Electrolysis Rust Removal at Home 1957 Pontiac Rear &Dana 60

8

87vette81big

Guest
I had seen in the past here on Grumpy's Forum a How to for at home Electrolysis rust removal using a battery charger with the parent part & and sacrificial anode.
A search turned up zero results here.

I have some Rear Differentials that I am rebuilding this fall & winter.
My own. Sand blasting one option to clean housings & drop out 3rd members.
I just bought another 1957 Pontiac 9.3 Bare housing.
Was under a Gasser 1957 Chevy. Being shipped from Pensylvania.
Bought at a fair low cost price.
Super hard to find today 1957 Poncho rear.
With axles & brakes installed it gives a 60-1/2" wide rear track.
Just it needs usual surface rust cleanup work.
Lots of nooks & internal seems for glass beads to get stuck into.
Rather electolysis chemical clean at home.

Thanks Grumpy.

Brian
 
Re: Electrolysis Rust Removal at Home 1957 Pontiac Rear &Dan

That's it Grumpy.
Thank You .
When the '57 Poncho rear housing gets to my house
I will continue this thread.
Build a Plywood box & line with plastic sheeting.
My electrolysis cleanup tank.
See if my results turnout as yours has.

BR
 
Re: Electrolysis Rust Removal at Home 1957 Pontiac Rear &Dan

Turns out I bought a 1958 Pontiac 9.300" Rear Housing Grumpy.
Never seen backside clear from photos sent to me.
1958 Pontiac Rear Housing same length as '57 Pontiac.
Original coil spring mounts cut off & lower control arm mounts.
1957 Chevy leaf spring pads welded on.
1958 Pontiac rear used a 3- link suspension.
Locating Track bar mounted on upper center of rear welded Banjo cover.
Cut flush also.
Its in decent shape for 55 years old.
Remaining welds will grind off clean easy.
Will make a good 4-Link Drag Race Rear.
Flat area on 3rd arm mount ro weld on a Competition Engineering Pro Magnum Diagnonal Track locating bar or A Watts Linkage.

1958 Was a Recession year.
Even rarer than the 1957 Pontiac Rear & Pair of 1957 Oldsmobile 9.3 Rears
I own too.

Get photos soon up here.

BR
 
Re: Electrolysis Rust Removal at Home 1957 Pontiac Rear &Dan

Woke up early this morning at 4 AM.
Went to work early cleaning up the 1958 Pontiac Rear.
Tried out my brand new Milwaukee 4-1/2" inch 7amp electric angle grinder. Powerful and worked flawless for old bracket removal & weld grinding removal.
Finished up with a 80 grit flap wheel.
My 1987 Corvette Convertible.
Photos give you a good Visual just how big & stout these 1957-64 Pontiac- Olds 9.3 rears are.
Makes a Ford 9 inch look tiny.





























































 
Re: Electrolysis Rust Removal at Home 1957 Pontiac Rear &Dan


How wide is that axle housing? Wonder how wide to the axle flanges?

Will it be a limited slip when you are done?

 
Re: Electrolysis Rust Removal at Home 1957 Pontiac Rear &Dan

Indycars said:

How wide is that axle housing? Wonder how wide to the axle flanges?

Will it be a limited slip when you are done?


Its documented as 55" inches Flange to Flange ('57-'58 Pontiac) Rick.
It actually measures 54-7/8" inches this 1958 Pontiac Rear.

My '57 Pontiac Rear is 54-13/16" inches Flange to flange.

I plan on posting more photos later tonight.
I have a Posi unit 3rd member. It has 5.38 gears now.
3.64 new Richmond gear put away.

Grumpys Dana 60 at my house here too.
 
Re: Electrolysis Rust Removal at Home 1957 Pontiac Rear &Dan


Is that axle flange that is 55"???

I was thinking how different / cool that would be to have that axle under my TBucket !!!

 
Re: Electrolysis Rust Removal at Home 1957 Pontiac Rear &Dan

Some confusion Rick.
I meant bare axle housing measurements.

With axles installed the '57 Pontiac rear not shown is 60-1/2" inchez Axle flange to axle flange.

I only have 1 rear complete right now with backing plates & drums.
Its a 1957 Olds. Was under a Gasser 57 Chevy.

