haven't seen anyone do that in a 8.8 yet. how much of a bitch is that? would think it would be easier to get the setup misaligned.

[highroller54]

you can also grind and drill out the welds on the center chunk, pull out the tubes, shorten, reinstall and weld. that is the best way.

Yes. Piece of piss

[Rioreded6]

you can also grind and drill out the welds on the center chunk, pull out the tubes, shorten, reinstall and weld. that is the best way.

If it counts for anything I vote this option.