Morph again

[AxleIke]

I promised Doug and a few others I'd post pics for my build this winter, so here it is.

We'll see. It'll either be great, or a total disaster. I'm not predicting anything in between.

To begin:

The end of an era. Both pieces of equipment served me well, but it was time to retire. The ARB was an amazing bumper, and I loved it. But, it was a little too big for what I wanted.

The sliders were a metal shop final project, and were not built, or welded, as well as they needed to be. Amazingly, they held up quite well, but its time for something better.

http://i29.photobucket.com/albums/c263/AxleIke/IMG_3622.jpg

http://i29.photobucket.com/albums/c263/AxleIke/IMG_3620.jpg

http://i29.photobucket.com/albums/c263/AxleIke/IMG_3619.jpg

http://i29.photobucket.com/albums/c263/AxleIke/IMG_3621.jpg

I took off the bumper to sell it, which can be found here: http://www.ttora.com/forum/showthread.php?t=115010

The sliders I cut off now, because the truck was still mobile, and could make it up to HOW north.

Neither one will be replaced for a number of months. Lots of other stuff to do first.

Next installment: Drivetrain lift preparation.

[Lysmachia]

Just let us know when you are ready for labor at yer place! ;)

[AxleIke]

HUGE props to Troy for helping cut my damn sliders off today. It's good to have friends like T & M.

Troy is on a plane now, heading out to Budapest for a work trip, and was literally working on my rig until he had to take a shower to head to the airport.

Thank you Troy.

Raising my beer to you tonight!

[Avsfreak1234]

im in boulder too if you want some help sometimes. i dont have a ton of time but dont mind those late nights of wrenching!

[AxleIke]

I'm going to strip the interior next, so I can start cutting. However, I've got a compulsive thing going on, so after the interior, I'm going to drop the tranny, and tcases, so that I can clean the underside for good welds, and just so it's clean.

So, I'll need lots o help dropping the tranny, and tcases. After its clean, I'll make the cuts. After that, I need more people to help get the spacers under the engine, and re attach the tranny/cases.

Then I'll build my crossmember.

[fjcruzer]

Keep us posted on when you plan to work. I'll have time off over Thanksgiving (or "Fall Break" for the PC) and several weeks over "Winter Break". I've never done any major work like this and would like to help and learn.

[mrdoug]

i'm always up to help somebody rip up their truck.. When work allows of course.. Give me a ring if/when you need a hand.

[ike]

I can also swing by after work during the week if you are working on it at night.

[RedRunnertc]

No problem man!

I'll be hoisting a few beers myself in a few minutes... The Hungarian local beer Dreher is pretty good.

[ike]

Make sure you have a budwieser while you are there.

[AxleIke]

Thanks all.

I certainly will be posting up when help is needed.

Dismantling the interior is really a one person job, since you have to be inside the cab, and I want to look at everything to see what all needs replacement.

I'm REALLY hoping to have everything stripped by next weekend. If I do, I'd love a few folks to help get the tranny/cases dropped.

However, I'll keep this updated with progress, so if I don't make it, people aren't changing their plans.

[AxleIke]

Ike, I will be working after work most nights. give me a ring or post up if you want to swing by, in case I've got other stuff going.

[AxleIke]

Got the rear end cleaned out, and the rear seats taken out, along with the old carpet in the rear.

Its definetly not going to be next weekend for the drivetrain drop. I am going to wait until the parts come in before starting, so I don't end up with an unmovable mess. :D

Anyone who would like to help completely remove a dash out of a first gen 4runner is welcome to stop by after 6 or so this week. PM me before you do, to get directions, and see what day's I'll be working on it.

[Lysmachia]

Why don't we make a night of it Isaac? Like wed or Thursday? I can bring steaks???

[AxleIke]

Hmmm....That sounds SO tempting. Let me see.

I got the darn passenger vent out. Holy crap what a pain. You have to take it out to remove the main dash, but DANG they don't make it easy. Oh well. With that out, we can get the rest quite quickly.

If we get the whole dash out, the carpet can get ripped up. NICE!

[fondigley]

This is sounding interesting and the work you have done is looking good.

I can give you a hand this week, just let me know where you exactly live. I am pretty sure you are only a couple streets away. I wouldn't mind getting back in to the truck scene. My other hobbies have been distracting me and my Toy is getting real jealous.

[poorboyota26]

WOW blast from the past! how are you Alex? sorry for the Hi-jack.

[AxleIke]

This is sounding interesting and the work you have done is looking good.

I can give you a hand this week, just let me know where you exactly live. I am pretty sure you are only a couple streets away. I wouldn't mind getting back in to the truck scene. My other hobbies have been distracting me and my Toy is getting real jealous.

PM sent

[AxleIke]

Ordered the xmember center and the lift blocks today.

http://www.4crawler.com/4x4/ForSale/Images/MotorMount6.jpg

http://frontrangeoffroadfab.com/nfoscomm/catalog/images/My-camera-026_main_thumb.jpg

[AxleIke]

Progress: Got most of the dash out. Holy crap, dash boards suck. I like how simple an FJ-40 dash is. Couple of bolts and out it comes. Ugh.

Should be able to finish the dash in another day or so.

Xmember center came today:

http://i29.photobucket.com/albums/c263/AxleIke/IMG_3629.jpg

[00regcab]

Nice man, glad to hear its coming along! I'll help ya out whenever ya need it as soon as i get over the wisdom teeth thing, and get a new steering rack in my truck! Should be next week sometime.

[Volcom]

Should be a fun project! Cut it off and start hanging some axles :D

[AxleIke]

Nice man, glad to hear its coming along! I'll help ya out whenever ya need it as soon as i get over the wisdom teeth thing, and get a new steering rack in my truck! Should be next week sometime.

Good luck man, and thanks!

[AxleIke]

Should be a fun project! Cut it off and start hanging some axles :D

LOL. I hope it will be fun. Axles are farther out in the future.

[AxleIke]

I'll be working on it tommorrow, starting about noon. PM me for directions if you need em.

[00regcab]

I might swing by, i'll give you a ring when i wake up and get motivated to start moving around

[AxleIke]

Going to the store and stopping by work to take care of something. Gotta have beer for the help! :D

Give a ring if you wish to come over: three 03-nine zero 5 74four0

[00regcab]

Sorry i didnt make it Isaac, i just woke up. Had me a couple too many vicodine last night before bed.

[Lysmachia]

Isaac we've been wrenching over here all day with Avsfreak and Layton. What about tomorrow? I know Mayhem needed help but not sure he can use our 220 welder tomorrow...

[AxleIke]

Huge thanks to Doug for swinging by today!

Got lots done. Its ready for cutting next. Thanks for the offers guys, but Its going to be a bit slow for the next week or so. I'm going to clean the inside a little bit more, as we had some issues with the carpet in the back seat area. Someone messed up back there, because it was the hardest damn thing to get torn up. Good grief.

Anyway, thanks again Doug!

Something's missing:

http://i29.photobucket.com/albums/c263/AxleIke/IMG_3632.jpg

The heater core was a pain too, but got it out, and the hoses reconnected so it will still run enough to move around.
http://i29.photobucket.com/albums/c263/AxleIke/IMG_3634.jpg

[ike]

Great progress. Now to plan out the :saw: !

[mrdoug]

Yeah, whatever was holding down that middle piece of carpeting should be used to patch the hole in the ozone layer or something... damn that's some strong adhesive. Can't wait to see more progress on this project.

[AxleIke]

Update:

Slow progress because of the holidays, on top of waiting for my motor mount stuff to be machined.

http://i29.photobucket.com/albums/c263/AxleIke/IMG_3652.jpg



Not that I needed those to do stuff, but I wanted to wait until I had them in hand before cutting, as they are pretty integral to the whole process, and I didn't want to get half way through, and then realize: Crap, no way to finish.

Anyway, I've been working at the carpet. It isn't going well. Even with the heat gun, it is an outrageous process. I am flabbergasted by this crap. I simply cannot believe that the carpet UNDER THE REAR SEAT needed to be glued down like it was. Good lord.

Anyway, much of the tranny tunnel is cut out. I'm cutting very sparingly, to try to avoid, as was pointed out at the party tonight, the "Hummer" look, ie, a HUGE tranny tunnel.

