The Ruffstuff Toyota 8" Axle Housing!

Gravel Maker · 09-08-2009, 09:22 PM

We released our Toyota housings this past weekend at the Cantina for the 'Conn and the response we got to them was fantastic. I am much happier with it than I thought I would be, everything came out perfect (on the third attempt).

Over 1000 people (by my count) checked them out, both the 9" and the Toyota 8", nobody at all had any suggestions for changes at all.

I think the best 2 responses we received on them were from a couple of big Toyota names. 1st was Marlin himself of Marlin Crawler, he played with it like he does and gave me his blessing. Marlin would have been my 1st choice to be my critic and he was entirely happy with the design and welding. I have known Marlin for around 5 years and there isn't anyone else as Toyota smart out there.

The 2nd came from a suprising corner, John Robertson looked at it and asked the 20 question game and then said he wanted one for his own buggy. For those of you that don't know John, he is the sales Manager for TG. He even took 20 pics, I missed his 9am call today but I can call him back tommorrow about getting one.

And to answer a few questions for you guys.....

We cannot yet weld the knuckleballs simply because we haven't yet made the jig, it should be done tommorrow.

We didn't ever plan to weld in used knuckleballs when we can make a better version which we are doing and they should be done in about 3 - 5 weeks. The new balls are improved over stock in 3 ways. I am not going to share how til they are done but it should be obvious to you if you think about how they could be better. Also, as far as I have seen the knuckleballs are not being made anymore by anyone, if someone dosen't make them this axle will die, afterall, when was the last one made?

In the meantime if you need the knuckleballs in today we would weld in yours if you got to have them now.

I made the initial design for these housings 3+ years ago and then refined them over the next year or so. The last 2 years have been spent trying to find a bender capable of the accuracy needed to make the right. 2 1/2 months ago we found the right bender!

The design certainly reflects the base work done by Brian at Diamond but I tried to draw as much influence from a Chrispman (round trophy truck housing). I decided the round shape was better overall but Brian was on the right track with bends for reinforcement. Ours is a result of that mix, nearly round with the bends reinforcing each other every step of the way. And by bending the housing we were able to minimize the welds. I cannot say which shape is stronger but without destroying one of each and I am not going to do that.

The last thing I would like to mention is a touch about my point of view on production of a product like these. I don't really believe in custom, and who wants 3" x .25" tubes that so many companies advertise as their $399 price for an axle housing anyway? I believe in building something to outlast your needs so all of our housings have 3.5" x .375" tubes, all of our housings have a .375" faceplate, and all come in 1 length (in the case of the Toyota, 6" over stock) and can be cut to fit. When you add the fact that we make large batches of things at the same time you can see where costs' are saved.

Now about the actual construction of the housings. All of our center sections are prewelded 90% complete before the tubes even come near them. That part is pretty easy to test for accuracy, if they don't fit together without gap they aren't good enough. Then the tubes go in the jig and the center is fitted with a dummy third with truebar pucks instead of bearings. Then the Truebar is fitted through the tubes and center section. At that point we know welding will warp the housing so it is a carefully planned sequence of welding and cooling to allow the warp to settle and the housing to remain true. We have 3 substantial jigs the are Ibeam based for rigidity but having 3 allows our welders to keep working on at least 3 at a time but usually 6 as they are welding 3 more center sections as they weld the 3 in the jigs. The key here is rigidity, a sheet of .25" plate is not rigid....

All in all it has been a learning experience but really not as difficult as I expected (Beyond finding a bender), however it is taking ~ 1.5 hours longer each to weld than expected. We are paying attention to that time as we make more of them but we only have 45 housings out there but if the time isn't reduced by greater experience we will have to raise prices by about $70, time will tell.....And nobody should take this as a slight to Diamond Axles, I have great respect for the high quality and strength of a Diamond, this just gives you another option and we will introduce a Chromolly option in 4-6 months to go with these.....

BTW, I will post a pic of this axle next to a 9" tommorrow so you can see the scale....

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**waskillywabbit** · 09-09-2009, 05:51 AM

Cool

Gravel Maker · 09-09-2009, 07:14 PM

Here is the size difference of our Toy 8" to our Ford 9"....

And a factory 8" besides ours....

And a comparrison of the inside, not very much different, I didn't see any reason to change a good thing...

The pics look a little off from where he was standing when he took them but the factory housing measures 10 1/8" at the widest point and ours measures 9 1/2".....

Gravel Maker · 09-17-2009, 08:52 PM

11 ordered, all but 2 are waiting for the Knuckleballs we are making but only a couple of weeks longer til they are ready.....

ScottyC · 09-18-2009, 07:04 AM

Dan, what is the price with knuckle balls added?

09-09-2009, 05:51 AM	#2 (permalink)
waskillywabbit Super Moderator-Sponsoring Member Staff Join Date: Jul 2003 Location: Tuscaloosa, AL Posts: 14,553	Cool __________________ WabFab Off-Road, LLC MySpace Twitter Facebook 7th Annual South East 4Runner Jamboree, 2010 The toughest part of a Jeep is the chick driving it. WabFab Off-Road 4th Anniversary Sale

09-09-2009, 07:14 PM	#3 (permalink)
Gravel Maker Registered User Join Date: Sep 2006 Location: Sacramento, CA Posts: 80	Here are some new pics..... Here is the size difference of our Toy 8" to our Ford 9".... And a factory 8" besides ours.... And a comparrison of the inside, not very much different, I didn't see any reason to change a good thing... The pics look a little off from where he was standing when he took them but the factory housing measures 10 1/8" at the widest point and ours measures 9 1/2"..... __________________ Dan Fredrickson 916.600.1945 www.ruffstuffspecialties.com Register on our Website for Free Stickers & Member Specials

09-17-2009, 08:52 PM	#4 (permalink)
Gravel Maker Registered User Join Date: Sep 2006 Location: Sacramento, CA Posts: 80	Well so far..... 11 ordered, all but 2 are waiting for the Knuckleballs we are making but only a couple of weeks longer til they are ready..... __________________ Dan Fredrickson 916.600.1945 www.ruffstuffspecialties.com Register on our Website for Free Stickers & Member Specials

09-18-2009, 07:04 AM	#5 (permalink)
ScottyC Registered User Join Date: Aug 2006 Location: Windsor/Greeley, CO Posts: 1,179	Dan, what is the price with knuckle balls added? __________________ Scotty http://www.addictedoffroad.com/ 970-420-4198 Toyota Winch bumpers on SALE!

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