Dana 60 Shave Kit Install: 1999-2004 Superduty - Ballistic Fabrication High Clearance Diff Cover
Channel: Aired Down
Date: 2020-07-19

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That's right! I shaved the front axle to match the rear. Now both the Dana 60 and the Sterling 10.5 are high clearance giving me the best chance at making it over those big rocks. 

This awesome kit is from ballistic fabrication. I mentioned that I worked with Ballistic to design the 99-04 bottom plate, since there were only 05+ kits available when I bought mine. I'm not sure they used my design 100%, but its likely that every 99-04 shave kit they sell will utilize my bottom plate design. 

However, since I had the 05+ plate in my possession, and I didn't want to wait any longer to make this video, I just trimmed the newer model plate to fit my 99-04.

There is debate on whether the center section is cast iron or cast steel, but judging by the amount and color of sparks shooting off the housing while grinding it, I believe the center section to be some variety of iron. Maybe its nodular iron instead of grey iron? I'm not sure. 

Anyway, since the center section is most likely iron, I use that ENiFe-Cl welding wire from Blue Demon for this job. I know this wire is very expensive, but I've bee able to buy it in 2 pound rolls from ebay. Just search "ENiFe-Cl Blue Demon 2Lb" and you should find if for $80 a roll or so. I'd say that's worth the peach of mind.