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This is what a Dana 30 looks like, out of a Volvo 244 wagon. The wagon uses a four link suspension setup with a panard rod. The pinion also uses a flange to mount the tail shaft where as the banjo just uses U-bolts.

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The 200 series volvos run rear disk brakes with a two piston caliper as standard. Remember this is in the late 70's, no wonder they are the safest car in the world.
The wheel locator (centre of the axle flange) is too large for a HK,T,G wheel so I had my mates dad turn it down in his lathe. The standard 13" HR wheels won't clear the volvo brakes so 14's or larger must be used.

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First the diff is chained down to a heavy steel bench while the brackets are being welded on. He uses a combination of short welds, water and wet rags to control the heat. after the brackets are welded on he then puts a large steel rod up the middle of the housing to check if its still strait.

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I sourced an old HR banjo diff housing from the wreckers, it was used as a donor and was cut up for the mounts and bump stops. A bloke in seaford, Steve Hillman welded the brackets on the Dana diff for me. He did a brilliant job it looks like it came out of the factory like that.

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Up near the flange the axle width is 36mm it then tapers down to 34mm and then down to 28mm where the splines are.

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27 spline axle

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