A common modification for off-road vehicles equipped with a Dana 60 axle involves increasing ground clearance by reducing the lowest hanging portion of the differential housing. This is achieved through a process often referred to as “shaving” the axle. Aftermarket kits facilitate this process, typically including a modified housing cover and sometimes additional hardware to ensure proper lubrication and structural integrity after the modification.
The primary benefit of this alteration is improved off-road performance. By increasing the clearance beneath the axle, the risk of the differential housing dragging on rocks or other obstacles is significantly reduced. This reduces potential damage to the axle and prevents the vehicle from becoming stuck. While the Dana 60 is a robust axle, its inherent design places the differential housing relatively low, making it a prime candidate for this type of modification, especially for vehicles engaged in serious off-road activity. Early adopters modified their axles without specialized kits, but the availability of designed kits streamlines the process and helps ensure a reliable outcome.
Subsequent sections will detail the process of shaving a Dana 60 axle, including necessary tools and safety precautions, a comparison of available aftermarket kits, and considerations for maintaining axle strength and reliability after the modification.
1. Clearance Improvement
The relentless churn of rocks beneath an off-road vehicle tells a story of calculated risk. Each obstacle represents a potential impasse, a moment where forward progress hinges on millimeters. In this narrative, “Clearance Improvement” via a Dana 60 shave kit is not merely a modification; it’s a strategic advantage gained in the battle against unforgiving terrain. The lower lip of a stock Dana 60, a known vulnerability, is a constant source of anxiety for those who push their vehicles to the limit. The shave kit directly addresses this, altering the axle’s geometry to grant vital inches where they matter most.
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Reduced Hang-Ups
The fundamental principle is simple: less axle hanging below the frame means fewer instances of being stopped by terrain features. A rock that would have snagged the unmodified housing now passes harmlessly beneath. This translates to smoother navigation over technical trails, reducing the need for winching or aggressive throttle inputs that can lead to breakage.
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Increased Approach Angle
While not a direct modification of the vehicle’s approach angle, the altered axle profile allows for a more aggressive approach in some scenarios. Obstacles that would previously necessitate careful maneuvering can be tackled more directly, as the lower axle housing is less likely to collide during the initial ascent.
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Preservation of Drivetrain Integrity
Each impact to the differential housing transmits force throughout the drivetrain, potentially weakening components like the ring and pinion gears, axle shafts, and even the transfer case. By minimizing these impacts through increased clearance, the shave kit contributes to the long-term health and reliability of the entire vehicle.
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Psychological Advantage
The benefits extend beyond the purely mechanical. The confidence gained from knowing the axle is less likely to snag provides a significant psychological advantage. Drivers can focus on line selection and throttle control, rather than constantly worrying about the potential for a catastrophic impact, leading to more controlled and successful off-road experiences.
The pursuit of “Clearance Improvement,” facilitated by the application of a Dana 60 shave kit, is a testament to the ingenuity and resourcefulness of off-road enthusiasts. It is a targeted solution to a specific problem, offering tangible benefits in terms of performance, reliability, and driver confidence. While the installation demands careful attention to detail, the reward is a vehicle better equipped to conquer the challenges of demanding terrain. The alteration transforms a potential weakness into a strength, giving the owner an edge in some situation.
2. Housing Integrity
The Dana 60 axle housing, a cast iron bulwark against the relentless forces of off-road abuse, is fundamentally altered when subjected to a shaving process. “Housing Integrity” after the application of a shave kit is not simply a matter of retaining structural form, but rather a carefully balanced equation of material removal, reinforcement, and stress management. This delicate equilibrium determines the longevity and reliability of the axle in demanding conditions.
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Material Weakening
The very act of shaving the axle housing involves removing material, inherently weakening the structure at the point of modification. The depth of the shave directly correlates with the degree of weakening. Thinner sections are more susceptible to cracking and deformation under load, particularly during impacts with rocks or other obstacles. Calculating the minimum safe thickness and adhering to those limits is paramount; deviations can invite catastrophic failure.
