Phase two of my first build, rear LT. Phase one was bolting up the total chaos kit to my 96 single cab 4X4 3.4l manual trans. I did the project 100% by myself so I have no one to blame.
6.5 inches stock
started by drilling out the spot welds
and mounted up the glassworks fiberglass
Extended the frame with pieces I cut off my buddies rolled truck and fit up the new rear bumper.
boxed the frame with 1/8" plate
tapered the frame into the bumper
welded up frame and bumper and smoothed out bumper for a clean look
welded in new and the old crossmember, and fitted up reinforcments for frame extention
front spring mounts and rear shackle hangers were tacked in. Both got moved during the corse of cycling the suspension
This is what I settled on. The front mount was 1/2 inch forward from stock. The front mount center to shackle pivot center distance was 54 3/8 inches.
boxed in pivots
I cut out my lower shock mounts with 4 1/2 grinder out of cold rolled 1/4 inch plate and a hole saw.
See what you can do with some patience!
Base frame completed and painted
Start of bedcage
Mocked up upper shock mounts
plate for bumpstops
New tire carrier
Sanded shiny and ready for paint
I cut the tack welds and started cuting up the bed. I welded in a rim to help support the weaked bed.
Got the bedcage welded on
Tires will clear even at full flex, metal to metal!
Rear proportioning valve-
Tucked between frame and fuel tank
exhaust had to be shortened and straightened
Rear is done rides great, cycles 17.25 inches full droop to hard bump. It could get 18 inches if hydro bumps were put in. It was a ton of hard work and a major learning experience fabricating this rear. Start to fininsh it was around 325 hrs( I work slow). I am already coming up with plans for a cage!