These rears are super strong but original parts are hard to find.
Real hit or miss searching.
Aftermarket parts like disc brake kits, new gears, ect made.
Prices may shock you.

The posi 3rd member I had to pay for.
650.
Going rate 1 year later now is 900- 1000.
 
Re: Electrolysis Rust Removal at Home 1957 Pontiac Rear &Dan

Super deal on this 1958 Pontiac Housing.
$33 to ship Fed Ex ground to me.
 
Re: Electrolysis Rust Removal at Home 1957 Pontiac Rear &Dan

When its all said & done Rick, shopping carefull, I will have less invested than A brand new Strange Engineering Ford 9 inch or Dana 60 from them.
Oklahoma salvage yards local may have a 9.3 Pontiac Olds.
Buy it cheap.
Posi units hard to find but still out there in original cars.
Posi in my old '63 GP. 3.23 Gears.
Had a strong running Tripower 455 in that car in past.
That's when I discovered how bullet proof the 9.3 Poncho rear is.
28 at the time. Raced nightly for 2 years.
Never let go.
 
Re: Electrolysis Rust Removal at Home 1957 Pontiac Rear &Dan































































 
Re: Electrolysis Rust Removal at Home 1957 Pontiac Rear &Dan

A few more pictures taken today for Rick , Grumpy , & others to check out.
The black axle is the 1957 Poncho with ultra rare Henry's Machine Race Axles.
The green is a 1957 Olds from a Real Gasser 1955 Chevrolet L88 427 BBC from Illinois.
The red is a bone stock 1957 Olds with 3.42 gears never opened & painted the Glyptol red paint by me.

Lots of 3rd members with 5' series race gears.
Ultra rare Kent Moore Pontiac Olds 3rd member holding tool.

My SUN MT400 Distributor machine & working good.
My 1964- 1979 Oldsmobile V8 Vertex Magneto Brown cap rebuilt by me & spin tested 24 hours straight at 6,000 RPM's. It never missed a beat. Perfect.

BR
 
Re: Electrolysis Rust Removal at Home 1957 Pontiac Rear &Dan

1957-1964 Pontiac and Oldsmobile Rearends - Revival
By Ron Ceridono, Photography by Fabcraft Metalworks
Street Rodder, March, 2013
2
1957 1964 Pontiac And Oldsmobile Rearends Don Moyers Rebel Reaper Rearend
Don Moyer, owner and driver of the “Rebel Reaper” ‘40 Willys, relies on a 9.3 rearend to repeatedly yank the gassers front wheels high in the air. Photo courtesy of http://www.dragstripgirldesigns.com.
1957 1964 Pontiac And Oldsmobile Rearends 9 Point 3 Inch Pontiac Oldsmobile Rearend
Before the Ford 9-inch became popular, the hot rodder’s choice for a tough rearend was the

In the ’50s and ’60s the search for high-performance parts usually meant a trip to the wrecking yard to rob components, engines, out of big, powerful cars of the day—Chryslers, Fords, Cadillacs, Olds, Pontiacs, and W-Chevys were all used. But when it came to rearends, the overwhelming favorites were those our of ’57-64 Pontiacs and Oldsmobiles.

These rearends were the Hotchkiss style, which means the ring-and-pinion gears, along with the differential components, are housed in a removable carrier, making gear changes and axle replacement quick and easy. They were tough with 9.3-inch ring gears, big pinion shafts, and large-diameter bearings and tough axles. In 1958 a good thing got better when limited-slip differentials were offered. Pontiac labeled theirs Safe-T-Trac while Oldsmobile called it Anti-Slip.
1957 1964 Pontiac And Oldsmobile Rearends Factory And Aftermarket Axles
These are the axles commonly used in Pontiac/Olds rearends, (left to right) a factory 29-s

Bigger engines introduced in both Oldsmobiles and Pontiacs for 1959 prompted the second generation of these rearends with 31-spline axles, which were reportedly 22 percent stronger than the previously used 29-spline shafts. During the production run a third-generation gear case was introduced, oddly enough with slightly smaller pinion bearings, which was probably a cost-cutting move. Other changes were made to the limited-slip carrier, but strength was not adversely affected. Another factor that made these rearends popular was the wide selection of factory gear ratios available, 2.56:1 through 4.30:1 while even lower drag racing cogs were available from aftermarket suppliers.
1957 1964 Pontiac And Oldsmobile Rearends Ring Gears
(Left to right) These ring gears are P/O 9.3-inch, 2.69:1; Ford 9-inch 2.75:1; and a Chevr