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Stress Concentration
Any alteration to a structural component, including the shaving process, can create stress concentrations. These areas, often located at sharp corners or abrupt changes in geometry introduced during the shave, become focal points for stress under load. Repeated stress cycles can lead to fatigue cracks initiating at these concentrations, propagating over time, and ultimately compromising the housing’s integrity. Proper weld geometry and stress-relieving techniques after welding can mitigate the risk of stress concentration.
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Weld Quality and Reinforcement
Many shave kits necessitate welding a new bottom plate or reinforcing the existing housing after the shave. The quality of the weld is critical; a poorly executed weld introduces its own stress concentrations and weakens the overall structure. Furthermore, the design and placement of reinforcement plates are crucial. They must effectively distribute stress across the modified area, preventing localized failures. Incorrect welding parameters or inadequate reinforcement can render the entire modification pointless, if not detrimental.
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Lubrication and Heat Dissipation
While not directly related to the initial structural integrity, the shaving process can impact lubrication and heat dissipation within the differential. Altering the housing’s shape may impede oil flow, potentially leading to inadequate lubrication of the ring and pinion gears. Insufficient lubrication increases friction and heat, accelerating wear and potentially causing gear failure. Furthermore, the reduced surface area of the shaved housing may diminish its ability to dissipate heat, exacerbating the problem. Careful consideration of oil flow and the potential need for additional cooling measures is essential.
The connection between a “dana 60 shave kit” and “Housing Integrity” is an intertwined story of risk and reward. While the increased ground clearance offers undeniable advantages in off-road environments, the potential compromise to the housing’s structural integrity must be carefully managed. The long-term reliability of the axle hinges on a meticulous approach, prioritizing proper material selection, precise execution, and a thorough understanding of the forces at play. It is a delicate balance, where cutting corners can have catastrophic consequences. The shade-tree approach to modifying an axle can often result in broken dreams when the housing integrity has not been consider.
3. Lubrication Management
The lifeblood of any mechanical system, lubrication in an axle is more than just oil; it’s the barrier against friction, the conductor of heat, and the silent guardian against premature wear. When a Dana 60 axle undergoes a transformation involving a shave kit, the carefully engineered internal environment is disrupted, placing “Lubrication Management” at the forefront of long-term reliability. The consequences of neglecting this aspect are dire: heat-seized gears, ground-down bearings, and the eventual, inevitable failure of a once-robust axle.
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Altered Oil Capacity and Flow Dynamics
Shaving an axle housing, by its very nature, reduces the overall oil capacity within the differential. This seemingly minor change can have significant implications. Less oil translates to a reduced ability to dissipate heat, particularly under the intense stresses of off-road use. Furthermore, the modified housing shape can disrupt the designed oil flow patterns. Pockets of stagnation may form, leaving critical components starved of lubrication. The once-reliable splash lubrication system may struggle to reach the upper pinion bearing, leading to accelerated wear. This is not a theoretical concern; countless modified axles have met their demise due to inadequate oil coverage. For example, an axle operating in a steep incline is prone to oil starvation without proper oil level and flow management.
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Introduction of Contaminants
The shaving process, involving cutting and welding, invariably introduces contaminants into the axle housing. Metal shavings, welding slag, and other debris can circulate within the oil, acting as abrasive agents that grind down gears and bearings. Even meticulous cleaning efforts may not eliminate all contaminants. A post-modification oil change is mandatory, and some advocate for multiple changes after an initial break-in period. However, the risk remains. Imagine the cumulative effect of microscopic metal particles acting as a continuous lapping compound, slowly but surely eroding the precision surfaces within the differential. Consider the damage inflicted by a single piece of welding slag caught between a pinion gear and a ring gear tooth. This is the insidious threat posed by inadequate contamination control.
