D44 RA Extension Question(s) (PICS)

[ashot]

Hey guys,

I'm in the process of extending the radius arms from a '79 bronco, in order to fit a full size HP D44 onto my '94 B4000, and have a few questions.

I am using 7/8" bolts to extend the arms, to utilize the stock bushing mount. Using 1-1/4" 3/16 wall DOM tube to sleeve the bolts. The rest of the arm will be boxed on both sides all the way up to the "C" ends.

Should i add another tube on top of the one i got? Or should I weld on something like 3/8" x 3/4" plate on top of the whole arm and extension?

Also, the weld at the end of the extension (where the bushing sits), is there a chance it will weaken the stud? Should I try to not put too much heat into it? Not do a complete weld?

Here are some pics to show you my progress so far. Any advice / pointers are welcome

 

[wahlstrom1]

Wish I had seen this soon enough to stop it...... Good luck not bending them, or having them fail at the weld. Both Shay and I bent stock length stock arms, there's a reason everyone uses 2x.250" DOM for making these with, and using it right up to the 'C'.

Not knocking the work, the welds look decent but you've created a weak link in the suspension with that design.

 

[railman]

by what he wrote, I believe he intends to plate and add another tube on top of the arm to add strength....

the pictures posted are just his base that he is starting with.....

l8r, John

 

[railman]

this is from Greg's ( 97trailrigdd) build....

Added 1/4 x 1 1/2 piece of bar to the bottom of the arms . Still need to put 3/16 on the sides .

sorta what I thought he was copying....

just this is before he plated the sides...

l8r, John

 

[ashot]

Wish I had seen this soon enough to stop it...... Good luck not bending them, or having them fail at the weld. Both Shay and I bent stock length stock arms, there's a reason everyone uses 2x.250" DOM for making these with, and using it right up to the 'C'.

Not knocking the work, the welds look decent but you've created a weak link in the suspension with that design.

Are you referring to "Lars Arms"? That is a great design, and i would go that route if i was using a johnny joint at the end. Unfortunately i do not see an easy way of attaching a 7/8" stud to the end of a 1.5" ID tube.

I am planning to box whats left of the stock arms on both sides.

The spot where the extension starts does look like a weak link to me, that's why I am debating between the 2 of my ideas - run a plate on top and/or bottom of the arm, or add a second sleeve to overlap with the stock arm.

this is from Greg's ( 97trailrigdd) build....

Not the same as i had in mind, but I like the offset, could you send me a link to the build thread?

Here are some highly artistic pictures trying to show what i mean

P.S. also posted @
http://www.fordrangerforum.com/lifted-suspension/40120-d44-ra-extension-question-s-pics.html
http://www.ranger-forums.com/showthread.php?p=1882522

 

[railman]

your best bet would be to combine your #1 and #3 pictures.....

a gusset that runs the full length of the arm as well as plate the sides past your "joint" where you added the bolt.....

Just like Whalstrom, I have seen just the stock arms bend, as well as the Stone Crusher extensions that are basically the same concept that you have made so far that can be used on any factory RA ( either a solid axle or TTB arms ) from Ford bend at that joint....

and here is the link to Greg's build thread....

http://www.therangerstation.com/forums/showthread.php?t=111464

l8r, John

 

[Bray D]

Its interesting to see builds and observe how different people think. I would plate the SHIT out of them. Use the plate on top, then another on bottom, and plate the sides. It'll be a heavy sombitch but it may keep it from failing.

7/8" stud into 1.5" ID?

http://www.ballisticfabrication.com/78-14-tpi-Tube-Adapter_p_1403.html

 

[NMB2]

doomed.

start over.

 

[97TrailRigDD]

Here is a easy way to box them in .
http://www.fullsizebronco.com/forum/showthread.php?t=21495&highlight=radius+arms

 

[AZFX4]

Heres an idea of how mine were done.