Pontiac/Olds rearends had been widely used full width under Gassers and other cars and even though lots of slingshot dragster pilots had their legs draped over a narrowed version, custom-width rearends were seldom seen in other applications and almost never under a street car. The simple cure when using wide tires with a stock-width rearend was to radius the fenders and let the tires hang out in the breeze. On early street rods it wasn’t unusual for the rear of the car to be jacked up so wider than stock tires could protrude several inches past the fenders, but then styles changed and the need for a narrower rearend that was reasonably strong led many hot rodders to the ’57 Ford 9-inch, particularly those under wagons and Rancheros as they were the narrowest.

As the popularity of the Ford 9-inch increased the P/O 9.3 began to fade from the scene. Ironically the heavy-duty nature of the 9.3 worked against it and played a part in its demise. Compared to the Ford, the P/O parts were more expensive. By 1965 GM replaced the 9.3 with a Spicer design using an 8.875-diameter ring gear that mounted the internals in the axle housing rather than a separate carrier. The P/O rearend and parts were getting harder to find and there were more Ford 9-inchers being made every day.
1957 1964 Pontiac And Oldsmobile Rearends Pinion Shafts And Bearings
The difference is pinion shaft and bearing sizes between these rearends is dramatic; (left

Today finding a P/O 9.3 may take some searching and it’s helpful to know what to look for. Six rib cases will be found on ’57 and ’58 rearends, ’59-64s have seven ribs. Housings with leaf springs were used under Pontiac and Olds in 1957 and Olds only in 1958-60; Pontiacs had coil springs in 1958-60 and from 1961-64 both had coils. Pontiacs had 1.75-inch-wide drums in 1957-58 while Olds used 2-inch from 1959-on, both used 2-inch brakes.

For a variety of reasons, not the least of which is the current Gasser craze, Pontiac and Olds rearends are enjoying renewed popularity. Thanks to the efforts of the Fabcraft Metalworks crew all the parts necessary to rebuild one are available along with a selection of improved components and special tools to make working on them easier. Fabcraft can also supply an excellent manual that tells you everything you need to know about these rearends, along with instructions on overhauling them, or they’ll refurbish a rearend for you.
1957 1964 Pontiac And Oldsmobile Rearends Differential Side Bearing Caps
These are differential side bearing caps. (Left to right) The P/O 9.3, Ford 9-inch, and Ch

In their day Pontiac and Olds rearends had a well-deserved reputation for toughness and reliability, that’s why they were found under so many hot rods on the dragstrip and the street. If you’re building a period-correct car, especially a Gasser, they are undoubtedly the perfect rearend for today.

FAQ’s

Some of the most frequently asked questions regarding the Pontiac/Oldsmobile 9.3-inch rearend:

Q: Are parts available?
1957 1964 Pontiac And Oldsmobile Rearends PO Third Member Cases
All P/O third member cases have casting numbers at A; first-generation cases have the date

A: Fabcraft Metalworks provides virtually every component for the Pontiac/Oldsmobile 9.3-inch rearend.

Q: What cars did they originally come in?

A: They came in all fullsize Pontiacs and Oldsmobiles from 1957-64.

Q: How are they identified?

A: By casting numbers and date codes, along with other external characteristics, all of which are shown in the manual by Zach Davidson and Brad Duerst.

Q: Are Pontiac/Olds rearends the same?

A: Starting in 1937 Pontiac and Oldsmobile rearend designs slowly began to converge, to the point that in 1957 all major components were virtually interchangeable, with the exception of some brake components, suspension attachments, and axle housing/axle widths.

Q: How strong is it?
1957 1964 Pontiac And Oldsmobile Rearends Factory Axles
Factory axles are easy to identify: (left to right) Olds 29-spline, Pontiac 29-spline, Old

A: Extremely strong! While the Ford 9-inch is the perceived benchmark of popular rearends today, in stock form the edge would go to the Pontiac/Olds. With its larger bearings, larger gears, and larger axles, the P/O 9.3 would fall somewhere between the Ford 9-inch and the Dana 60 in terms of strength.