Pics so far:

http://i29.photobucket.com/albums/c263/AxleIke/IMG_3650.jpg

http://i29.photobucket.com/albums/c263/AxleIke/IMG_3646.jpg

[AxleIke]

I'll be needing some assistance shortly. Not sure exactly, as I have to drop the tank, and get my crossmember built. Next couple of weeks though.

I also need a cherry picker. Anyone willing to lend one for a weekend?

[00regcab]

Just food for thought, Isaac.

I'm not sure if its been talked about yet in this thread, but will you (if need) be shortening the shifters (for the tranny mainly) so they arent sitting up super tall?

[mrdoug]

When I ripped up the linoleum in my office to put down wood flooring, there was some adhesive remover stuff I used.. not sure if that would help with that carpet crap, but it might be worth a shot if it's still that big of a pain. Look down the flooring isle at Home Depot or Lowes.

[AxleIke]

Just food for thought, Isaac.

I'm not sure if its been talked about yet in this thread, but will you (if need) be shortening the shifters (for the tranny mainly) so they arent sitting up super tall?

I'm fairly sure that will be needed. It'll be one of the last things done, however, as I'll need to fit everything else.

[AxleIke]

When I ripped up the linoleum in my office to put down wood flooring, there was some adhesive remover stuff I used.. not sure if that would help with that carpet crap, but it might be worth a shot if it's still that big of a pain. Look down the flooring isle at Home Depot or Lowes.

Good idea. I'll check that out.

[ike]

Progress looks great. Come on you dont want the hummer look???

[AxleIke]

More stuff. Got the tank dropped.

Getting the fuel lines out is going to be a bit harder. Not sure how to make that happen yet.

Tank dropped:

http://i29.photobucket.com/albums/c263/AxleIke/IMG_3653.jpg

Lots of clearance :D

http://i29.photobucket.com/albums/c263/AxleIke/IMG_3655.jpg

This spot now has lots of potential for cargo/something;

http://i29.photobucket.com/albums/c263/AxleIke/IMG_3654.jpg

http://i29.photobucket.com/albums/c263/AxleIke/IMG_3656.jpg

[AxleIke]

Added bonus for the next person/persons to come over to help.

Gas is only good for about 30-45 days. Then it starts to get wierd.

There are probably 5-7 gallons in the tank as it sits, so someone can get some free gas!

[AxleIke]

Also now apparant: I will need to get my hands on plasma. Couple of crossmembers that have to get cut out, and new ones built. I'm NOT doing it with a saw.

[fjcruzer]

I continue to be impressed! Someday when I get my shit together I'll come see it in person, hopefully before January rolls around :rolleyes: And yes, I still have the UCAs to play with :)

[mrdoug]

I might be available to help out next weekend, let me know when you plan to work on it again.

[AxleIke]

I continue to be impressed! Someday when I get my shit together I'll come see it in person, hopefully before January rolls around :rolleyes: And yes, I still have the UCAs to play with :)

I might be available to help out next weekend, let me know when you plan to work on it again.

You can get some free gas!

[AxleIke]

I should get a picture of the skid from the gas tank.

when I got the last bolt out, it went, "PING" and curled up a bit. I'm glad I had that thing. Dang.

[Quick Draw]

So you haven't made it quite clear.....maybe it's a suprise....but what are your final plans for it? I saw that you're going to do a drivetrain lift. So I suppose that entails your motor, tranny, and t-case with the motor mount blocks and new crossmembers. Are you clocking the t-case up at all? Are you going to flat belly it? Looks like you have a lot of stuff torn down, so you're planning a lot of big stuff.


Oh and most importantly: When are you cutting that IFS off? :D

[AxleIke]

Final plans are undisclosed because they aren't final yet.

The drivetrain lift is pretty much set at this point :D

Flat belly is the goal. We'll see how that works. I don't want to have to redo the factory seat mounts, so I'll cut as much as I can, then see how high it will go. I think I can get it flat.

Not clocking the tcase as that requires another adapter, and I don't like how the shifters get pushed over in the clocked case.

After the drivetrain lift, the gas tank is going under/through the rear floor.

After that it'll be suspension. Not cutting the front off yet. Still having fun with the IFS, and I don't have the cash to build the axle I want. I refuse to put stock crap under the truck. If its getting cut up, then something better is going up there.

Lastly will be some body work/half doors/soft top (if I can afford it).

Also, hopefully a FF rear. Still holding out for a supra rear set up, but can't find the calipers.

Lots to do. Hoping to have it done by the Moab takeover in late may. I'm not sure it'll make that though.

[Lysmachia]

Isaac. Talk to Troy and I. We might be able to get Pete's plasma cutter just for you. Also see if we can use Troy's work buddies cherry picker - that is if the hydraulic cylender has been fixed.

FJCruzers buddy needs our help this weekend. So we should figure out what day would be best for us to come help you. It sounds like FJCruzers buddy needs our help saturday. So could we help you sunday?

[AxleIke]

Molly,

Thanks for the offer. I gotta see. Balancing out everything else too. Still waiting on some steel.

Plan is the following:

Cut out flooring as little as possible.
Lift motor.
Build and position crossmember, get everything tacked in.

Drop the tranny and transfercases.

Clean and begin welding in supports/new crossmember.

I would love to borrow pete's cutter. Don't need it for long, though I may need it twice. I'm leary about letting the truck sit without xmembers for too long. May just do the horsecollar one, and then work on the rear two later.

[AxleIke]

Progress this evening:

BLAGH. Those fuel lines are a PITA. Good grief. Anyway, got them out of the way enough to get some choppy choppy done, but not enough. Just have about half an inch to go, but it was late and chopping stuff is loud. Decided to wait.

Another lovely thing: They started double paneling the floor once you get back a little way. Yeah, not fun.

Anyway pics:

Inside:

http://i29.photobucket.com/albums/c263/AxleIke/IMG_3657.jpg

Closer to flat:

http://i29.photobucket.com/albums/c263/AxleIke/IMG_3660.jpg

Like, bummer dude:

http://i29.photobucket.com/albums/c263/AxleIke/IMG_3658.jpg

That horsecollar thing is going to suck a bit.

http://i29.photobucket.com/albums/c263/AxleIke/IMG_3662.jpg

[RedRunnertc]

If you're worried about the body warping, just weld in some temporary bracing and then cut the crossmembers out.

Damn, seeing the pictures made me think what a PITA it is gonna be to get those factory crossmembers out!

[AxleIke]

If you're worried about the body warping, just weld in some temporary bracing and then cut the crossmembers out.

Damn, seeing the pictures made me think what a PITA it is gonna be to get those factory crossmembers out!

Good plan.

Not going to remove the horsecollar one completely. Going to just cut out the center, and fit DOM inside, bent to the proper height.

[ike]

you should have gone to the carwash before starting this project.

[RedRunnertc]

If you can find some pipe big enough, you could put it in there whole and have a driveshaft safety ring.

[Lysmachia]

I am sure pete would be ok to get the cutter twice. We just need to find a replacement tip right now wheich we are having a hell of a time trying to find!

[AxleIke]

you should have gone to the carwash before starting this project.

I did. What you see is what the carwash didn't take off.

If you can find some pipe big enough, you could put it in there whole and have a driveshaft safety ring.

Not a bad plan. We'll see if that will work. There is a pipe place in boulder that may have some scrap.

[RedRunnertc]

You're gonna need something BIG. That little piece for mine is 4", and that's the bare minimum - look for like 8" or 10" at least .250" wall ... fortunately, you only need a short piece of it

[AxleIke]

Well, when i was a lab boy on campus, we ordered up a section of 18" from this company, I'd bet they have 8.

I'm liking this pipe idea better and better.

[85xtracab]

i was thinking about doing something like this with mine.

http://i28.photobucket.com/albums/c202/lauren12114/IMG_2309.jpg
http://i28.photobucket.com/albums/c202/lauren12114/IMG_2317.jpg
http://i28.photobucket.com/albums/c202/lauren12114/IMG_2371.jpg

[AxleIke]

Thats about what I was thinking with the pipe. Also a good option.

Thanks!

[Lysmachia]

Better than what Troy and I have to do - and go back and fix the driveshaft crossmember...


And we were so shure it was gonna work!

[RedRunnertc]

The pipe idea is very similar to that, just saves a bunch of welds that can get skewed.

The crossmember is right ... it's the tcase that needs to be lined up right.... probably drop the crossmember tomorrow night and lengthen the holes a bit so it will slide over a skotche

[chilitoy]

I have some 6" and 8" pipe at my shop and probably some other stuff too. I also have some square tube in big sizes that would probably work for the other idea you showed. I'm pretty sure it all .250 at least.

