Super Duty Dana 60 Casting Trim and Axle Swap Prep

**After trimming, you should truss the axle or at least weld the casting to the tube to reinforce that area again. This is also necessary because you are removing the plugs welds which are needed to prevent a spun axle tube or the tube pulling out of the casting.**

How to trim a Super Duty Dana 60 front axle casting for the Artec JK 1 ton Super duty Swap, to weld on axle trusses, or for custom applications in general. We also show how to remove brackets from axle tubes and how to clean the tube afterwards for a smooth finish.

Simple step by step is to use a torch, plasma cutter, or angle grinder and cutoff wheel to cut the brackets down as close as you can to the tube without gouging or cutting in to it. Then use a flap disc (lower grit the better) to remove the last of the brackets and welds. Finally, finish the tube with a handheld belt sander to give it a uniform round finish.

To trim the casting, I used a portable bandsaw to cut just under 1/2" deep through the casting to get close to the tube. After that, I used a cutoff wheel to slowly finish the cut. I also had to cut around the plug welds that hold the casting to the tube. After making those cuts, the pieces of the casting fell off easily. From there, it was just a matter of sanding down the raw cuts.

This covers the process for 2005+ Dana 60's. 1999-04 Dana 60's are easier since you are only removing the 2" of casting that goes over the tube.

I am trimming this axle as the first step in doing a solid axle swap (SAS) in my Dodge Dakota quad cab 4x4 build on 40" tires. Trimming the axle is done to fit new link mounts for when we fabricate a custom link suspension with coilovers.

Link to the Artec instructions here:

http://www.artecindustries.com/assets...

Video is for entertainment purposes only. Not for instruction or education. All vehicle modifications should be done by certified professionals. Creator/channel assumes no liability for viewer actions.