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Impact on Venting System
Axle housings require a venting system to equalize pressure changes caused by temperature fluctuations. A restricted or blocked vent can lead to pressure buildup within the axle, forcing oil out through seals or creating excessive stress on components. The shaving process may inadvertently damage or compromise the venting system, leading to these problems. A small crimp in the vent line can lead to seal failure, sending oil spewing across the undercarriage. A blocked vent can cause a pressure differential that stresses the axle housing itself. This is another example of how a seemingly minor detail can have major consequences.
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Requirement for Modified Covers and Lubrication Aids
To counteract the reduction in oil capacity and potential flow problems, aftermarket manufacturers offer modified differential covers with increased oil capacity and features designed to improve lubrication. These covers often incorporate cooling fins for enhanced heat dissipation and internal baffles to direct oil flow towards critical components. Some covers even include integrated oil pumps that actively circulate the lubricant. The choice of cover depends on the intended use of the vehicle. A rock crawler may require a high-capacity cover with robust protection against impacts, while an overlander may prioritize cooling and reliability. The wrong choice can negate the benefits of the shave kit and lead to premature failure.
The story of a Dana 60 shave kit is not complete without acknowledging the critical role of “Lubrication Management.” It is a constant battle against the forces of friction, heat, and contamination. A failure to address these challenges is a gamble with long-term reliability. Successful implementation requires a comprehensive understanding of the altered dynamics within the axle housing and a proactive approach to mitigating the associated risks. The quest for increased ground clearance must be tempered with a commitment to ensuring adequate lubrication, lest the pursuit of off-road prowess end in mechanical heartbreak. The owner that invest in the right oil will have the longest lasting axle.
4. Gear Engagement
The metallic symphony of a Dana 60 differential in operation relies on a precisely orchestrated dance of meshing gears. Ring and pinion, side gears and spider gears each component bearing its share of the load, relying on perfect alignment and contact for efficient power transfer. When a shave kit is introduced, altering the housing’s geometry, the delicate equilibrium of “Gear Engagement” is fundamentally challenged. The slightest deviation from factory specifications can induce abnormal wear patterns, amplified noise, and ultimately, catastrophic failure, transforming the symphony into a discordant cacophony.
The primary concern arises from the potential for altering the pinion angle. The pinion gear, responsible for transferring power from the driveshaft to the ring gear, must maintain a specific angular relationship for optimal tooth contact. Shaving the housing can inadvertently change this angle, resulting in improper meshing. Imagine the microscopic stresses concentrated on the edges of the gear teeth, rather than evenly distributed across the surface. With each revolution, these stress points fatigue the metal, leading to pitting, spalling, and eventual tooth breakage. Examples abound in the off-roading community: axles prematurely failing after shave kit installations, the ring and pinion gears exhibiting unusual wear patterns upon inspection. Experienced builders understand the crucial need to re-evaluate and potentially correct the pinion angle following the shave, using shims or other corrective measures to restore the optimal geometry.
Furthermore, the act of welding on the axle housing can introduce distortions, subtle shifts in the relative positions of the bearing surfaces that support the gears. These distortions, even if imperceptible to the naked eye, can translate into misalignment, compromising “Gear Engagement” and accelerating wear. The practical significance of this understanding lies in the meticulous care required during the welding process. Pre-heating the housing, using proper welding techniques to minimize heat input, and post-weld stress relief are all essential steps in mitigating the risk of distortion. Ultimately, the successful integration of a shave kit hinges not only on achieving increased ground clearance, but also on preserving the critical relationship between the gears, ensuring the ongoing harmony of the differential’s internal orchestra.
5. Axle Strength
The Dana 60 axle is revered for its inherent robustness, a characteristic forged in the fires of heavy-duty applications. When a “dana 60 shave kit” enters the equation, the narrative shifts. What was once a given exceptional “Axle Strength” now becomes a calculated risk, a variable subject to the skill of the installer and the quality of the kit. The removal of material and the introduction of welds inherently alter the stress dynamics within the axle housing, demanding careful consideration to avoid compromising its legendary durability.
