Neilm

I RECENTLY SWAPPED A DANA 80 INTO MY 92 TOYOTA PICKUP AND WAS ABLE TO RETAIN FACTORY TOYOTA DRIVE LINE SO MY SPARE DRIVE LINE I CARRY WOULD STILL WORK. THE PROBLEM WAS NO ONE SELLS AN ADAPTER FOR THIS, SO I DESIGNED AND BUILT MY OWN. YOU WILL NEED ACCESS TO A CNC PLASMA OR LASER TABLE BUT MOST FAB SHOTS CAN CUT WHATEVER YOU NEED LONG AS YOU HAVE THE FILE.ALSO I BASED THIS DESIGN USING YUKONS DANA 80 COMPANION FLANGE. ONE THING TO NOTE I PURPOSELY UNDERSIZED HOLES SLIGHTLY SO IF THE CNC CUTTING WASN'T EXACT MY DRILL BIT WOULD BE. THE ADAPTER IS A FAIRLY SIMPLE DESIGN THAT WORKS. THE BETTER OPTION WOULD BE MACHINE ONE SOLID PIECE OF METAL BUT THIS METHOD SAVES TIME AND MACHING COST AND IS PLENTY STRONG.

THEIR IS TWO SEPARATE PLATES TO THIS DESIGN, THE TOP ONE WITH THE TOYOTA FLANGE IS 1/2" MILD PLATE AND THE BOTTOM IS 3/16" MILD PLATE. THE PURPOSE OF THE BOTTOM PLATE IS SIMPLE TO ADAPT FROM THE LARGER HUB CENTERING OF A DANA 80 COMPANION FLANGE, WHILE THE TOP SECTION ADAPTS DOWN TO THE TOYOTA HUB SIZE ALONG WITH THE COMMON 60MM X 60MM SQUARE TOYOTA FLANGE. ENDED UP TAPPING THE TOYOTA FLANGE PART OF THE ADAPTER TO M10-1.5 AND USED GRADE 10 BOLTS 20MM IN LENGTH. THE 4 OUTER BOLTS THAT ACTUALLY BOLT THE ADAPTER TO THE COMPANION FLANGE ARE GOING TO BE 7/16-14. I ENDED UP TIG WELDING THE TWO PLATES TOGETHER AND YOU COULD EASILY MIG WELD IT, BUT IN ALL HONESTLY THE 4 7/16 BOLTS HOLDING THE ADAPTER TO THE FLANGE IS MORE THAN ENOUGH IF YOUR SOMEONE WITH MINIMAL RESOURCES. HOPE THIS HELPS SOMEONE OUT IN THE SAME SITUATION I WAS TRYING TO RETAIN A FACTORY DRIVE LINE. THE ZIP FILE CONTAINS THE DXF FILE REQUIRED FOR CNC CUTTING, I ALSO INCLUDED A SCREENSHOT OF THE RAW DXF FILE WITH CORRECT DIMENSIONS CAUSE I HAVE SEEN WHERE OTHER SOFTWARE CAN RESIZE FILES WHEN UPLOADED.