Dana 60 Shave Kit Install: 1999-2004 Superduty - Ballistic Fabrication High Clearance Diff Cover

Thanks for clicking on my video, and I hope you subscribe!
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.

[@AustinBoling899]

Great work man, I have a set sitting in my garage waiting to replace the 44 under my Durango and your videos are very informative and helpful. Very excited to see this beast come together!

[@aireddown813]

Thanks a bunch my friend. I’m glad these videos are helping you out. Us Durango guys should all do a trail ride sometime when we are built.

[@AustinBoling899]

@@aireddown813 Absolutely man! Not to many of us out there so for sure it would be cool to see.

[@BSG4x4]

Niiiiiiiiiiice. Great work, those are gonna look incredible

[@maxrogers762]

Great video, awesome lookin axle!!🔥🔥💪💪

[@northwestoff-roadopportuni7176]

Absolutely obsessed with your work man lol great job!

[@aireddown813]

Thanks for compliment!

[@jerameylandino2506]

Its so nice to see that thing cleaned up!

[@aireddown813]

Thanks man. That thing was dirrrrrty.

[@Charlie_Foxtrot_]

Bro I’m digging your work. Keep it up 🤙🏼🤙🏼

[@aireddown813]

Thanks man! Will do 🤘

[@NTC2900]

Nice work. Video was also well done.

[@aireddown813]

Thank you! And thanks for the sub my friend

[@williamreeves1873]

Great job for the time TIG welding

[@aireddown813]

Thanks! I’ve practiced a decent amount, just never put it to the test.

[@flatblackandy]

I gotta bring my 60/10.5 to you to shave them! Taking on side jobs? 😂

[@aireddown813]

Haha. I’ll do em’, but I think ballistic will do them better and cheaper 😂

[@matty86suk]

I bought a weed burner for pre heating cast iron. Super quick.

[@aireddown813]

I’ll try that. I even have a weed burner already

[@d7k8gsxr600]

Did you have to turn the dana 60 ring gear down? Mine is hitting the cover at the bottom and ballistic fab says no ring gear turning in their instructions.

[@aireddown813]

I haven’t installed a ring gear yet. I’m waiting for some juicy Black Friday deals. Did you get a super 60 ring and pinion?

[@d7k8gsxr600]

@@aireddown813 i found out the Yukon zip locker is actually hitting the edge of the diff cover on the vertical welded piece. Called ballistic today and they asked for photos because this is the first time they have had this issue.
I have the Yukon dana 60 4.56 gears and the Yukon zip locker. Yukon 4.56 in the rear and zip locker on the sterling 10.5 and I just got done grinding and fitting the shave kit for the 10.5

[@aireddown813]

@@d7k8gsxr600 I had to grind my ballistic cover to fit my sterling 10.5 as well. I kept the tone ring and that was making serious contact.

[@d7k8gsxr600]

@@aireddown813 i just got my ring gear for the 10.5 machined down this week so i will test fit this weekend and make sure it fits.
Luckily i won't have to shave the d60 ring gear now that i know its not hitting the cover.

[@aireddown813]

@@d7k8gsxr600 very nice! I love the way the shaved axles look. It’s next level high tech looking.

[@jonelliot854]

How much clearance do you actually gain for all that work?

[@aireddown813]

On this particular axle, 3/4” I think. I was kind of surprised how little I ended up gaining. Ballistic fabs website mentioned gaining much more than that. To be honest, I’d rather keep the housing stock and keep the possibility of adding a Dana 70 gearset if the 60s can’t keep up. In the end, clearance is good, and I don’t regret the kit.