Hunt4Steve SAS Project

[Hunt4Steve]

Well, I guess I should throw up some stuff on what I'm doing and see what you all think.

I have a '99 4Runner Limited with a factory locker that was just begging to have a SAS done on it. After breaking numerous axles, including the ORS axles and outboard joints, it was time.

I will be putting on 14" travel SAWs with sleeved links that may be up to 48" in length. The total thickness of the locating links will be 1/2", pretty beefy. The front axle is a Waggy D44 with Flat Top knuckles, Parts Mike Cross over steering links, Flaming River steering shaft, ARB carrier, Warns axles, Longfield joints and some 37" tires. The front axle setup will be very close to the Ultimate Tacoma setup, with the coils sitting on the forged knuckles. This will allow a longer pan-hard bar setup. The ABS will be completely removed, and Sky's rear disc brakes will go on back to help slow everything down.

So, here are a few pics of the progress, I'll post more as the project progresses.

All pictures, inlcuding larger pictures can be seen at this link:
http://www.hunt4steve.com/or/99_4runner_ltd/SAS.htm


http://www.hunt4steve.com/or/99_4runner_ltd/pics/SAS/P1010003_.JPG http://www.hunt4steve.com/or/99_4runner_ltd/pics/SAS/P1010027_.JPG


http://www.hunt4steve.com/or/99_4runner_ltd/pics/SAS/P1010041_.JPG http://www.hunt4steve.com/or/99_4runner_ltd/pics/SAS/P1010052_.JPG

[Davidtaco]

Looking nice

-David

[CHINOTACO]

Looking killer!

chino

[Bighead]

Lookd good Steve. Is this going to be ready in time for the CO trip?

[Hunt4Steve]

Thanks guys, much appreciated.


Yeah, I think it will be ready. Jim came over today, and put in about 10 hours. He helped quite a bit with the locating of the shocks, and did a bunch of cutting of the wheel wells. He thinks it'll be ready, and I think I can get it running for the trails.

Jayson (loosehead) is coming over tomorrow for a few hours to see what he can do as well.

I think it'll be ready. I have a few friends coming over next weekend as well, and I'm working on it everyday after work as well. I have a few more parts coming in, and today we found that Parts Mike sent a drag-link that was too short by about 4 inches. So, Monday morning I'll give him a call and get a another one sent out.

We pretty much have the axle placed and tomorrow I'll work on creating a pan-hard bar, just so all the bars are in place. I'll have some more pictures up tomorrow, its coming out pretty good.

[Hunt4Steve]

A few more pics, and a bit more work over the weekend.


http://www.hunt4steve.com/or/99_4runner_ltd/pics/SAS/P1010063_.JPG (http://www.hunt4steve.com/or/99_4runner_ltd/pics/SAS/P1010063.JPG)


http://www.hunt4steve.com/or/99_4runner_ltd/pics/SAS/P1010066_.JPG (http://www.hunt4steve.com/or/99_4runner_ltd/pics/SAS/P1010066.JPG)

[Cebby]

Great work Steve. I'll be watching this closely - I want to do something similar (coilovers/links) to my 2nd Gen at some point.

[Hunt4Steve]

If you look closely, you can see that the draglink is waaaaayyyy too short. I called Parts Mike today to get the correct length and hopefully I'll have it in a few days. This week I'll be putting in the pan hard bar and hooking up the rear brake line stuff. Yesterday I finished the transfer case mount. I'll have some pictures on that soon.

[Hunt4Steve]

Here is some work we did over the weekend. The site below has more pics.

http://www.hunt4steve.com/or/99_4runner_ltd/pics/SAS/P1010092_.JPG (http://www.hunt4steve.com/or/99_4runner_ltd/pics/SAS/P1010092.JPG)



http://www.hunt4steve.com/or/99_4runner_ltd/pics/SAS/P1010094_.JPG (http://www.hunt4steve.com/or/99_4runner_ltd/pics/SAS/P1010094.JPG)



http://www.hunt4steve.com/or/99_4runner_ltd/pics/SAS/P1010088_.JPG (http://www.hunt4steve.com/or/99_4runner_ltd/pics/SAS/P1010088.JPG)


More at: http://www.hunt4steve.com/or/99_4runner_ltd/SAS.htm

[Brain]

Looks great! It looks like you are doing a setup similar to Dean's (tacodab)and Jake (tacominator). You'll like it a lot! Are you going to rig up a sway bar?

