D350
+1y
August 18, 2008
A big thanks goes out to my brother Nate for this one.
I wanted a 5 lug Mustang axle with posi-traction and disc brakes... and I couldn't find one anywhere.  The one place that had one wanted $500 for it.  Screw that!
I nearly went with a Jaguar independent rear suspension set up with inboard disc brakes.  It would've been really cool if it wasn't rusted to hell when I went to pick it up.  It wasn't posi anyway.
So ANYWAY, my brother hears what I want and we set off to the junk yard once more.  I told him they didn't have what I wanted the day before but we went anyway.
Sure enough... nothing.  So Nate, the Mustang whiz starts tearing apart an old 90s Fox Body Mustang GT posi axle.  He rips off the drum brakes and pulls out the 4 lug axles.  Then he locates a '04 V6 Mustang with disc brakes.  He takes off all of the disc brake parts and pulls out the 5 lug axles, and carries it back to the old Fox Body.  Amazingly, (to me) everything he just snagged from the '04 bolted right up to the old axle.  Abracadabra... we had the equivalent of an '04 Mustang GT 5 lug posi-traction axle.
The kicker... the scrap yard charged me $135 for it.
I couldn't wait to get back to the shop and put it all together... This is one of four link bars.  The ends are from a Toyota 4runner and they are elongated using very heavy gauge steel piping.  I choose to do it this way because the Toyota's link ends have proven themselves to be strong and I don't like the idea of adjustable links with jamb nuts.  The way I see it... if I make precise measurements, there should be no need to adjust them.  If I'm wrong I will make adjustments at the link brackets.   My method for mounting the axle was to temporarily weld the axle to the frame notch using my old U bolts.  This allowed me to slide the axle side to side and tilt the pinion angle up and down.  Once everything was perfect, I tacked the U bolts to the axle to keep it from moving.  Then I welded the brackets and link bars into place.   Once everything was welded I cut off the U bolts to free the axle from the frame.  I jacked up the frame far beyond the max height of the air bags to make sure I did my math right and make sure the pinion angle didn't change. 
Perfection.  Good thing too... I fully welded the brackets rather than tacking them.  It would've been a bitch to cut them off if I had messed up.
ALWAYS TACK WELD FIRST!   Here's me doing what I love.