Q: Why do Pontiac/Olds 9.3 parts cost more than those for a Ford 9-inch?

A: Ford 9-inch is like the small-block Chevy of rearends. Many Ford 9-inch parts are made offshore; they have smaller bearings and smaller diameter gears requiring less material. The high-volume production runs of Ford-9 inch components allow them to be relatively inexpensive. Pontiac/Olds 9.3 parts are manufactured in the United States and are made in smaller custom production runs using high-quality alloys and the best materials available. These smaller volumes and domestic content result in slightly higher prices.

1957 1964 Pontiac And Oldsmobile Rearends 3 Different Types Of Carriers
Three different types of carriers will be found: A is a standard open drive, B is a ’58-63
1957 1964 Pontiac And Oldsmobile Rearends Mickey Thompson Lighweight Differential Cases
Rare items today, Mickey Thompson offered lightweight differential cases for drag racing:
1957 1964 Pontiac And Oldsmobile Rearends Crush Sleeves
These are crush sleeves used to preload the pinion bearings: ’57-62 on the left, ’63-64 on

1957 1964 Pontiac And Oldsmobile Rearends Fabcraft Metalworks Axle Assembly Kit
A shortage of P/O parts isn’t an issue thanks to the team at Fabcraft Metal Works. They’ll
1957 1964 Pontiac And Oldsmobile Rearends Solid Spacer
A worthwhile improvement is the installation of a solid spacer and shims in place of the c
1957 1964 Pontiac And Oldsmobile Rearends Comparison Of Rearends Chart
Here’s a comparison of the features found on P/O, Ford 9-inch, and GM 12-bolt rearends.

1957 1964 Pontiac And Oldsmobile Rearends Pontiac Olds Rearends Book By Zach Davidson And Brad Duerst
For complete information on Pontiac/Olds rearends this book from Fabcraft Metalworks by Zach Davidson and Brad Duerst is a must-have.

1957 1964 Pontiac And Oldsmobile Rearends Don Moyers Rebel Reaper Rearend
1957 1964 Pontiac And Oldsmobile Rearends 9 Point 3 Inch Pontiac Oldsmobile Rearend
1957 1964 Pontiac And Oldsmobile Rearends Factory And Aftermarket Axles
1957 1964 Pontiac And Oldsmobile Rearends Ring Gears
1957 1964 Pontiac And Oldsmobile Rearends Pinion Shafts And Bearings
1957 1964 Pontiac And Oldsmobile Rearends Differential Side Bearing Caps
1957 1964 Pontiac And Oldsmobile Rearends PO Third Member Cases
1957 1964 Pontiac And Oldsmobile Rearends Factory Axles
1957 1964 Pontiac And Oldsmobile Rearends 3 Different Types Of Carriers
1957 1964 Pontiac And Oldsmobile Rearends Mickey Thompson Lighweight Differential Cases
1957 1964 Pontiac And Oldsmobile Rearends Crush Sleeves
1957 1964 Pontiac And Oldsmobile Rearends Fabcraft Metalworks Axle Assembly Kit
1957 1964 Pontiac And Oldsmobile Rearends Solid Spacer
1957 1964 Pontiac And Oldsmobile Rearends Comparison Of Rearends Chart
1957 1964 Pontiac And Oldsmobile Rearends Pontiac Olds Rearends Book By Zach Davidson And Brad Duerst



Read more: http://www.streetrodderweb.com/tech/130 ... z2gLZnBPym
 
Re: Electrolysis Rust Removal at Home 1957 Pontiac Rear &Dan

thanks for posting an informative /educational link and info/pictures

chopper2585 said:
Great idea, I'll definitely add this. Thanks!






Ah, it's so simple and what it does is amazing. I wish I had taken before pics of the support, it was so rusted I almost gave up on it. After this, 90% of the rust and paint wiped right off, then it just takes a little time to get the real caked stuff off.

All you need is a big enough bucket or tote, a scrap piece or two of metal (steel works best), a manual battery charger, and some Arm & Hammer Super Washing Soda. It's hard to find it in most places. I could only find it on Amazon and Walmart.