[Hunt4Steve]

Yup, I'm doing it very much like Dean's. He has been very helpful in answering my questions as well.

eventually I'll get the Currie sway bar.... As it goes:
modify the transmission dipstick
Build a panhard bar and mount
set the caster
Weld everything in solid
yadda, yadda, yadda.......lots to do.

[awsumdc]

Well, I guess I should throw up some stuff on what I'm doing and see what you all think.

I have a '99 4Runner Limited with a factory locker that was just begging to have a SAS done on it. After breaking numerous axles, including the ORS axles and outboard joints, it was time.

I will be putting on 14" travel SAWs with sleeved links that may be up to 48" in length. The total thickness of the locating links will be 1/2", pretty beefy. The front axle is a Waggy D44 with Flat Top knuckles, Parts Mike Cross over steering links, Flaming River steering shaft, ARB carrier, Warns axles, Longfield joints and some 37" tires. The front axle setup will be very close to the Ultimate Tacoma setup, with the coils sitting on the forged knuckles. This will allow a longer pan-hard bar setup. The ABS will be completely removed, and Sky's rear disc brakes will go on back to help slow everything down.

So, here are a few pics of the progress, I'll post more as the project progresses.

All pictures, inlcuding larger pictures can be seen at this link:
http://www.hunt4steve.com/or/99_4runner_ltd/SAS.htm


http://www.hunt4steve.com/or/99_4runner_ltd/pics/SAS/P1010003_.JPG http://www.hunt4steve.com/or/99_4runner_ltd/pics/SAS/P1010027_.JPG


http://www.hunt4steve.com/or/99_4runner_ltd/pics/SAS/P1010041_.JPG http://www.hunt4steve.com/or/99_4runner_ltd/pics/SAS/P1010052_.JPG

Very clean job. Looks really good.

[Hunt4Steve]

Thanks,



By the end of this week, I should have the 37" MT/R tires mounted as well as the Axle permenantely in place.

[tacodab]

looks good :)

damn I remember the days of burning metal :) soooo nice!

[CUBuff 4Runner]

How's it coming? Did you get the new springs?

[Hunt4Steve]

New springs......well, lets see, the last event was that they shipped the wrong springs overnight. I shipped them back and talked to Wyatt about the problem, Dave (owner) was out to lunch. We both concluded that they were going to credit me 148 for the oversized 12" 300ppi coils, and they would swap out the 10" 100ppi and the 175ppi for the 10" 250ppi coils. As well, Wyatt thought they should refund the overnight shipping costs of 48 bucks to me as well. I expressed that I no longer needed the coils in a hurry, so the money would be great, but to run this little proposition by Dave. So, we shall see. I hope to hear something from them today or tomorrow. Wyatt seems to have the attitude that Poly Performance should make it right, but when speaking to Dave last week, I got the passive "oh well" attitude. So, in short, I'm still waiting on the correct springs.

[CUBuff 4Runner]

That sucks. I seemed to have the same issue but with other parts. I would get something in look at it and something would be missing or be the wrong part. :mad: Soon the fun part of fixing all the minor kinks comes. I ended up not having too many, my brake pad and rotor combo didn't work, I put on hawk pads with brembo rotors and for some reason they constantly squeeked, put some cheaper pads and no more squeeks. I also have my damn power steering leak which has caused my to not take it on too many runs because it blows ATF all over the engine bay. Other then that random squeeks that I have slowely been pinpointing. Good Luck..

[awsumdc]

New springs......well, lets see, the last event was that they shipped the wrong springs overnight. I shipped them back and talked to Wyatt about the problem, Dave (owner) was out to lunch. We both concluded that they were going to credit me 148 for the oversized 12" 300ppi coils, and they would swap out the 10" 100ppi and the 175ppi for the 10" 250ppi coils. As well, Wyatt thought they should refund the overnight shipping costs of 48 bucks to me as well. I expressed that I no longer needed the coils in a hurry, so the money would be great, but to run this little proposition by Dave. So, we shall see. I hope to hear something from them today or tomorrow. Wyatt seems to have the attitude that Poly Performance should make it right, but when speaking to Dave last week, I got the passive "oh well" attitude. So, in short, I'm still waiting on the correct springs.
Wow, There's someone else out there named Wyatt besides me. I don't feel so alone anymore. BTW, Truck looks great! :)

[Hunt4Steve]

So, I have been pretty busy lately on this thing, and here is a couple of pics for the update.

http://www.hunt4steve.com/images/misc/latest_.JPG (http://www.hunt4steve.com/images/misc/latest.JPG)

FROR Full Floater rear axle with Supra disc brakes, and almost ready to be squeezed out of the garage.....


http://www.hunt4steve.com/images/misc/interior_.JPG (http://www.hunt4steve.com/images/misc/interior.JPG)

lots of goodies in the cab, including a remote winch rocker switch, dual battery switch, electric brake line lock, in-dash Cobra CB (tweaked to 42W) with a dash mounted SWR meter, GPS, inclinometer, and XM ready.