[ike]

6" and 8" sounds huge for a vehicle aplication. :confused:

[RedRunnertc]

6" and 8" sounds huge for a vehicle aplication. :confused:

That's what she said

bahdumdum

[AxleIke]

I have some 6" and 8" pipe at my shop and probably some other stuff too. I also have some square tube in big sizes that would probably work for the other idea you showed. I'm pretty sure it all .250 at least.

If you are willing to part with it, I'd love it. Let me know! Thanks!

[chilitoy]

I have some other sizes too, but I saw you guys were talking about going bigger than 4". Let me know what size you need and what length and I'll get it for you. Not easy to talk about pipe without getting Troy all excited is it?

[RedRunnertc]

I have some other sizes too, but I saw you guys were talking about going bigger than 4". Let me know what size you need and what length and I'll get it for you. Not easy to talk about pipe without getting Troy all excited is it?

Especially 8"! :rofl:

[AxleIke]

I have some other sizes too, but I saw you guys were talking about going bigger than 4". Let me know what size you need and what length and I'll get it for you. Not easy to talk about pipe without getting Troy all excited is it?

8" diameter, probably a 3" section. I'll measure tonight.

[ike]

Now i see, this is just for the tunnel in the cross members. I can also get ahold of small sections of pipe up to 24" fairly easily from work.

[Lysmachia]

Isaac (AxleIke) What's the story for this weekend?

Troy aand I are going to Denver to help FJCruzer and Pal Friday night. Not sure about saturday but they need help sat too. Would it work for us to come help you on Sunday?

[AxleIke]

No. I will be mocking and fabing this weekend. I have decided to make the most of the help, and so won't need aid until next weekend.

Thank you so much!

[RedRunnertc]

Cool - I have a cowroker from Hungary in this week and would like to take him 'wheeling on Saturday. Next week we will be in Steamboat Friday and Saturday ... could help on Sunday.

[colorado125]

I have some other sizes too, but I saw you guys were talking about going bigger than 4". Let me know what size you need and what length and I'll get it for you. Not easy to talk about pipe without getting Troy all excited is it?

Maybe there's something he's not telling Molly.....:lmao:

[RedRunnertc]

That's why she doesn't get excited until we start talking about over 10", cuz she's gotten used to it. :rofl:

[colorado125]

That's why she doesn't get excited until we start talking about over 10", cuz she's gotten used to it. :rofl:

No wonder why she's always "busy" when you're out of the country. That explains it.

[ike]

I wont be availble to help out until after christmas, but i plan on making it your way for atleast a weekend sometime.

[AxleIke]

Got enough crap out of the way to get the belly flat.

May be able to do this without lifting the motor after all. The rear driveline will be the only issue.

[mrdoug]

Don't mean to second guess you at all, but by changing the angle of the tranny/t-case without lifting the motor mounts, doesn't that put some added stress on the existing motor mounts? I guess I'm just picturing the can opener/lever effect on the existing bolts.

[fjcruzer]

Got enough crap out of the way to get the belly flat.

May be able to do this without lifting the motor after all. The rear driveline will be the only issue.

Wow, cool can't wait to see it!

[AxleIke]

Don't mean to second guess you at all, but by changing the angle of the tranny/t-case without lifting the motor mounts, doesn't that put some added stress on the existing motor mounts? I guess I'm just picturing the can opener/lever effect on the existing bolts.

Very good point, and that occurred to me last night, so I'm looking into it.

However, stock, the motor angles down toward the back, and thus the motor mounts are slightly tweaked.

also, they are rubber, so they should be able to flex a bit, and in fact do. The motor REALLY rotates when starting up. Its pretty impressive.

Also, the angle isn't that great. But, I will be looking at that over the weekend.

[ike]

Motor is angled down for saftey in collisions I believe. I think it will work if you can get the driveline angles right coming out of everything. Worst that will happen is you break a motor mount next season.

[AxleIke]

Motor is angled down for saftey in collisions I believe. I think it will work if you can get the driveline angles right coming out of everything. Worst that will happen is you break a motor mount next season.

Good to know.

That is actually funny.

Safety in a first gen 4runner? Laughable. Stock, in a side impact, the other vehicle is coming through the tin can doors and the tin can body to the frame rails. Not a ton of safety there.

[ike]

Nope, that is why when the tacos came out the "side impact protection" In the doors was a big deal.

You will be stressing the hell out of those motor mounts though in my opinion it will only be a matter of time until they break. Any chance of having a shim or such made to make the matting surface between the motor/mount flush again?

[Volcom]

http://www.4crawler.com/4x4/CheapTricks/DrivetrainLift/index.shtml#MotorMountSpacers

You could do a mild motor mount lift to correct for the drivetrain lift.

[AxleIke]

http://www.4crawler.com/4x4/CheapTricks/DrivetrainLift/index.shtml#MotorMountSpacers

You could do a mild motor mount lift to correct for the drivetrain lift.

Already got those. My goal is several fold:

-Obviously, flat belly.

-be able to still, easily change out the clutch.

-cut as little tranny tunnel as possible.

So far, the cutting hasn't been bad at all, and is very easy to work with.

If I put in the 1" spacers I have for the motor mounts, I may have to cut out the front of the tranny tunnel, which I'm trying to avoid.

If I leave the spacers out, I will have no issues with the clutch either.

If I have to, I'll put the spacers in, but just looking at my options.

[Lysmachia]

That's why she doesn't get excited until we start talking about over 10", cuz she's gotten used to it. :rofl:

Tru dat! ;)

Ok AxleIke... Troy will help a week from Sunday then. I'll try and send some steaks along... :D (I'm staying up in steamboat).

[AxleIke]

Update:

Got the rest of the floor cuts done. One cut has to be done with the tranny out, since the tcase is too close, and the saw will cut the case. Easier to wait.

Exhaust, headers and intake removed.

I've looked all over, looked at my own truck, and talked to some people.

Stock, the motor mounts flex backwards, just slightly. If I raise the tcase, but not the motor, the mounts flex forward, just slightly.

Given the hellacious amount of work to lift the actual motor, I am going to give this a try. Should I break a mount, I'll get a junkyard replacement, and put in the spacers, which I already have.

However, in theory, I should only be stressing the mounts the same amount as they are stock, just in a different direction, and, since they are big rubber pads, I doubt they care.

I assumed I would have to, due to angles, and the fan, but as it sits, everything except the intake and the headers clear. Both are very easily modified, and I was going to modify the intake anyway.

Also got the xmember stuff all cut today. Going to drill holes at work, after hours, and clean up the cuts. Should have some fab stuff done by mid week or so, I hope.

[ike]

Any Pics?

[AxleIke]

No. Too cold. Just kept working. I'll get some pics later in the week.

[Son of Mayhem]

No. Too cold. Just kept working. I'll get some pics later in the week.

Weak....:D

[Quick Draw]

Damn...suprised you worked at all... I couldn't even stand to top off my damn power steering fluid yesterday..

[AxleIke]

My work space is open to air, but its underground. It was probably around 5-10 above open, and I have some blankets that I pull across like curtains over the opening. Then crank up the propane heater. It wasn't bad until we hit 10 below outside. Then it got pretty miz, even with the blankets and the heater. Called it quits about then.

[AxleIke]

Progress:

Got the parts that I cut ground down at work, and de-mill scaled for welding. Started on beveling the edges.

Having issues with my bushings. Company that was going to have them for me, hosed me.

Then, got stock spring bushings from NAPA, too small, barely. Going in the morning to try and find something else that is 1.25" OD and rubber.

[Jacket]

I'll be away for Christmas, but back around between Xmas and New Years with some time off if you need an extra set of hands.

[AxleIke]

Back from NAPA. After an hour of searching, found something that "should" work. We will see.

[ike]

Did the new bushing work out for you?

[AxleIke]

Would have, except that NAPA screwed up something royally. While I got the right part number, the bushing was ANYTHING but what it was supposed to be.

[AxleIke]

Update:

About ready to start making smoke.