Fill the bucket or tote with water, put the part and scrap in, making sure they do not touch.

If you can submerge the whole part, that's best but not needed. The scrap needs to have some part sticking out of the water.

Attach the negative wire to the rusted part under water. Try to find a relatively clean spot for it.

Attach the positive to the scrap part above the water. Don't let the positive terminal sit in the water. You can daisy chain multiple scraps like I did.

Then add the washing soda. There's no real set measurement, but I've heard somewhere around a tablespoon per gallon. I just pour some in without thinking about it much. If you add too little or too much, it still works, but might be a little slower.

Then plug in the battery charger. It has to be manual because the automatic ones will only work if they detect voltage at the contacts. Mine is a 2A/10A charger from sears. The washing soda can only conduct 2-3 amps, so no real need to set it to 10A. Once plugged in, you should hear or see some bubbling, and in no time, you'll start seeing some rust coloring in the water. I left it running for 2 days, occasionally taking a solo cup and scooping out some rust that foams up around the scraps. (It's safe to stick your arms in the water, just don't touch both the part and scrap at the same time or you might get a little shock! :laughing:)

After that, a light sanding to clean up the residue and leftover rust is really all that's needed, maybe a little wire brushing if the rust was real bad. Cool stuff.
rus1.jpg


obviously theres larger plastic containers that might be used for some components, but this can save you a great deal of repair work, this works well with steel and iron but it can be a problem with aluminum clean-up
 
Re: Electrolysis Rust Removal at Home 1957 Pontiac Rear &Dan

I plan on adding more info to this Link when time allows Grumpy.
I have Brad Durest's & Zach's book
Bought it last spring hot off the printing press.
Recommend reading it if anyone serious of using a '57-64 Pont-Olds rear

Will build up a 3'rd member of mine.
Learned some info not covered in Brad's book.
Only in vintge GM Service manuals I bought too.
Lucky fleabay finds.
 
Re: Electrolysis Rust Removal at Home 1957 Pontiac Rear &Dan


Thanks Brian !!!

If I read that right, it would be the 59 and later that would be the most desirable ones to have?

 
Re: Electrolysis Rust Removal at Home 1957 Pontiac Rear &Dan

grumpyvette said:
thanks for posting an informative /educational link and info/pictures

In general Rick.
1958 was only year for 29-spline axle shaft Posi.
1959-64 was 31-spline axle shaft posi.
1957 no posi offered.

Many custom hybrid 1957-64 Pontac Olds diffetentials built by hotrodders & racers back in the day. You could find a 1957 Pontiac Rear or Olds with a 31-spline open or posi that had axles cut down & resplined or aftermarkets made to fit.

1957-58 Pontiac Olds is what I have been buying.
Perfect fit into Vettes & Pontiac Firebird Trans Am without narrowing

Stock 29-spline axles have held up to 600+ HP 10K rpm launches with 5.86-6,14 gears talking to old time drag racers now 73-85 years old.

All are good Rick.
Period correct for T-bucket.
I have 2 complete 1959 cast date 3rd members. The 7-rib big pinion bearing units also.
Will take anything you or me can dish out playing hard.
 
I found an Original set of 1957- 1958 Pontiac 9.3 Axles Grumpy.
A Matched Set.
Drivers Left Hand side with Left Hand wheel stud threads.
Right Hand Passenger side witih conventional Right Hand Threads.
I took 3 years of searching and waiting.
But I finally found and bought them.
Cost less than a Benji Franklin.
I will upgrade to Custom Strang Hy- Tuff Pro Race Axles later,
One 9.3 Rear I have is 1957 Olds that was under a 1955 Chevy Gasser Original that was L88 Powered. Raced Super Hard here in Illinois . 5.86 :1 geared and Low 10-second ET Car No power adder.
All Motor. That 9.3 is equipped with stock axle shafts and never failed & axles have Zero Twist or any trauma present.

1957-58 Pontiac factory axle shafts are Super Rare.
I found by accidental .
Miss Advertised as Olds.
I recognised as '57-58 Pontiac .
Buy it now used.

Building A Race Car in 2016.
 
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