Project Jeep CJ-7 – Scout II Dana 44 Axles Swap onto a CJ-7 Frame
Fabricated Leaf Spring Hangers
Front Leaf Springs – Rear Hangers
My choice of axles was factored by a few things. First, I had no axles to begin with so I could think with some latitude. I decided on a set of available Scout II Dana 44 axles. In retrospect, I probably would have looked for a Wagoneer front axle instead of the Scout but my idea for a mounting system gave me the ability to change the axle even if the spring pad width was different then the Scout axle I installed. The next question was do I modify the front axle to meet the frame or do I modify the frame to meet the axle. The Scout II front Dana 44 had a wider spring pad width than the CJ-7 frame. About 1 3/4 per side wider. Modifying the axle meant either shortening the long tube and shifting the axle towards the driver side. Higher expense to do so since I have more time than money. Modifying the frame meant widening the spring hangers to meet the pads. After reading and talking to others who had done the same project I finally decided to just design my own bolt-on hangers. After much sketching, thinking and measuring I came up with a design that I think is well over-engineered and yet is a bolt-on design (after some pre-drilling) and uses all of the existing holes up front. All of the hardware is 1/4 inch steel angle iron with the exception of a large 3/8 piece of angle iron on the rearward hangers. This page covers the rear hangers.
These are the halves of the rear hanger. Length is 6½”
Rear hanger getting cut down.
Rear hangers. Same width and drop off the frame as stock. All cutting was done with an angle grinder and a thin metal cutting wheel.
Inside width is 3″ (Springs 2½” plus bushings at ¼” each). Height is 3¼”
Old and the new (not welded yet)
Drilling out the hole for the greasable bolts. Hole was drilled 2¼” above the base of the angle iron. 2¼” because I was maintaining the same distance off the frame as the old hangers and accounting for the angle iron used to mount these hangers.
With both halves clamped down and flat,I used the bolt to align both halves and tack welded them together. Then I removed the bolt and welded the halves.
Next came the end plates (3 3/8″ x 1″) to box it off and strengthen the hangers. Where all the pieces came together, the metal was notched to allow a good welding bead to fill the notch. This allowed areas that needed to be flat to be ground down without grinding off the bead of weld.
Ready for welding.
Old were hanger measured for accurate location of new hanger then cut off.
Here is a shot of a coat of Coroless being applied to protect the bare metal. Then Black Chassis paint was applied.
The budget Rebuild by Ralph HasselThe complete build is documentedhere on www.Offroaders.comThis 1978 Jeep CJ-7 never started life as a complete Jeep; rather it was built completely from parts. The goal was to build a […]
A Budgeted Jeep CJ-7 Rebuild from Concept to Conception by Ralph Hassel My evolution of thought… It all started with a humbling realization a number of years ago. My current vehicle, a 92 Toyota pickup 4×4, […]
This relatively simply oil pan modification, though it’s being done on Project CJ-7, can be installed on almost ANY 4×4 with an exposed oil pan. Though it may be a rare event to poke a […]
This Project CJ-7 article is about converting and armoring a Dana 300 skid plate to work with a Dana 20 transfer case. An ounce of prevention is worth a few pounds of steel. After hearing stories […]
In swapping the T-18A onto this Jeep project, a good tip was passed onto me from Mike of www.Jeepfan.com. This tip has to do with the stock clutch fork being used in the stock bell […]
Fabricating Custom U-Bolt Plates with Skid Protection for Project Jeep CJ-7 With the job of a Dana 44 axle swap to the project CJ-7 came the need for new u-bolt plates. Two things made stock u-bolt […]
A Simple yet very effective method of protecting your tie rod from impact with rocks and things, is to raise the tie rod up. Raising the Drag link also reduces bump-steer, a side effect of […]
Using 6 bucks worth of material to protect a 300 dollar 3-core radiator and to cool the V8 Engine. When looking at the grill of my 78 CJ-7, the one thing that just stuck out like […]
After doing some research I finally decided to look for a Borg-Warner T-18A manual transmission. Manual because that is what I prefer. The T-18A because of it’s 6.32:1 first gear and it’s heavy duty, cast […]
Project Jeep CJ-7 Daystar Swaybar Bushings Tip. When swapping out your stock CJ swaybar bushings with the Daystar Swaybar Bushings, here’s a Tip – Use the CJ bracket! Here’s why…First off, upgrading your sway bar bushings […]
Project Jeep CJ-7 – Disassembling the Scout II Dana 44 Front Axle. After acquiring the Dana 44 axles I also picked up a Dana 30 narrow track front axle that was in great shape. The […]
Continuing on from the front axle prep, the rear axle’s spring pad angle recorded and spring pads were removed. That was followed up by an inspection of differential and rear drum brakes to make sure […]
Project Jeep CJ-7 Scout II Dana 44 Axles Swap onto a CJ-7 FrameNew Custom Fabricated HangersFront Springs – Front HangersThe front hangers were a little easier to design than the rear hangers. Mainly because they […]
Project Jeep CJ-7 Scout II Dana 44 Axles Swap onto a CJ-7 FrameFabricated Leaf Spring HangersInstalling the Front Leaf Springs HangersBelow is the whole set of hangers. Gussets have been welded in and all the holes […]
Project Jeep CJ-7 U-Bolt Skid PlatesFabricating Custom U-Bolt Plates with Skid ProtectionWith the job of a Dana 44 axle swap to the project CJ-7, came the need for new u-bolt plates. Two things made stock […]
Project Jeep CJ-7 – Restoring the Jeep CJ-7 Tub – Part One Goals for the Jeep CJ-7 body: Rust Removal Repair of sheet metal Repair of body mounts Preparation for painting As the restoration begins it happened to start right about the time […]
This section categorizes many popular Automotive Drive Train, Axles, Differentials and Rebuild Kits, and other 4×4, offroad and performance related vendors. Browse the links below to find Automotive Drive Train, Axles, Differentials and Rebuild Kits related […]
This section categorizes many popular Drive Train, Axle, Transmission, Transfer Case, Parts and other 4×4, offroad and performance related vendors. Browse the links below to find Drive Train, Axle, Transmission, Transfer Case and Parts related retailers. […]