Got all my stuff cut, and fabbed up.

http://i29.photobucket.com/albums/c263/AxleIke/IMG_3666-1.jpg

Plasma kicks ass. Two bottom brackets are 3/8", two L brackets are also 3/8", round tubes are .120 wall DOM, and the 4 smaller L brackets are 3/16", and the gussets are all 3/16".

http://i29.photobucket.com/albums/c263/AxleIke/IMG_3665.jpg

Plan is that the two large brackets will go on either side of the FROR crossmember, the two round tubes through the holes, and the four L brackets will mount to the main beam at the bottom. A bolt will go through the bushings, and the L brackets. The two larger L brackets will weld to the the frame, and the large beam will bolt to them.

Word.

[ike]

Looks great!

[AxleIke]

Update:

Got the center section fabbed up. Also got the ebrake out of the way. Fuel and brake lines are giving me trouble. Still, got the main beam up, and tacked to the brackets so that I can drill them out.

Pictures:

All tacked up:

http://i29.photobucket.com/albums/c263/AxleIke/IMG_3667.jpg

Tacked and put onto my spare case, to check for fitment:

http://i29.photobucket.com/albums/c263/AxleIke/IMG_3669-1.jpg

You know whats good? Remembering to turn on your shielding gas.

No gas:

http://i29.photobucket.com/albums/c263/AxleIke/IMG_3672.jpg

Gas:

http://i29.photobucket.com/albums/c263/AxleIke/IMG_3673-1.jpg

Welded:

http://i29.photobucket.com/albums/c263/AxleIke/IMG_3677.jpg

[fjcruzer]

WOW! It almost looks like you know what your doing :D Very cool stuff :kewl:

[AxleIke]

Word.

I have no idea what that means, but its what the cool kids say.

Now, to see if NAPA can pull their heads out of their asses.

[AxleIke]

Forgot to mention, I tried to drain off part of my fuel tank to make it easier to move (welding next to a half tank of fuel that's open is probably not a good idea, right?).

Bad plan. I smell like gas. Yummy.

[ike]

Not likely, but good luck.

[poorboyota26]

It is better to weld with a full tank than a half empty to empty one. My grandpa told me a story of a guy that welded the bullet holes shut on airplanes while the tanks were full, in WWII. he wouldn't do it if they were empty.

fumes= explode
liquid= burn

[ike]

That doesnt sound like a fun job.

[AxleIke]

It is better to weld with a full tank than a half empty to empty one. My grandpa told me a story of a guy that welded the bullet holes shut on airplanes while the tanks were full, in WWII. he wouldn't do it if they were empty.

fumes= explode
liquid= burn

Never heard of that. Not sure I could handle that.

My tank isn't on the truck anymore, so I just drug it over away from the welding.

[poorboyota26]

that sounds like a better idea to me. :D

[AxleIke]

Cleaned stuff up a smidge, got the tabs drilled out, and finally have a set of bushings that will work, after about a half hour of shaving them down to fit.

[AxleIke]

Huge thanks to TC today!!!

Crossmember is fully fabbed, frame brackets are welded in, and the tranny is on the ground.

Time to clean.

[Volcom]

Nice fab work!!! Very impressed :welder:

[Lysmachia]

Awesome you and Troy got so much done. We are missing him in Steamboat but we get him back on Wednesday!

[AxleIke]

Thanks Aaron.

It was great having troy down here. Lots of fun.

I'm less than thrilled about the next part. Its going to be long, and sucky.

[RedRunnertc]

Hopefully the weather warms up a bit - it's COLD down there in the garage!

[AxleIke]

Yeah, sorry about that. I need a better heater.

[AxleIke]

Cleaning.

If anyone feels like coming over and being cold and greasy this weekend, I'd love a set of hands or two.

Got a tyvek suit for working under the truck. Could get another if I get a helper or two.

Next dilemma is parking brake.

Despite my holding out, I think that, going to ff rear, I'm not going to get lucky enough to get a set of supra calipers from the most impossible years ever. However, having already fabbed up my crossmember, I have a problem. No aftermarket set up is going to fit my new stuff.

This leaves me to customizing stuff. Which I like. What I DON'T like, is that the aftermarket kits start out at 200 bucks.

I have no problem paying 200 bucks for someone else's engineering time, where I can just open, bolt on, and go. However, I don't want to spend that money, to THEN go back and DE-engineer stuff, and make my own.

So I did some reading on the best BB ever, (to read, not post of course) Pirate.

Turns out the aftermarket stuff uses an ATV or motorcycle style caliper.

Here is where I need help. Having no interest in Motorcycles, nor ATV's, I was hoping someone had a cable actuated caliper I could get my hands on, or knew of some place, like a yard or something. Simple google search turned up a few wrecking yards, but they looked like mostly auto stuff.

Anyway, long winded post cut short: Help one day on the weekend if anyone feels like it (I got a second, heater), and a caliper.

Thanks.

[vwfastg60]

Boulder bike works...Ty's here in longmont

Ty's is off of 3rd behind Ford....a few streets back but you can see it from behind ford.

There is one off of boston but it might be Boulder bike works. I never wound up making it there cause Ty had what i needed for my 3wheeler.

[ike]

I would try ty's. There is also a bike yard down off of santa fe, but i forget what the street name is that it is off of.

[AxleIke]

Thanks

[AxleIke]

Can anyone stop by tomorrow?

[RedRunnertc]

Sorry man, we have to take Layla to the vet.

I don't get what you need an ATV brake caliper for ... tcase ebrake?

[AxleIke]

Sorry man, we have to take Layla to the vet.

I don't get what you need an ATV brake caliper for ... tcase ebrake?

Yes....

[Lysmachia]

Troy we will be done with Layla at 1:00. I know we have so much to fix on this house But We so OWE AxleIke some helpage ;)

We can chat tonight....

[AxleIke]

Don't worry about it Molly and Troy.

If no one can help, its not a big deal. Just seeing who was around.

There will be LOTS of oportunities, so if you have stuff you gotta get done, do that. I'm not worried about it at all.

[Lysmachia]

Thanks Iassc. Troy reminded me of the like 5 things we have to diagnose on his truck not to mention the 5 million things we have to fix on our house before I leave for california with Nic. *sigh* the holidays make us all put so much off...

Thanks for understanding Isaac. You have just helped us so much we want to make sure we help back!

[AxleIke]

Sorry for the lack of updates, I've been cleaning, and with the holidays, not a ton got done.

Got started up again this past week.

After cutting out my floor, and getting the pipe from chilitoy (thanks again!) I decided to get my rear suspension set up, so that, when building my tunnel, I wouldn't have any issues with the driveshaft in the rear.

So, last week, I pulled out my extra rear housing, from an 87 runner, and cleaned it. Then, I gutted it, pulling the axles, diff, brakelines, an diff studs.

On Saturday, I forgot my camera, but I drove to my buddy kevin's house, and plasma'd off the bracketry. Plasma is awesome. Burned everything off, and then had just a couple passes with a grinder to clean up. Super fun.

When that was done, it looked like this:

http://i29.photobucket.com/albums/c263/AxleIke/IMG_3684.jpg

In Saturday's mail, my shaving kit arrived. Awesome!

http://i29.photobucket.com/albums/c263/AxleIke/IMG_3686-1.jpg

The steel is all 3/8" plate.

So, I got to work.

Inked in:

http://i29.photobucket.com/albums/c263/AxleIke/IMG_3687.jpg

Cut.

http://i29.photobucket.com/albums/c263/AxleIke/IMG_3688.jpg

The cutting sucked. I cut too much in an error of judgement, as I thought the plate would sit differently. Not a huge deal, but just added extra welding, which translated to extra time while I let the housing cool between welds. One of those, kick-yourself-in-the-ass moments.

Set in place, ready to weld:

http://i29.photobucket.com/albums/c263/AxleIke/IMG_3689.jpg

I took more pictures, but my internet sucks at home. So, I can barely get photobucket to work.

Finished product.

http://i29.photobucket.com/albums/c263/AxleIke/IMG_3695.jpg

My axle housing base is now smooth, and armored to 3/8". It also should give me about an inch of clearance. I will be measuring to see if its actually that much.

Currently its sitting in the garage with some old engine oil in it, to see if it leaks. Hopefully not.

Cheers.

[fjcruzer]

Shiny-shiny! Keep making us jealous :D

[ike]

Looks sweet man! I dont know if i will ever have the balls to cut into a housing like that.

[AxleIke]

Looks sweet man! I dont know if i will ever have the balls to cut into a housing like that.

Get a spare. I figured if I messed it up really badly, It could just go in the dumpster, and all I was out was a 25 bucks or so.

[Volcom]

Cutting the drain plugs out is so worth the extra time and effort! It's nice to have a smooth bottom to just slide over the rocks and not have to worry about the plugs falling out.