[Tacominator]

Wow, looks good! I haven't been on here much lately, but I certainly like what you've done. Are you planning on making a 'strut brace' to take some lateral load out of the frame?

[Hunt4Steve]

Wow, looks good! I haven't been on here much lately, but I certainly like what you've done. Are you planning on making a 'strut brace' to take some lateral load out of the frame?

Thanks.

Yes, I already made the Strut Brace and put that on before I mounted the front coils. unfortunately, I just havn't had the time to post anything. I'll see if I can dig up some pics, and get em posted.

[AK98Taco]

What type of material are the links composed of? Length of upper and lower?

Are those Johnny Joints?

[Hunt4Steve]

The Lower links are composed of:
2" OD DOM .250 wall, sleeved with 1.5" OD DOM .250 wall. The axle side has bushings, and the crossmember side has Currie Johnny joints.

The upper link is compose of:
1.5" OD DOM .250 wall, bushing on frame side, and Johnny joint at crossmember side.

[AK98Taco]

The Lower links are composed of:
2" OD DOM .250 wall, sleeved with 1.5" OD DOM .250 wall. The axle side has bushings, and the crossmember side has Currie Johnny joints.

The upper link is compose of:
1.5" OD DOM .250 wall, bushing on frame side, and Johnny joint at crossmember side.

Thanks!

What are the lengths? They look a little short to me.

What size Johnny Joints? Source?

[Hunt4Steve]

Thanks!

What are the lengths? They look a little short to me.

What size Johnny Joints? Source?

Sorry I haven't gotton back to you sooner. I have been in Moab, in the Back Country for the last week.

Lengths, well, I would have to measure that. Actually, that is as long as I could make them, due to the location of the transfer case and the gas tank. I don't have a doubler, and don't really need one as I have an automatic.

the size of the Jhonny Joints???? They have a 9/16" Grade 8 bolt with a greaseable zerk fitting. They have a 1" threaded studd that goes into the links, so size....BIG. I got them from
http://www.redrock4x4.com/shop/

[Hunt4Steve]

Well, the Beast is driveable again. My dad came in last Friday night, and we continued to work on the 4Runner until Saturday night. We finally left for our Moab adventure Sunday morning.

On the drive out to Moab, the Beast drove great. No death wobble, even at 75mph, it tracked straight (so our ghetto alignment worked great), the 37 tires were smooth as glass, thanks to the Centramatic balancers, and most of all, it flexes great. In the following pictures, it shows a little bit of flex. I couldn't find a place to really flex it out to the limit straps.

Thanks to FROR for the Full Floater kit. This kit is great! We, again, overloaded the 4Runner for the springs, and pretty much road the beast the entire back country route on the bump stops.

The Dual battery setup worked great. FYI, when using a DC - AC convertor, be sure to charge your main battery. I have an optima deep cycle as my main battery, and then a Red top for the backup. I charged my laptop battery for a while with no engine juice, which brought the battery down low enough where it would not start the rig. No problem, flip the switch join the two batteries, and the engine fires right up. This saved our bacon once during this trip. We often like to kill the engine, and listen to XM radio as we are setting up camp or just hanging out. Having a second battery is, IMHO, a necessity when in the outback.

Lets see, what else......Well, what can I say. This thing flexes with ease, drives straight, has a great return to center coming out of a turn, its just plain awesome!


http://www.hunt4steve.com/or/99_4runner_ltd/pics/SAS/misc/flex/P1010078_.JPG (http://www.hunt4steve.com/or/99_4runner_ltd/pics/SAS/misc/flex/P1010078.JPG)
Sitting level on the ground. No bump steer on the road. I need a professional alignment, but it works for now.



