Die Grinder

[sierradmax]

I've never had a need for a die grinder until now. I'm trying to enlarge the diameter of two holes in order to install "Johnny Joints" or control arm bushings in an axle. My dremmel just isn't up to the challenge and I cannot press fit them in, the opening needs to be enlarged. The Johnny Joint is serviceable so I plan on welding it in place.

Pneumatic, 120V, or cordless? What about grinding wheels?

 

[xela456]

Die grinders use alot of air. If you don't have a good compressor I would go with 120. They have alot more balls as well. I've got dewalt corded and m18 cordless I likr both, I've also got some small air die grinders bit I haven't used any of them since I got electric.
Another thing to consider is that electric die grinders are about 2 times the size for the same capacity.

 

[xela456]

And for wheels I would go with hard stones for that application. Carbide burrs make it easy to take more than you intended

 

[Stooge]

not one to dissuade the purchase of a die grinder, as they are real handy and im constantly using one, but how much do you have to enlarge the inner diameter of the hole? Could it be a better job for a reamer, especially where you can take the joint apart and it would make for a cleaner, more true round hole as a die grinder can sometimes get away from you a bit and could be hard to make it evenly round.

 

[NUTTSGT]

This thread just popped up the other day about air die grinders.

https://www.garagejournal.com/forum/showthread.php?t=402894


Air die grinders are those tools that once you have one, you wonder how you went so long without one.

 

[Tonyuk]

You'll need a decent compressor if you want to run one for any real length of time.

Swapping the attachments out can be a pain, i have a few of them, one with a roloc holder, one with a sanding disc holder etc..

Saves messing about during a work order.

 

[dnschmidt]

Air is great is you have a massive compressor. Otherwise electric or cordless is the way to go. Also the electric is designed in a manner that it's used with two hands which provides you with much better control particularly with a cutting disc.

 

[eyeball]

I see this JJ conversion done often on Jeeps. Assuming this a Jeep, few things come to mind...

(1) It might be tough to get a big electric die grinder in there if the axle is still in the vehicle.

(2) It might be easier to buy a new axle bracket weld in the JJ then then replace the mount on the axle. This is assuming you don’t anticipate needing the die grinder in the future. - Currie sells the kits.

(3) Use the money saved on the grinder to buy the JJ rebuild tool, it makes the servicing of the joints much more enjoyable when the time comes.

(4) If you are not working on a Jeep, items 1-3 may not apply.

 

[trackwelder]

If you close an electric die grinder make sure it’s variable speed.

 

[2oolhound]

I was just watching a JJ video. In 4 places they just used a drill and bit to enlarge holes.

 

[sanddan]

IF you have a compressor I would get this die grinder

https://www.amazon.com/dp/B000VZC9PI/?tag=atomicindus08-20

And this burr set

https://www.amazon.com/dp/B01NBQIRAF/?tag=atomicindus08-20

I have both and have used them for just this type of project. The double cut burrs can get used with great precision, with some practice, and will make short work of enlarging the holes for the JJ. Since you are going to weld the JJ in the burrs will leave a good enough surface finish. I also have a set of sanding drums which can be used to dress up the holes if they were to be left open and needed a better finish to the opening.

I also have a Dremel tool that I use when I'm doing fine detail type work. I've had die grinders for many years but only got the Dremel about a year ago.

 

[Wamsutta]

I was just watching a JJ video. In 4 places they just used a drill and bit to enlarge holes.

That guy sure has some beautiful long blond fluffy hair. I can see him making a lot of girls jealous.

 

[eyeball]

I was just watching a JJ video. In 4 places they just used a drill and bit to enlarge holes.

Just speculation on my part but I believe the OP is not just looking to enlarge the hole for the bolts, rather he is looking to install a JJ on the passenger side of the front axle. That requires removing the existing rubber bushing from the bracket welded to the axle housing and reaming out the hole to accept the new joint in place of the rubber bushing.

While I applaud him for this DYI fix, I still think cutting off the bracket and welding on the appropriate sized bracket will be much easier and not a whole lot more expensive than buying the electric die grinder. However, like many around here, I am always looking for a project that will “force” the purchase of a new tool.

 

[sierradmax]

So yes, it is for a Wrangler TJ front dana 44. The axles are removed from the Jeep and are completely stripped.

I had purchased two of these Currie Johnny Joints to replace the UCA bushings on the front axle.
https://www.summitracing.com/parts/CUR-CE-9112M2

Prior to me knowing about this kit.
https://www.currieenterprises.com/CE-9102K1

Oh well. I was able to press on the drivers side without an issue. For the passenger's side, yes, I needed to remove some material on the factory bracket in order for the JJ to center. I ended up finding a pneumatic Husky Die-grinder on clearance last night at Home Depot for $30. About 20 minutes with a 1-1/4" grinding wheel and it fit snug. Welded up and good to go.

Eyeball, you are right and it sounds like you are aware of the D44 flaws. However, I'm limiting my build on these axles to 35" tires. I could have trussed the axles, sleeved them and welded C-gussets but IMO, and with the advice from other forums, 35's is pretty much the limit on TJ D44's and the factory housings can support them. I plan on going 37's later but when funds allow, I'll spend the $$ on D60's