[AxleIke]

Cutting the drain plugs out is so worth the extra time and effort! It's nice to have a smooth bottom to just slide over the rocks and not have to worry about the plugs falling out.

Yeah, I did a bunch of research on it, and NONE of the reviews/writeups had a negative or "I wish I'd left it stock" comment.

I've taken to jokingly calling it my baby's bottom, since its now smooth like a baby's bottom.

[AxleIke]

Bummer this morning. It leaks.

Good news is, its a small little leak, that can easily be plugged.

Bad news: Gotta clean everything out, weld, then put the oil back in to see if the leak is fixed.

[RedRunnertc]

Can you test it with some compressed air and soapy water instead of messing with the oil?

[ike]

Definately a better test, but more dangerous. Compressed air turns things into bombs really quick if it has a weak spot.

[AxleIke]

Can you test it with some compressed air and soapy water instead of messing with the oil?

Definately a better test, but more dangerous. Compressed air turns things into bombs really quick if it has a weak spot.

That would require a ton more effort. The oil is messy, but really just takes a couple of minutes. Good ideas, but not going to bother with it.

A big hairy lumberjack stopped by for chatting tonight, so I didn't get anything done, which was fine, as I am tired.

[Volcom]

Did you weld the inside also? Crossed my fingers for no leaks when I did mine and it worked :D

[RedRunnertc]

What's Adrian been up to? When's he coming wheeling with us?

[AxleIke]

Did you weld the inside also? Crossed my fingers for no leaks when I did mine and it worked :D

Yes. The problem is that I cut the back a little lower than the front, because I'll be rotating the housing some. There are two rings at the back of the case, one stiffening ring, and then the back of the axle housing. I cut through both, so, in essence, there were two cracks to weld. The front was easy, but the rear was tough. The gun doesn't fit in the housing, so the welding was harder.

[00regcab]

so this may be a very stupid question, excuse my ignorance.

But how much of a pain in the ass is it going to be to change the oil in your diff now?

Looks sick, and ive always thought about it, but being as mine is my DD, and fluids get changed frequently, its kind of steered me away from it.

[AxleIke]

What's Adrian been up to? When's he coming wheeling with us?

He's been doing school. He has his lockers rewired (an animal ate them), and his winch rewired. He also has his sliders back on. He just needs a belly pan. He said he's pretty hopeful for the summer.

[AxleIke]

so this may be a very stupid question, excuse my ignorance.

But how much of a pain in the ass is it going to be to change the oil in your diff now?

Looks sick, and ive always thought about it, but being as mine is my DD, and fluids get changed frequently, its kind of steered me away from it.

Not stupid at all. Nothing to forgive.

However, the fluid change is no different. The difference is the way in which you do it. The interior base is now only a fraction of an inch below the lower two diff studs. I'll be welding the nuts to the bottom two studs. To change the oil, I now just pull the lower two studs. Two bolts instead of one, and to replace I have to torque them, but thats it.

I'll be putting a mag plug in the fill spot.

[ike]

Cool, I never realized that that was how it was done either.

[mrdoug]

Wow!

It's funny tho. When I had my 98 ranger, there was only one plug in the diff, and I'd curse about having to use a vacuum plunger to "drain" the diff. When i saw the toyota diffs actually had a drain plug I was pretty happy. You seem to be going the opposite way. But I think I understand how you're going to drain it and that makes mucho sense.

[ike]

But then the american diffs let you inspect the gears without pulling the third. Something i wish you could do on a yota diff.

[RedRunnertc]

But then the american diffs let you inspect the gears without pulling the third. Something i wish you could do on a yota diff.

x2

[devinsixtyseven]

I'll be welding the nuts to the bottom two studs. To change the oil, I now just pull the lower two studs. Two bolts instead of one, and to replace I have to torque them, but thats it.

But then the american diffs let you inspect the gears without pulling the third. Something i wish you could do on a yota diff.My 9" works the same way. Only one bolt tho, and it's a bolt threaded to the housing rather than a double threaded stud, not torqued anywhere as far down as the actual studs & nuts. Fill is through the breather on mine, believe it or not.

Yours is gonna work out great...the leak shouldn't be hard to fix, if it's just a pinhole.

[00regcab]

Not stupid at all. Nothing to forgive.

However, the fluid change is no different. The difference is the way in which you do it. The interior base is now only a fraction of an inch below the lower two diff studs. I'll be welding the nuts to the bottom two studs. To change the oil, I now just pull the lower two studs. Two bolts instead of one, and to replace I have to torque them, but thats it.

I'll be putting a mag plug in the fill spot.

Makes sense. So would you back the rear of the truck onto some of those drive-up wheel stands, or just put the rear axle on jack stands to help it tilt forward to drain more out, or would that really be necessary?

Im really looking forward to seeing this done, i still need to make time to swing by and help ya out one of these days.

[AxleIke]

Makes sense. So would you back the rear of the truck onto some of those drive-up wheel stands, or just put the rear axle on jack stands to help it tilt forward to drain more out, or would that really be necessary?

Im really looking forward to seeing this done, i still need to make time to swing by and help ya out one of these days.

Not sure yet. I'll have to see how far I tip it up. I will probably jack it up to drain, just for the hell of it.

We'll see.

[vwfastg60]

I love my shaved drain plug but its a PITA to drain. I pull the bottom bolts out of the 3rd and let it pee out. I found this last time it doesnt get everything out and leaves a small bit in there even tilting it forward. Maybe an air pen on the back would help....I will try it after i change the fluid when its back on the road and the gears are broke in.

[ike]

Even with the stock drain plug i doubt you get a complete drain. I know with the engine you definately do not.

[AxleIke]

You do not get a complete drain from a stock set up.

[chilitoy]

Looks good. Just wondering, could you drill and tap bigger holes for the ones you are using for drainage? Not sure if they would be big enough to make a difference, but just a thought.

[ike]

Wouldnt think it would really be needed.

[AxleIke]

Ya, not really needed. Good thought though. All the reading I've done says that drainage is all good with just the stock holes.

Anyone around on Saturday for a few hours?

[ike]

npoe, going to either be snow bashing or helping Erics freind move.

[mrdoug]

I might head down to lend a hand for a few hours. I really need to get in my garage and get some work done on my junk, but I haven't been motivated all week. I'll be heading up to FTC to help load up Eric's friend, and depending on if I feel like avoiding work at my place, i might then head down to lend you a hand.

How's that for non-comitment? I'll give you a ring to let you know Saturday. I really want to take a first hand look at that axle housing work you did as well as the other progress you've made.

[AxleIke]

Cool Doug. No worries about it. Just FYI, I have to quit around 4. Got socalizing to do at 6:30 and I have to get prepped for that.

[AxleIke]

So, today I finished the axle. No more leaky leaky.

Also got the suspension figured out, and am simply waiting on a shipment from Ballistic. Saturday will be removal of the rear suspension. If I get my box tomorrow, I'll be able to get things going this weekend. If not, its gonna be a slow deal.

[Quick Draw]

Bump. Any progress?

[AxleIke]

Still flipping waiting. Fedex says Saturday on the shipment, I'll believe it when I see it.

Rear suspension is out. Bumpstops cleaned off the frame. Half of the front spring hangers are off the frame. Still have to finish cleaning those.

I'll post up when something more exciting changes. For now just waiting.

[jarboarder1]

I just read through all of this thread. Everything looks great.
Question for you on your flat belly. Are you going to make the cross member separate from the belly skid, or are you going to have it all incorporated into one piece?

[ike]

Any more pics of the progress??

[AxleIke]

I just read through all of this thread. Everything looks great.
Question for you on your flat belly. Are you going to make the cross member separate from the belly skid, or are you going to have it all incorporated into one piece?

Separate.

[AxleIke]

No more pics as of yet. I'll get some up soon. Its been slow.

[jarboarder1]

Yea I like the idea of going separate. If you bend the skid or something you can take it off without messing with your drive train. I was just wondering because I also like the looks of post #16 on this thread
http://www.pirate4x4.com/forum/showthread.php?t=634019

[mrdoug]

Good taste...

I saw that thread a few months ago and that same one popped out at me too.

[AxleIke]

My welder is down as of last weekend. Should have it back by Friday.

However, I have family stuff this weekend, so likely not much work will be done until next week. I have nearly everything to get the rear suspension done. I hope it will be soon.

