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"Hardcore" 89 (Black and Blue). IT RUNS, DRIVES, AND STOPS. BUILD ON HOLD

Yeah I am not sure. .010 isn't much, and yes it is just a slug. I am going to see if I can find some small pieces of 1.375 locally this week and see how they fit.

@blazinzuk input?
 
DOM is pretty close on their tolerances. I had to clean out a little surface rust out of the inside of a piece this weekend to make a slug fit without using a hammer. Now poop pipe has a big ridge of material running the whole length of it. I can't remember about HREW tube

HREW has the seam inside too
 
I also found out that this cage is 1.625 DOM and not 1.75 so sleeving it will be more difficult as I will need to find some 1.385 OD material. 1.375 is all I am finding though.
What is the wall thickness on the 1.625? Going with .010" clearance on the OD is not much. It will still fit tight and you will actually appreciate the clearance for assembly. If you do a full penetration weld it won't matter anyway. The sleeve will only serve to align the tube.
 
What is the wall thickness on the 1.625? Going with .010" clearance on the OD is not much. It will still fit tight and you will actually appreciate the clearance for assembly. If you do a full penetration weld it won't matter anyway. The sleeve will only serve to align the tube.

It .120 walled. I am just going to go with the 1.375 for sleeves. I talked to a few guys on a fab page. The consensus is .010 will be a good fit.

Got the new halo done and the 60 is about ready to go back together. Had to replace all the bearings and seals in the hubs. I will update pics tonight.
 
Ok pics!

It was nice a few days in a row during the holiday break so I was able to pull the trailer out and rearrange all the parts that were stuck in my side yard behind the Blazer and trailer.

Got the cages out in the front yard and the axles off the trailer.

Now you have a good shot of my mud pit work area lol.

The last pic I'm sitting in the garage trying to figure out how to get that 60 up my 45° driveway..

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Now I had fully planned on swapping my springless stuff and bronze bushings to this axle from my old and slamming it in, but while I was rolling it around I kept hearing a noise so I investigated. Found a lot of muddy water in the hubs. Driver side took a lot to get the hub off. Inner bearing was stuck on the spindle. Since I was going to need to order parts I just combined with the disassembly.

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Axle is together. Cage had to be taken apart. I was really hoping the in cab portion would fit, but not even close. Dash is cut out, and windshield is removed.
 
Ah the D60 snowball, amazing how many parts and how much it all adds up to when you tear into one of these. Yours is going to be really nice when you are done with all that cleaning/painting/assembly.
 
Got the garage cleaned up so I could move the Blazer in, and begin the surgery.
 

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