http://www.hunt4steve.com/or/99_4runner_ltd/pics/SAS/misc/flex/P1010080_.JPG (http://www.hunt4steve.com/or/99_4runner_ltd/pics/SAS/misc/flex/P1010080.JPG)
stretching its legs




http://www.hunt4steve.com/or/99_4runner_ltd/pics/SAS/misc/flex/P1010081_.JPG (http://www.hunt4steve.com/or/99_4runner_ltd/pics/SAS/misc/flex/P1010081.JPG)
Here you can see the top tender coil at work, keeping tension on the coil pack



http://www.hunt4steve.com/or/99_4runner_ltd/pics/SAS/misc/flex/P1010089_.JPG (http://www.hunt4steve.com/or/99_4runner_ltd/pics/SAS/misc/flex/P1010089.jpg)
I found a stock 2000 4Runner Limited. This is the stock height of a 3rd gen 4Runner....where mine used to sit.


More pics at:
http://www.hunt4steve.com/miscpics.htm (http://www.hunt4steve.com/miscpics.htm)


Also, I wanted to send out a heartfelt thanks to the folks who came over and gave me a hand to get this thing done.

Jim Hughs, Jayson Blanchard, Terry Rust, Chris Steller, Rich Capener. I'll have some pic up soon of this deal. At one point, we had my entire parking lot full, and lots of guys peering into the engine bay, pretty cool deal.

All of these guys came up with some great ideas on how to do this and that, which ended up being the final result on some items. Its always great to get other peoples input when working on such a large project.

[AK98Taco]

Sorry I haven't gotton back to you sooner. I have been in Moab, in the Back Country for the last week.

Lengths, well, I would have to measure that. Actually, that is as long as I could make them, due to the location of the transfer case and the gas tank. I don't have a doubler, and don't really need one as I have an automatic.

the size of the Jhonny Joints???? They have a 9/16" Grade 8 bolt with a greaseable zerk fitting. They have a 1" threaded studd that goes into the links, so size....BIG. I got them from
http://www.redrock4x4.com/shop/

Don't apologize, you got back to me and that's all I care about.

I understand on the location of the t-case and gas tank. I've been looking at mine and figuring how long I can really make the links.

Thanks for the info and link!

[Hunt4Steve]

Here is a close up picture of the Currie Johnny jointhttp://www.hunt4steve.com/or/99_4runner_ltd/pics/SAS/misc/flex/P1010084_.JPG (http://www.hunt4steve.com/or/99_4runner_ltd/pics/SAS/misc/flex/P1010084.JPG)

[AK98Taco]

Thanks!

What diameter is it? 2.5-inch?

[AK98Taco]

I love it! Great work! That's the ideal front setup I'm shooting for.

[Hunt4Steve]

Thanks!

What diameter is it? 2.5-inch?

ummm, I think so. Again, I would have to measure it. Take a look at my website and let me know what measurements you would like me to get. I'll be going out of country Thursday afternoon. If I can't get the measurements for you by then, I'll be back November 2nd, and we can go from there.

[AK98Taco]

ummm, I think so. Again, I would have to measure it. Take a look at my website and let me know what measurements you would like me to get. I'll be going out of country Thursday afternoon. If I can't get the measurements for you by then, I'll be back November 2nd, and we can go from there.

That's okay. Don't worry about.

I'll figure it out.

Have a good, safe trip!

[Davidtaco]

Looks SWEEEEET.

Gonna run some trails arouns Socorro in the 12th... if your free it would be a great place for you to work out some bugs

-David

[Hunt4Steve]

Ah yes...the 11th is my day, Veteran's Day. I'll have to consider that. Give me some more details. Camping? Day trip? Let me know.

[Hunt4Steve]

A few more pics from the Tank Trap. Jim and I went there after work to get a bit of wheeling in before I went on vacation. Here are some pics, and more are on my website.

http://www.hunt4steve.com/or/99_4runner_ltd/pics/ActionShots/SAS_flex/SteveO%20SAS%20Tank%20Trap%20019_.jpg (http://www.hunt4steve.com/or/99_4runner_ltd/pics/ActionShots/SAS_flex/SteveO%20SAS%20Tank%20Trap%20019.jpg)
My favorite shot showing the strength of the SAS, and way-cool flex! http://www.yotatech.com/images/smilies/woowoo.gif


http://www.hunt4steve.com/or/99_4runner_ltd/pics/ActionShots/SAS_flex/SteveO%20SAS%20Tank%20Trap%20017_.jpg (http://www.hunt4steve.com/or/99_4runner_ltd/pics/ActionShots/SAS_flex/SteveO%20SAS%20Tank%20Trap%20017.jpg)