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Housing Fatigue and Crack Propagation
The axle housing, after being shaved and potentially welded upon, becomes susceptible to fatigue. Repeated stress cycles, born of hard impacts and constant torque loads, can initiate microscopic cracks. These cracks, if left unchecked, propagate slowly but surely, weakening the entire structure. The area around the weld, often a point of stress concentration, is particularly vulnerable. Imagine a hairline fracture, invisible to the naked eye, steadily growing with each off-road excursion, until one final impact triggers a catastrophic failure. Proper weld preparation, careful execution, and the use of stress-relieving techniques are crucial in mitigating this risk. It is not merely about making a strong weld, but about managing the long-term fatigue resistance of the entire housing.
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Spindle Integrity
The spindles, those critical components that house the wheel bearings and connect the axle shafts to the wheel hubs, must endure significant forces. A shave kit, if improperly installed or designed, can indirectly impact spindle integrity. Distortions in the axle housing can throw the spindle alignment off, leading to uneven bearing wear and increased stress on the spindle itself. Consider the scenario where a misaligned spindle causes premature bearing failure, leading to excessive play and ultimately, spindle breakage under load. Ensuring proper housing alignment throughout the shaving and welding process is essential to protect these vital components.
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Axle Shaft Vulnerability
While the shave kit primarily targets the axle housing, it can indirectly influence the axle shafts. Any misalignment or stress concentration introduced into the housing can transfer to the shafts, increasing their susceptibility to breakage. A bent or warped housing can cause the axle shafts to bind, placing undue stress on the splines and leading to torsional failure. Imagine the consequences of a snapped axle shaft on a steep incline, leaving the vehicle stranded and potentially endangering its occupants. Maintaining proper axle housing alignment after the shave kit installation is crucial to preserve the integrity of the axle shafts.
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Ring and Pinion Support
The ring and pinion gears are the heart of the differential, responsible for transferring power from the driveshaft to the axles. Proper “Axle Strength” is required to ensure that the housing can properly support these components under high torque loads. The “dana 60 shave kit” will reduce the original strength which will require reinforcement or modification. The choice should be determined by the operator and consider what the end goals are.
The relationship between “Axle Strength” and a “dana 60 shave kit” is a complex interplay of trade-offs. The pursuit of increased ground clearance must be balanced against the potential compromise to the axle’s inherent durability. A successful installation demands a comprehensive understanding of the forces at play, meticulous attention to detail, and a commitment to reinforcing the housing to compensate for the material removed. When approached with caution and expertise, a shaved Dana 60 can offer a significant off-road advantage without sacrificing its legendary strength. However, shortcuts and compromises can transform a once-reliable axle into a liability, underscoring the importance of prioritizing “Axle Strength” throughout the modification process.
6. Installation Precision
The story of a Dana 60 axle and its transformation via a shave kit is, at its heart, a tale of tolerances. The ruggedness of the original design offers a degree of forgiveness, but introducing a shave kit fundamentally alters the equation. Suddenly, the margin for error shrinks, the consequences of imprecision amplify, and “Installation Precision” becomes the linchpin upon which the project’s success hinges. It is a story where millimeters matter, where a thousandth of an inch can spell the difference between triumph and disaster. Each step, from the initial cut to the final weld, demands a level of accuracy that borders on the surgical.
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The Art of the Cut
The initial cut, removing the lower portion of the axle housing, is not a brute-force act. It demands the eye of an artist and the steady hand of a surgeon. The cut must be clean, square, and precisely aligned to the axle’s centerline. Deviations here cascade through the entire process. A crooked cut results in uneven stress distribution, a weakened housing, and potential gear misalignment. Imagine the blade wandering, creating a jagged edge that invites cracks and compromises the integrity of the weld. This is not merely a cosmetic issue; it is a fundamental flaw that will haunt the project for years to come. A skilled machinist, using precise measuring tools and a steady hand, is indispensable at this stage.