I'll post pics soon.

[AxleIke]

Some small picture updates:

After finishing the rear axle up, I cleanup up a bit, did a lot of organizing, and turned the truck around. Also, due to the extreme generosity of a friend, I picked up a 14" abrasive chop saw for a six pack of beer.

So, I took off my rear axle, and cleaned my frame:

http://i29.photobucket.com/albums/c263/AxleIke/IMG_3703.jpg

I also began fabbing my frame side bracketry. After cutting this stuff up, my welder quit. I'll fill in that story when I know the rest of it.

Here are my frame plates:

http://i29.photobucket.com/albums/c263/AxleIke/IMG_3699.jpg

http://i29.photobucket.com/albums/c263/AxleIke/IMG_3700.jpg

And the back "plates" (rectangular tubes) that will be where the tabs weld to, along with the plates and some square tubular gussets:

http://i29.photobucket.com/albums/c263/AxleIke/IMG_3701.jpg

And the last of my bling arrived via the UPS man:

http://i29.photobucket.com/albums/c263/AxleIke/IMG_3705.jpg

18" 300 lb/inch coils

[mrdoug]

Damn, you have the patience of Job... The way you clean and prep is outstanding. Sucks to hear about your welder tho.

[AxleIke]

Thanks doug.

Its also been described as Anal. :D

Good thing about the welder is that I'm being treated VERY well by Miller. They are paying for parts and labor.

[ike]

Great to hear they are standing behind their product. Though not a suprise from them.

[devinsixtyseven]

Looking good there. Nothing like clean material to get a good weld.

Four months til Moab :xpimp:...

[AxleIke]

Yup.

Got some tube inserts coming next week, and then its off to the races. Couple more brackets to make, and we'll be rocking. I'm excited.

[AxleIke]

Welder is back and works better than ever. Super excited.

Got back to work.

Frame side brackets and Axle side panhard mount all burned in:

http://i29.photobucket.com/albums/c263/AxleIke/IMG_3713.jpg

http://i29.photobucket.com/albums/c263/AxleIke/IMG_3716.jpg

I got a 3/4" drill bit (borrowed) but its for a 3/8" chuck, and my drill is 1/4". Bummer. I'll be drilling out tab holes for the frame side stuff tomorrow at work (I hope), and getting that burned in.

[mrdoug]

looking forward to seeing them mounted on the truck. I'm having trouble figuring out how you're planning on using the frame side mount.

[RedRunnertc]

I got a 3/4" drill bit (borrowed) but its for a 3/8" chuck, and my drill is 1/4". Bummer.

I think you mean 1/2" and 3/8" respectively ... step bits are the way to go for metal BTW - I have some you can borrow if you need to (and they fit 3/8" chuck)

[AxleIke]

looking forward to seeing them mounted on the truck. I'm having trouble figuring out how you're planning on using the frame side mount.

The flat "T" shaped piece is the frame plate. It will be welded flat to the frame to reinforce it. The small square tube gusset will face the front of the truck, and two tabs will be welded to the other side of the rectangular tube to and face the rear.

I think you mean 1/2" and 3/8" respectively ... step bits are the way to go for metal BTW - I have some you can borrow if you need to (and they fit 3/8" chuck)

Could be. I was just guessing at what the shank on each bit looked like. I hadn't thought about the step drills. That is a great idea. For now, the holes are currently 9/16" and I'll be going up to 3/4", so it won't be too hard.

[devinsixtyseven]

Isaac, aren't you fairly close to me? Got a drill you can borrow, if you still need it.

S&D style bits (everything 1/2"+) all have a 1/2" shank, but the step bit is way easier...I do have one that goes to 3/4", and fits a 3/8" chuck...think I got it at Lafayette Ace, like 10-15$, after seeing how well Troy's worked at the last HOW S.

[AxleIke]

I drilled out the holes at work on a drill press. Sean, I may hit you up for that drill at some point. Depends on how many more holes I need to drill. At least two.

Got some more done, but it was slow tonight. A lot of stacking/creative leaning, to get things to line up properly, and actually sit without falling:

http://i29.photobucket.com/albums/c263/AxleIke/IMG_3719.jpg

Even still, I'm going to have to pound this bracket a little once its welded to the frame. Both tabs are leaning about 1/32 or so inboard. Not good. But, easy to fix. However, it means that gussets will have to be done on the truck. :(

Doug, this should help a little with the visual. Imagine that the firebrick is actually the frame rail, and that you are looking down on the set up from above (ie through the truck, xray vision style). You can see how the bracket mounts, and how the arm comes off of it.

http://i29.photobucket.com/albums/c263/AxleIke/IMG_3720.jpg

[AxleIke]

Due to welder delay, and shipping delay, I will be taking thursday off of work to finish the other frame side bracket, make the axle side brackets, and begin tacking in the suspension.

If anyone wants to stop by Thursday, PM me, and you are more than welcome to come on by. I'll have grinding to do, and a couple other things, and measurement is always easier with two people.

[ike]

Will likely be heading out to Elizabeth in the am to get the truck registered. May have time on the way back to stop by, though i work at 6.

[mrdoug]

A lot of stacking/creative leaning, to get things to line up properly, and actually sit without falling:

http://i29.photobucket.com/albums/c263/AxleIke/IMG_3719.jpg


I love that double swivel square magnet. I got one too, comes in really handy!


Doug, this should help a little with the visual. Imagine that the firebrick is actually the frame rail, and that you are looking down on the set up from above (ie through the truck, xray vision style). You can see how the bracket mounts, and how the arm comes off of it.

Yep, it's all clear now! nice, looks beefy as hell. Any magic math in figuring out your fish plate size?

Getting that nut off down the road might get tricky you think? or is the picture throwing off my sense of size? Parts tend to be a lot bigger than they look on the net sometimes. I'm just thinking at some point you might want to put a socket on that nut and I can't tell from here if there's space between that and the frame rail. I'm not sure how much torque you're putting on that nut tho, so you might be fine with a open end.

[ike]

Looks to be plenty of room to get a closed end wrench in there. With the magic of air tools to do the initial break loose i dont think it would be a problem.

[AxleIke]

Yeah, I can get the closed end of a wrench in there no problem. It only goes to 75 or 80 I think.

Doug, I don't understand the fish plate reference? Not sure what you mean there.

[mrdoug]

I guess you called it a frame plate earlier in the thread.. I've heard it called a fish or scab plate too, it's the plate you weld to the frame that all your other stuff connects to. I know it's to distribute force to a wider area on the frame.

I was just curious if there was a ratio or something for determining how large a plate compared to the items connected to it.

[AxleIke]

Oh. No, no particular math involved. I cut it out to give myself enough room to mount the bracket and a gusset, and fit in the material I had on hand.

There may be a ratio of some sort, but with the thickness of this metal, I'm not worried about it. Its beef.

[AxleIke]

Will likely be heading out to Elizabeth in the am to get the truck registered. May have time on the way back to stop by, though i work at 6.

Sounds awesome. I plan to quit at about 6 anyway, so not to worry about that.

Probably get started at about 9:30-10.

[ike]

Doug, you could figure out sheer and bending forces on the frame at the plate. Would take a shit load of time, and the main factor would likely be the contact area of the scab plate and not its thickness due to how thin our frames are.

[jarboarder1]

So I had a question about the horse collar cross member. All the pictures I see show that you have to move it up and clearance it a lot for the flat belly, but from the pictures I have seen it looks like it would be possible to run a tube under instead of over the top. There could be clearance issues that I cant see in pictures that you can see directly on the truck, but would that be a possible solution?

[ike]

Axleike, where do you live? give me a call tommorow around noon, or pm me you #, and i will head out that way. 9704207403

[RedRunnertc]

So I had a question about the horse collar cross member. All the pictures I see show that you have to move it up and clearance it a lot for the flat belly, but from the pictures I have seen it looks like it would be possible to run a tube under instead of over the top. There could be clearance issues that I cant see in pictures that you can see directly on the truck, but would that be a possible solution?

No - he had to flat cut it out to clear the tcase and driveshaft.

Not sure what you mean by running a tube under...

[85xtracab]

No - he had to flat cut it out to clear the tcase and driveshaft.

Not sure what you mean by running a tube under...

yea he means instead of modifying the existing one/moving it up to just run a tube underneath the cases there to replace that crossmember. Basically he was just wondering if there was enough clearance under the cases near the old horse collar to run a piece of tubing.