http://www.hunt4steve.com/or/99_4runner_ltd/pics/ActionShots/SAS_flex/SteveO%20SAS%20Tank%20Trap%20008_.jpg (http://www.hunt4steve.com/or/99_4runner_ltd/pics/ActionShots/SAS_flex/SteveO%20SAS%20Tank%20Trap%20008.jpg)


http://www.hunt4steve.com/or/99_4runner_ltd/pics/ActionShots/SAS_flex/SteveO%20SAS%20Tank%20Trap%20021_.jpg (http://www.hunt4steve.com/or/99_4runner_ltd/pics/ActionShots/SAS_flex/SteveO%20SAS%20Tank%20Trap%20021.jpg)

More can be seen at the below link:

http://www.hunt4steve.com/or/99_4runner_ltd/action.htm (http://www.hunt4steve.com/or/99_4runner_ltd/action.htm)

[AK98Taco]

That was a mean looking pit. After dark, you maniac!

[Tacominator]

Lookin very good Steve.

[Hunt4Steve]

Thanks guys. Indeed, it was crazy, but fun.

Since then, I have yanked the hubs and repacked the grease, as water crossings are not good, or rather deep water crossings are not good.

Anyhow, its been really awesome. This weekend I'm heading out again for some hardcore stuff, hopefully I can get some good pictures, and maybe some video too.

[Davidtaco]

Thanks guys. Indeed, it was crazy, but fun.

Since then, I have yanked the hubs and repacked the grease, as water crossings are not good, or rather deep water crossings are not good.

Anyhow, its been really awesome. This weekend I'm heading out again for some hardcore stuff, hopefully I can get some good pictures, and maybe some video too.

HEHE... I'll PM you directions to either my house or the meeting place... Some people are staying over night, but i am coming home saturday evening... Meet at 9am in socorro and i'm leaving my house about 7:30ish....

-David

[Captkirkyota]

My favorite shot showing the strength of the SAS, and way-cool flex! http://www.yotatech.com/images/smilies/woowoo.gif


http://www.hunt4steve.com/or/99_4runner_ltd/pics/ActionShots/SAS_flex/SteveO%20SAS%20Tank%20Trap%20017_.jpg (http://www.hunt4steve.com/or/99_4runner_ltd/pics/ActionShots/SAS_flex/SteveO%20SAS%20Tank%20Trap%20017.jpg)

That is some SIC flex! Nice looking rig man.

[Hunt4Steve]

Thanks. The cool thing was, it wasn't even maxed out. I think I had another couple of inches in this shot.

[99FlowedTaco]

damn what a beast !

[Hunt4Steve]

Folks, I finally got around to posting some info about my SAS, finally.

http://www.hunt4steve.com/99RunSas.html

check it out and let me know what you think.

http://www.hunt4steve.com/OR/4RunnerLtd/action/SAS_flex/flexing.JPG

[AK98Taco]

Folks, I finally got around to posting some info about my SAS, finally.

http://www.hunt4steve.com/99RunSas.html

check it out and let me know what you think.

Nicely done!

I like this line: "A 4Runner Limited is considered the crem-d-la-crème of the 4Runner fleet, and is usually not considered the ideal vehicle for rock crawling." :D

Ran you $4,000, eh? That's pretty damn good.

[Hunt4Steve]

Thanks,

Somewhere around 4k. I got a lot of parts used, and the critical parts (steering linkage). I got two 14" SAWs with double rate spacers off the pirate board for 500 bucks. Deals like this saved me a considerable amount of money.

[AK98Taco]

Thanks,

Somewhere around 4k. I got a lot of parts used, and the critical parts (steering linkage). I got two 14" SAWs with double rate spacers off the pirate board for 500 bucks. Deals like this saved me a considerable amount of money.

Good information!

[Captkirkyota]

Thanks,

Somewhere around 4k. I got a lot of parts used, and the critical parts (steering linkage). I got two 14" SAWs with double rate spacers off the pirate board for 500 bucks. Deals like this saved me a considerable amount of money.
Oh, that explains it then, I was like, dude, better do a better receipt tally, cuz there is no way, but with used , then ok. :)

[Hunt4Steve]

Yeah, lots and lots of parts were used. Its one of those things like: I purchased the axle for $250, then sold some IFS parts for 1k, then purchased other parts, and sold other parts. So, yeah....I still need to do a receipt tally, but 4k is where I think it all washed out to.