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Discussion Starter · #21 ·
Made a few alterations to the 4-link bracket design. The leading edge under the frame is now straight instead of curved. That will make for less welding and a longer straight edge to bend.

That means I need to do another round of mock up so these pieces were cut out of 12 gauge. Hopefully going to put in work tonight with mocking up these & panhard brackets.

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Discussion Starter · #22 ·
The 4-Link brackets will need two small changes. Figured this out pretty quickly so I moved on to other things. Measured the brake hoses, need something 4" longer than stock. Removed the coil springs so I can test the rates of them and the Skyjackers tomorrow at work.

I've had some ideas for the panhard brackets so I went to town on the axle side tonight. There's not a whole lot of room to go wider and keep the anti-sway bar. I will be able to raise it 2" and move it over 6". Anything more than that and it will run into the frame at full droop.

I just bit the bullet and cut the stock bracket off so I could start mocking up some cardboard.
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Discussion Starter · #23 ·
The stock spring rate is roughly 160 lbs.

Stock spring compressed 1" = 162 lbs
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Stock spring compressed 2" = 320 lbs
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Stock spring compressed 3" = 476 lbs
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The Skyjacker springs are roughly 240 lbs.


Skyjacker spring compressed 1" = 238 lbs
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Skyjacker spring compressed 2" = 477 lbs
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Skyjacker spring compressed 3" = 718 lbs
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I forgot to measure the spring lengths when installed. The new springs are 65% stiffer so a little more than what skyjacker had said but no worries. The new springs show the same rate compressed 2" as the stock ones were at 3". I am sure these will settle a little over time. I just don't want the truck to sit too high. Trying to keep it around 2" over stock in the rear. That should put the rear suspension right in the middle of travel.
 
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Discussion Starter · #24 ·
My work doesn't have bungs big enough for the 1.5" O/D Chro-Moly so I grabbed some bar and made my own.



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I put too much heat drilling the one on the left

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I'm sure the CNC lathe would have made quick work of these but when you only need two it's quicker to just run them manually.

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Discussion Starter · #25 ·
I have been busy all week but I don't feel like I've made any progress. Lots of cardboard cutting and mock up. I am working on six different brackets but none of which are completed. I should probably just concentrate on one but that wouldn't be any fun.

I have gone back and forth with completely redesigning the frame bracket for the panhard. I finally decided on the easy option. A 2x3 rectangle tube slides right into the factory mount with some persuasion. This will provide many weld and reinforcement points.

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Seeing this build makes me miss fab work so much. Awesome job man!
 

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Discussion Starter · #28 ·
One step forward, two steps back. The new anti-sway bar end link on the passenger side hits the new panhard bracket at full droop. It's an easy fix, just need to move the adjuster nut down 2". The other issue I am having is at full compression the new panhard bracket on the axle side is hitting the frame. This will also be an easy fix by moving the bracket towards the middle of the truck .5".

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Sub'd...I haven't wrenched in awhile and this build makes me get the itch


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Discussion Starter · #30 ·
I am now on the 3rd iteration of the panhard bracket for the axle. This latest revision captures the axle on a greater scale adding strength. I also lowered it .25" and moved it over .5".

I hadn't planned on doing the free travel mod so these pictures are with the stock bump stop fully compressed. The axle is centered in this picture which won't be the case once the bar is installed. The bar will pull the bracket to the center roughly 3/8" which will gain some space between it and the frame.

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Discussion Starter · #32 ·
I was in such a hurry to get home and install the new bracket that I forgot my welding helmet. I have tomorrow off so I'll be borrowing one to get the truck back on the road. Work is 40 miles away.

Here is the finalized bracket cut out of .188w ChroMoly.
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I also made a bracket to connect the top and bottom(not shown) of the bracket together. SO the bottom will have to be welded on first in order to get to all the weld areas.

I cleaned off all the weld areas.

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Juts one last round of mock up to confirm fitment before final welding.

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Discussion Starter · #33 ·
I was a little rusty using my own welder. It took a little practice but it came back quick once I cleaned the tip out so the wire could feed properly.

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I guess I'll call this Phase 2..........Brake hoses are from my work. Just need two banjo adapters to -3. I debated between regular reservoirs with air bumps for the rear. Decided to go with bypasses without air bumps. It ended up being the cheaper option. These have 12" travel and will require custom upper mounts. The limit straps will be used on the front. The 10" coilovers that are currently on the back will be moved to the front.

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The front is going to be so dang wide that without rear spacers it would just look funny.

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Discussion Starter · #34 · (Edited)
Spent a little time this weekend on the truck. I've been working on designing the new upper shock mounts. No matter what design I end up with the stock exhaust & hanger are going to be in the way. So I did some measuring and figured out a good place to cut it and do a simple rework.

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This hanger needs to removed to clear the new upper shock mount.

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I cut the stock tip off and reused a short bend radius. Then just added roughly 15" of straight pipe. The outlet sits right underneath the stock bumper(with hitch removed) This will be a temporary fix until I make the new rear bumper.
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I didn't have much else to do with the rear suspension this weekend. Not wanting to waste valuable time I moved to the front. I removed the bumper cover for easier access to the inner fender. Inner and outer fender were removed as one assembly.

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I started drilling out all the spot welds.

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There was one area that still required some cutting near the door jam. Then the two halves could be split.

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I didn't take any pics during the fiberglass modification portion of the install. There was a bunch of trimming at the top/front to clear headlights. The passenger side fit much better than the driver side. Plus the gaps on the driver side are terrible at the door jam. I will have to fill in the gaps later. Luckily the wife doesn't care what it looks like right now. She sees the bigger picture.

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Discussion Starter · #35 ·
Here's a couple pics of the exhaust mod. I had planned on this being a temporary fix until the rear bumper is made but it's tucked up high enough that I might be able to leave it.

I still need to make e-brake cable clamps. Zip ties are there temporarily, hopefully.

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I cut the stock hangar off and reused it further back.

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A little set back on the upper shock mounts. I have been working on these off and on for the last week. The further along they went the more I didn't like them. There's not a lot of space in the area where they will be mounted and I just didn't think this design was going to be strong enough. So, I am going to scrap them and start fresh with a completely different design.

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Discussion Starter · #37 ·
So the company I work for recently did some suspension work for a SEMA project for Toyo. I used that connection to get some new kicks. I'm still trying to work on American Racing Wheels which we also have a hook up on. I like the wheels currently on the truck but I need a set with less backspace.

305/70/17 Open Country A/T's

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A little teaser of what's to come for the front. We use Chromoly material to build spindle pins for our front ends. I'll be using this material for some custom uniball mounts.

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Wheels are the only thing I don't like about this build.

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Which vehicle were you guys working on for Toyo? Just curious.
 

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Discussion Starter · #40 ·
Wheels are the only thing I don't like about this build.
HAHA! I am 100% certain that the wife and I will not see eye to eye on wheel choice. When we bought these wheels I kept telling her that dark wheels will not look right on her dark truck. She fought me tooth and nail and eventually caved. After they were installed she instantly realized that she liked the machined look. We will likely stick with that theme on the next go round. I'd like to change the color of the beadlock though, if we end up with beadlocks. American Racing also owns KMC & ATX Wheels so I am looking at the....

XD222
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& AX757
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Which vehicle were you guys working on for Toyo? Just curious.
It was built by Demented Customs using our chassis/suspension.

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