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The Science of the Weld
Welding, in this context, is not simply about joining two pieces of metal. It is about fusing them into a unified whole, restoring the housing’s strength and integrity. The weld must be strong, consistent, and free from defects. Improper welding techniques introduce stress concentrations, creating weak points that are prone to failure under load. Imagine the arc sputtering, leaving behind porosity and slag inclusions that compromise the weld’s strength. The housing flexes under stress, and the flawed weld yields, initiating a crack that steadily grows until it reaches a critical point. A certified welder, versed in the nuances of working with cast iron and steel, is essential. Proper preheating, careful weld bead placement, and post-weld stress relief are not optional steps; they are mandatory protocols.
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The Alignment Imperative
Throughout the shaving and welding process, maintaining proper alignment is paramount. Distortions in the housing, even subtle ones, can wreak havoc on gear engagement and bearing life. Imagine the housing warping under the heat of the weld, throwing the pinion angle off by a fraction of a degree. The gears grind, the bearings wear prematurely, and the once-smooth symphony of the differential becomes a discordant chorus of noise. Precise measurements, careful clamping, and the use of jigs are essential to prevent distortion and maintain alignment. A dial indicator becomes the builder’s most trusted tool, measuring runout and ensuring that everything is true and square.
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The Torque Specification Testament
Reassembly, after the shaving and welding are complete, demands a strict adherence to torque specifications. Over-tightening bolts can distort components and induce stress, while under-tightening can lead to loosening and eventual failure. Imagine the differential cover bolts being cranked down with excessive force, crushing the gasket and warping the cover. Oil leaks, bearings fail, and the entire assembly is compromised. A calibrated torque wrench becomes the embodiment of precision, ensuring that each fastener is tightened to its exact specified value.
The tale of a Dana 60 shave kit serves as a stark reminder that even the most robust components are vulnerable to the consequences of imprecision. “Installation Precision” is not merely a desirable attribute; it is the bedrock upon which the entire project is built. Neglecting it is akin to building a house on sand: the foundations will crumble, and the entire structure will eventually collapse. The shaved Dana 60 can be a testament to the skill and care of the installer. This will result in a longer life for the unit. The Dana 60 in a shave kit is more than just modifications. It becomes a testament to proper instillation.
Frequently Asked Questions
The following addresses common inquiries surrounding the modification of a Dana 60 axle using a shaving kit. These are based on observations from the field and engineering principles.
Question 1: Does shaving a Dana 60 automatically compromise its strength?
Not inherently, but the process reduces the section modulus of the housing. If performed without proper reinforcement, yes, strength is compromised. Think of a bridge; removing a support beam weakens the entire structure unless compensating measures are taken. A skilled installer will reinforce the shaved area, mitigating the loss of material and maintaining the axle’s load-bearing capacity. Neglecting this step is akin to inviting premature failure.
Question 2: Is a specific welding process required for shave kit installation?
Yes. Cast iron, the common material for Dana 60 housings, demands specialized welding techniques. Nickel-based welding rods are often employed, along with pre- and post-weld heating to minimize stress and prevent cracking. A novice welder using standard steel rods risks creating a brittle, unreliable weld that will fail under stress. It’s a bit like trying to glue glass with wood glue; the bond will never hold.
Question 3: Will I lose significant ground clearance after installing a shave kit?
The purpose of the “dana 60 shave kit” is to achieve ground clearance. A properly installed kit will, by definition, increase ground clearance. The amount of increase varies depending on the specific kit and the depth of the shave, but gains of one to two inches are typical. Failure to achieve any measurable increase suggests an improperly executed installation. It defeats the entire purpose if there isn’t an increase.
Question 4: Do I need to modify my driveshaft after shaving my Dana 60?
Potentially, but not always. Altering the pinion angle during the shaving process can necessitate driveshaft modifications to maintain proper U-joint angles and prevent vibrations. It is a domino effect: the shave affects the pinion, the pinion affects the driveshaft, and the driveshaft affects the vehicle’s overall drivability. A careful assessment of driveshaft angles after the modification is crucial.
Question 5: Will shaving my Dana 60 void its warranty?
