Reinforcing D35 TTB Beams

[Ranger44]

I have some questions about where to reinforce the beams on a D35 TTB. I have an extra set of beams and will have the front-end apart, again......soon. I figured while I have everything apart, I may as well make a set of beams "better".

I would be using my truck for trails, and a little fast track/road driving. Not quite prerunner material, but I may have some rough stuff to deal with.

I don't want to go ALL out....., just need to know what main places to reinforce, maybe what thickness of material that's suggested, and I may incorporate some "armor/skid" into the driver's side beam to protect the diff.

Thanks,
Ryan

 

[Ranger44]

bump

 

[CopyKat]

1/4" plate around the lower 5 bolt holes on the front. could add some 1/4" underneath also.

1/8" plate, Box the back side of the passenger beam where it is open. Box the back side of the drive beam around the pivot, make sure you leave room for the axle shaft movement.

Cut the axle shaft window larger to clear the axle shaft for max travel. Plate with 1/8" around opening and along top and bottom.

lastly truss the front of the drive beam with a 1/8" wall tube or 1/8" plates.

This is more than enough for a set of stockish beams.

 

[Nhaz]

theres a guy in the fab section posting his re-enforcement of his TTB. Lots of pics of what and how he is doing it.

 

[4x4junkie]

The most likely place you'd run into anything cracking is on the backside of the passenger beam right where the boxed area opens up (cracking right where the welds stop). Boxing in the rest of this area should prevent it from ever cracking.
Also, if you open up the window for the axle shaft real wide, some plates above and below the window wouldn't hurt (don't forget trimming the ends of the p-side radius arm bolts. The axleshaft can hit those too with enough flex).

IMO, the rest of the beam is pretty sturdy for general use. I don't see much need to reinforce it elsewhere unless you plan to be jumping the thing or running it real hard. However I would strongly recommend putting on a skidplate that covers the lower front & bottom of the diff (repeated bashing of the diff into rocks will slowly deform the beam over time, resulting in a slow leak around the bottom of the diff).

 

[Ranger44]

Thanks copycat and junkie. I appreciate the advice.

I'm gonna be rough on it, so I think some reinforcement would be good.

Ryan