[AxleIke]

PM Sent Ike.

With the horsecollar, I think you could do that. Just move the xmember forward a bit, and then get rid of it all together. Certainly a possibility. Still looking at how best to do that.

[jarboarder1]

cool I just wasn't sure if it would fit. I think it would be soo much easier than modifying the stock one, but have never seen it done before.

[ike]

How did everything go yesterday?

[AxleIke]

Great.

Got my second frame side bracket built, and the first one straightened. Both gusseted. Also got the axle side brackets built.

Tomorrow I will be getting the axle under, and measuring everything 100x, and hopefully tacking in most of it.

With being able to work on sunday too now, I hope it will be rolling by the end of the weekend.

[RedRunnertc]

I should be available to help on Sunday.

[ike]

That will be record time.

[AxleIke]

Not getting the record time post.

Troy, sounds good man. Though you seem to pick to cooler days to come over...LOL

[ike]

Just considering how long Troy took, and how much less he did to Ron. As compared to your progress.

[AxleIke]

A good weekend.

I realized I hadn't exactly explained my suspension before, so here goes:

This is a total experiment. I'm going to see how it works. It may work well, and be really cool, or it may suck huge and have to get changed next winter.

The good part is, if it does need to be changed, I can convert to either a true 3 link, and jeep 3 link, or a different radius arm set up. I'll be out about 65 bucks if that happens.

The idea came from staring at an 80 series land cruiser and listening to the owner complain about his front radius arms being rock magnets.

After staring for a few minutes, I thought to my self, "wow, those do hang down far. But, if you flipped them on top of the axle, they'd have a TON of clearance." And, so, I kept turning it over in my head, and finally picked up a set of used arms from Slee Offroad for 50 bucks.

I stuck them up under my truck, and was happy to see that not only did they give me virtually nothing hanging below the axle (the rear mount hangs down 1/2", and is smooth), but, when tucked above the bottom of the frame, they were higher up than my leaf spring. Much better clearance all around.

Anyway, obviously I see the issues with this, and there are a few, as well as the fact that it would be much easier to link it, and call it good. However, I like different. I figure I'll see where this goes, and go back to the norm if it doesn't work out.

Back to the pictures :D

On Saturday, with the help of a buddy, I got things measured, and remeasured, and remeasured, ad nauseam. However, things turned out straight, so thats good.

http://i29.photobucket.com/albums/c263/AxleIke/IMG_3722.jpg

Setting the pinion angle

http://i29.photobucket.com/albums/c263/AxleIke/IMG_3724.jpg

Axle strapped down so it wouldn't move.

http://i29.photobucket.com/albums/c263/AxleIke/IMG_3725.jpg

Tacked in the radius arms. Looking good so far.

http://i29.photobucket.com/albums/c263/AxleIke/IMG_3726.jpg

That's as far as we got. Troy came over today, and helped me get the rest going.

Panhard in:

http://i29.photobucket.com/albums/c263/AxleIke/IMG_3729.jpg

Spring buckets in:

http://i29.photobucket.com/albums/c263/AxleIke/IMG_3730.jpg

Small snag, due to a dumb mistake. I calculated a loaded truck rear axle weight to be 1200 lbs. I wasn't far off. However, I miscalculated. If the truck has a 1200 lb weight on the axle, then each spring has 600 lbs. Bummer. So, I got 18" 300lb/inch springs, thinking they'd compress around 4". Wrong. Loaded, they'll get about 2. So, sending these back, and getting a set of 16". That should be about perfect.

http://i29.photobucket.com/albums/c263/AxleIke/IMG_3732.jpg

Before Troy left, we hauled out his spare, which is the tire and rim set up I hope to run. I like it!

http://i29.photobucket.com/albums/c263/AxleIke/IMG_3733.jpg

I booger welded in the frame brackets tonight. I don't know what it is, but I can't for the life of me make pretty welds upside down. Practice makes perfect I'm sure, and I've gotten all the tips and tricks. I just suck at it. Oh well.

[ike]

Looks great man. Will definately be the only one like it i have seen. In theory it should work great.

So you plan on goint to 33 10.5 KM2s soon.

[RedRunnertc]

Yeah, there were a couple funny moments this afternoon ... the first was after we put the springs in and were raising the axle up to ride height ... Isaac was watching the axle and I was running the jack and watching the ceiling - it got REALLY close, and the truck was all stinkbug ... we figured out how much the spring compresed and back calculated the weight, and I said " x2" and ike gets this look on his face and says "ohhhhh shit" ... then as I was leaving, I opened up the door to the truck and Isaac says "what's that" ... "what's what" ... "your spare - lemme look at that" it was such a funny "only a truck guy would notice" moment :rofl:

Mine flexes better :D

[Avsfreak1234]

Yeah, there were a couple funny moments this afternoon ... the first was after we put the springs in and were raising the axle up to ride height ... Isaac was watching the axle and I was running the jack and watching the ceiling - it got REALLY close, and the truck was all stinkbug ... we figured out how much the spring compresed and back calculated the weight, and I said " x2" and ike gets this look on his face and says "ohhhhh shit" ... then as I was leaving, I opened up the door to the truck and Isaac says "what's that" ... "what's what" ... "your spare - lemme look at that" it was such a funny "only a truck guy would notice" moment :rofl:

Mine flexes better :D

that may be something you want to get checked out. :rofl:

[AxleIke]

Mine flexes better :D

The ladies like it stiff.

[AxleIke]

Looks great man. Will definately be the only one like it i have seen. In theory it should work great.

So you plan on goint to 33 10.5 KM2s soon.

Thanks man!!! We'll see how it turns out.

I hope to go to the KM2's. Trying to sell my 9.5's right now. I hope to get about half the cost of the new tires. We'll see.

[ike]

Isaac's lockers work:rolleyes:

[RedRunnertc]

Trudat ... I don't know WTF is going on with my bad luck ... get the locker fixed, and then the compressor shits the bed.

[AxleIke]

I know what's going on.

For every 100,000 products ARB makes, they get one lemon. Then they send that lemon on to you. :D

[ike]

Guess they figure who better to send the lemons to than a quality manager.

[Volcom]

Nice custom fab on those FJ80 radius arms and using them in a rear application and upside down!!! Your work looks top notch so far :cool:

[AxleIke]

Nice custom fab on those FJ80 radius arms and using them in a rear application and upside down!!! Your work looks top notch so far :cool:

Thanks man. I just hope they actually work after all this. The suspension was NOT easy to cycle, but when it did, it had pretty good flex. It may just need new bushings.

[AxleIke]

Slow progress. Lots of grinding, welding, etc...

Axle is done, and ready to go back under the truck.

http://i29.photobucket.com/albums/c263/AxleIke/IMG_3735.jpg

Here is a shot of one of the radius arm brackets gusseted in:

http://i29.photobucket.com/albums/c263/AxleIke/IMG_3739.jpg

And my favorite part, a little bling:

http://i29.photobucket.com/albums/c263/AxleIke/IMG_3736.jpg

:D:D:D:D:D

[Jacket]

WOW! Major bling! I think you should get some gold paint on that thing!

Here's a dumb newb question - where do you get those right angle magnets for holding the steel for welding?

[AxleIke]

Harbor freight has a TON of good stuff like that. Its right off of 36 and Sheridan. Thats where I got mine.

[Quick Draw]

If this works for you, I think it would be cool to try on Doris... So I'm anxious to see how this thing performs on the trail. Something that I read said that radius arms in the rear don't have to much anti-squat, so you're rear axle is always trying to drive under you. But if it works, you reallly may be on to something. Really, this is a lot like Trail-Gear's 3 link.

[AxleIke]

To be honest, with Doris not having a bed, this would be a waste of time for you. If you were going to change the suspension, a 4 link would be RIDICULOUSLY easy. And, you could run Coilovers with no issues.

This works well for me, so I don't have to try to get the suspension to come through the floor, or find someone to bend it like troy's.

[jarboarder1]

agreed you already got rid of the bed, a 4-link would be bad ass.

The angles on your radius arms dont seem to be that steep, I wouldnt think there should be that much anti-squat. guess you will have to see when you wheel it the first time. Are you planning on running a limit strap or winch off the top of the housing?

[AxleIke]

Limit straps.

I need to get the truck running so I can flex it out, make sure everything clears, and get measurements for shocks, straps, and bumpstops.