Almost certainly, yes. Any modification to a factory component typically voids the manufacturer’s warranty. It’s akin to adding aftermarket parts to a new car and expecting the dealer to cover any resulting issues. One assumes the risk of any failure, the responsibility falls squarely on the owner.
Question 6: Can a Dana 60 shave kit be installed by a novice mechanic?
While technically possible, it is strongly discouraged. The process involves precise cutting, specialized welding, and a thorough understanding of axle mechanics. A novice risks compromising the axle’s integrity and creating a potentially dangerous situation. This is a job best left to experienced professionals with the proper tools and expertise. It’s like performing surgery on oneself after watching a YouTube video, the chances of success are slim.
In summary, modifying a Dana 60 axle with a shave kit is a complex undertaking that requires careful planning, skilled execution, and a thorough understanding of the underlying principles. It is not a weekend project for the faint of heart.
The next section will address the long-term maintenance and care of a shaved Dana 60 axle.
Dana 60 Shave Kit
The whispering wind across the desert floor carries tales of those who pushed their rigs too hard, those who underestimated the unforgiving nature of the rocks. Among these tales, some speak of the Dana 60, a legendary axle humbled by well-intentioned but ill-fated modifications. Here are hard-earned lessons to heed, gleaned from the experiences of those who walked that path.
Tip 1: Measure Thrice, Cut Once. The metal remembers every mistake. The initial cut is not a moment for bravado, but for meticulous calculation. A crooked line etched by the cutting wheel becomes a permanent scar, a source of stress that will haunt every revolution of the wheels. Verify your measurements. Re-verify. Only then, commit the blade.
Tip 2: Embrace the Heat, Respect the Metal. Welding is not simply about melting two pieces together. It is about coaxing the metal to surrender, to fuse into a unified whole. The housing, ancient and hardened, must be persuaded with gentle heat, coaxed into accepting the new weld. Rush the process, and the metal will rebel, cracking and spitting defiance.
Tip 3: The Reinforcement is Your Shield. The shaved housing is a warrior wounded, its armor weakened. The reinforcement is not an afterthought, but a critical component. It must be strong, properly placed, and meticulously welded. Consider it the shield that deflects the blows of the trail, the barrier between triumph and catastrophe.
Tip 4: Let the Oil Flow Freely. The lifeblood of the axle is its oil, the lubricant that keeps the gears from grinding themselves to dust. The shaved housing can disrupt this flow, creating pockets of starvation. Heed the warnings of those who have seen gears seized and bearings melted, and ensure that the oil flows freely, reaching every critical component.
Tip 5: Alignment is the Silent Savior. Misalignment is a silent killer, a creeping malignancy that slowly consumes the axle’s strength. A fraction of a degree out of true can translate into catastrophic wear. The dial indicator becomes your guide, your compass, ensuring that every component is aligned with unwavering precision.
These are not mere suggestions, but the distilled wisdom of those who have learned the hard way. Heed these lessons, and the Dana 60, even in its shaved form, will continue to serve you with unwavering loyalty. Disregard them, and you risk joining the chorus of tales whispered by the desert wind, tales of broken axles and shattered dreams.
The following section will explore the process of diagnosing common issues and troubleshooting problems associated with a modified Dana 60 axle.
The Scarred Guardian
The preceding exploration has illuminated the multifaceted nature of the “dana 60 shave kit,” transcending its simple definition as a modification tool. It has shown the process to be an intricate dance between increased off-road capability and the potential compromise of inherent strength. The discussions surrounding housing integrity, lubrication management, gear engagement, axle strength, and installation precision have underscored the critical importance of meticulous planning and execution.
The story of the shaved Dana 60, therefore, is not merely a tale of mechanical alteration, but rather a narrative of calculated risk and responsible engineering. It is a testament to the enduring pursuit of enhanced performance, tempered by the recognition that true progress demands respect for the delicate balance between innovation and reliability. As one contemplates embarking on such a transformation, remember the lessons etched in steel and oil, and tread forward with knowledge as both guide and shield.