As for anti squat, I don't think it'll be too much of an issue. Low anti squat numbers mean the truck squats hard under acceleration. Bad if you have a lot of power, not so bad if you have 4 cylinders of fury.

It can also be an issue on climbs, but more so, I think, for comp buggies, and less so for DD trucks that see mild trails. I read up about it, but its not a huge concern.

Higher anti squat is good because it gives you better traction on acceleration, essentially forcing the body and axle apart.

[AxleIke]

Well balls.

First real snag of the process.

They don't come from ARB like that:

:(

http://i29.photobucket.com/albums/c263/AxleIke/IMG_3741.jpg

Good news, pinon and ring gear appear to be undamaged. I guess the locker softer than the pinion. Also, the funky gear pattern hasn't damaged anything else.

Also good news, this is almost for sure the crush sleeve. Solid spacer to fix the issue, and a quick rebuild of the diff.

Not ideal, but c'est la vie.

[RedRunnertc]

You might want to shorten that copper line while you're in there... doesn't need to be even half that long!

[Quick Draw]

Are you talking about the teeth cut into the locker? Wow, I almost didn't see that because that looks like its supposed to be that way. That's pretty cool... So you're just going to leave it as is?

[AxleIke]

No, not going to leave it. And, yes, teeth cuts into the locker.

I wish :D

However, if the pinion has moved that much in, then the preload is toast. I think all the bearings, and ring and pinion are fine. I'll just pull it all apart and reassemble the diff with a solid spacer from Marlin. 30 bucks and a days worth of work should fix the problem.

Troy, the copper line was a result of my tubing cutter not being able to cut it. Since I wanted to get done, I just bent it out of the way. It will DEFINITELY get trimmed down.

[Quick Draw]

Oh yeah, obviously you will fix the pinion. But I was wondering if you were just going to leave the locker that way. Sounds like you are.

[AxleIke]

Oh, yes, I'm leaving the locker. No reason to do anything. Its just the housing, and I'd guess the gouge is maybe a 32nd deep. It'll sling oil better this way! :D

It does look pretty cool though, doesn't it? :rofl:

[ike]

Damn, even customizing the ARB

[AxleIke]

No pictures, but the truck is sitting on its own wheels again. Its totally stinkbug, but, it is also COMPLETELY empty. No gas tank, no tranny transcase, no spare, no tools, no nothing. I'm hoping it will sink some. We'll see.

[Lysmachia]

So Troy and I are coming over Saturday yo! Just let us know what time ;)

[AxleIke]

Big thanks to Troy and Molly for swinging by today and helping me out. They were a HUGE help!!! Thanks guys!

First off, here is a shot of the truck with no weight in it, besides the transmission. Troy and molly sat in the back, which is roughly how much weight I wanted, and it came down to a perfect height! Awesome!

http://i29.photobucket.com/albums/c263/AxleIke/IMG_3754.jpg

Here is the flat Belly:

http://i29.photobucket.com/albums/c263/AxleIke/IMG_3749.jpg

http://i29.photobucket.com/albums/c263/AxleIke/IMG_3753.jpg

http://i29.photobucket.com/albums/c263/AxleIke/IMG_3751.jpg

And, a shot of the motor mount, so you can see why I didn't feel that lifting the motor was needed:

http://i29.photobucket.com/albums/c263/AxleIke/IMG_3747.jpg

And a quick interior shot showing how it fits inside. The Pass seat fits! It will be close but, I can make it work...

http://i29.photobucket.com/albums/c263/AxleIke/IMG_3758.jpg

http://i29.photobucket.com/albums/c263/AxleIke/IMG_3755.jpg

[Avsfreak1234]

lookin good!

[ike]

Looks great man! you are really making some good progress on that thing.

[mrdoug]

wow, looks GREAT man. Can't believe how much sits up in the cab tho.. that's going to be tricky to work with. The whole drive flange is sitting in the cab! :eek:

I'm sure you have a vision of how you're going to work out the driveline routing tho.

Oh, and yeah, I see what you mean about the motor mounts.

I can't wait to see this in person.

[AxleIke]

lookin good!

Looks great man! you are really making some good progress on that thing.

Thanks dude!

wow, looks GREAT man. Can't believe how much sits up in the cab tho.. that's going to be tricky to work with. The whole drive flange is sitting in the cab! :eek:

I'm sure you have a vision of how you're going to work out the driveline routing tho.

Oh, and yeah, I see what you mean about the motor mounts.

I can't wait to see this in person.

Thanks doug. Well, its going to be tricky, but that will be a little fun too. I like these little challenges in engineering.

And, if things just WON'T work, the bottom of the tcase is more than an inch above the tbar mounts. I wanted to go up higher in the event of a C/O or solid axle swap, I could suck my skid up higher after cutting the tbar mounts off. I can always lower the drivetrain a hair if I have to.

[poorboyota26]

just curious about the motor mounts. What am I looking for? That they are straight even though the trans and cases are riding shotgun.


Good work man I like how you were thinking outside the box on the LC arms!

[vwfastg60]

Looking good!!! What did you use to clean the tranny/cases? Mine didnt come that clean after 4 soakings and pressure washing. :(

[RedRunnertc]

At least 4 cans of engine clean, a ton of SimpleGreen, and scrapers.

[AxleIke]

just curious about the motor mounts. What am I looking for? That they are straight even though the trans and cases are riding shotgun.


Yup. There was concern that the mounts would be really torqued, and there fore have issues with the DT lift. However, when we were mocking it up, it became apparent that an engine lift was not needed, which makes this MUCH easier as far as a modification goes.

[AxleIke]

Looking good!!! What did you use to clean the tranny/cases? Mine didnt come that clean after 4 soakings and pressure washing. :(

At least 4 cans of engine clean, a ton of SimpleGreen, and scrapers.

Along with some plain jane degreaser, a wire wheel on a drill, and a wire wheel on a grinder, MULTIPLE cleaning sessions, and finally a trip to the car wash.

It took maybe 12 hours of work to get it that clean, spent over a week and a half.

[mrdoug]

It took maybe 12 hours of work to get it that clean, spent over a week and a half.

Sounds good, I'll drop my junk off this week, pick it up on the 10th? :D

[AxleIke]

You wish buddy.

[poorboyota26]

When I was 16 and swapping out tyranny's like underwear (once a week:D) I used to coat the whole thing in degreaser let it set over night, then take it to the car wash, repeat about 3 times and minimal scraping required.

Looking good. I like the "slider clearance" on the pinch welds :D

[motochain]

Nice work! Took some time to get through all 9 pages.. :D...

It kills me to not have a garage to work on my own....

[jarboarder1]

is that just flat bar for your cross member? if so are you switching to square tubing or something stronger?
Everything looks great by the way

[poorboyota26]

I see custom seat frames in your future.

[AxleIke]

is that just flat bar for your cross member? if so are you switching to square tubing or something stronger?
Everything looks great by the way

Yes it is for the crossmember, and no, not switching to stronger at this time. It is 3/8" thick, and should hold the tranny fine. It will be completely covered by a skid.

If it starts to deform at all with use, It will get replaced.

[AxleIke]

I see custom seat frames in your future.

Check back a few posts. The seats fit. That was a big part of my excitement.

[poorboyota26]

sorry I'm one of those pic readers

[AxleIke]

Got more work done.

Truck now moves under its own power.

Got the old crossmember torched out, and the new one put in:

http://i29.photobucket.com/albums/c263/AxleIke/IMG_0597.jpg

http://i29.photobucket.com/albums/c263/AxleIke/IMG_0598.jpg

Hole cut for the tank:

http://i29.photobucket.com/albums/c263/AxleIke/IMG_0599.jpg

Tank in:

http://i29.photobucket.com/albums/c263/AxleIke/IMG_0600.jpg

This was cool. Lots of clearance under the tank. I didn't think it would sit up that high. Very cool

http://i29.photobucket.com/albums/c263/AxleIke/IMG_0601.jpg

http://i29.photobucket.com/albums/c263/AxleIke/IMG_0602.jpg

Lastly, got the horseshoe crossmember dealt with.

http://i29.photobucket.com/albums/c263/AxleIke/IMG_0603.jpg

Started on the tranny tunnel. One cross piece is all, as it took a little adjustment to change from welding 1/4" to sheet metal. Burned a few holes before I got it dialed in. I will likely go to oxy/acetylene for the rest. Its much easier to keep from burning through with that.

http://i29.photobucket.com/albums/c263/AxleIke/IMG_0604.jpg