Back from cruise and starting my new project.

[tbd85hilux]

Sorry I haven't been around a whole lot. Been busy on the Nassau and spent a week working on my junk. Got allot of parts in while I was out with more to come. Right now I'm in the process of working the front end before I move to the rear (still waiting for the disk brake conversion to come in). The plans are to run 35's with 5" of lift and drop the body lift down to about 1". here's what I got done so far.


http://i102.photobucket.com/albums/m93/tbd85hilux/Suspension%20build/DSC00565.jpg
Last shot on 33's

http://i102.photobucket.com/albums/m93/tbd85hilux/Suspension%20build/DSC00567.jpg
Front axle pulled

http://i102.photobucket.com/albums/m93/tbd85hilux/Suspension%20build/DSC00569.jpg
Before cleaning the frame of unneccassary bracketrey

http://i102.photobucket.com/albums/m93/tbd85hilux/Suspension%20build/DSC00570.jpg
Look what I found... The reason my steering was binding at the end of my last trail run!

http://i102.photobucket.com/albums/m93/tbd85hilux/Suspension%20build/DSC00571.jpg
Look familiar?

http://i102.photobucket.com/albums/m93/tbd85hilux/Suspension%20build/DSC00572.jpg
Stripped housing

http://i102.photobucket.com/albums/m93/tbd85hilux/Suspension%20build/DSC00573.jpg
Stripped and cleaned of brackets.

I've since completed the addition of the gusset kit, the knuckle gussets and new shock mounts, as well as the repair of the differential skid that I had. The new (for me) steering box is mounted and needs to have the final fit and welds burned in. Once this is done I should be ready to hang the axle and get the new shock towers tacked in and finalize everything and start rebuilding the axle. Still to go is new drive shafts, brake lines, axle shafts (d44 cromoly conversion), gears (5.29's), and brake upgrades. I'll be running trxus MT's on black steelies with Staun internal beadlocks when all is said and done. I'll keep everyone posted with new pics when I get them updated.

Paul G.

[88rnr86up]

so how far have you gotten on it
any update pics for us

[tbd85hilux]

I haven't got much accomplished but heres a few more pics and the scoop.

http://i102.photobucket.com/albums/m93/tbd85hilux/Suspension%20build/DSC00582.jpg
Setting up the new 5.29 ring gear
http://i102.photobucket.com/albums/m93/tbd85hilux/Suspension%20build/DSC00583.jpg
The pinion set.
http://i102.photobucket.com/albums/m93/tbd85hilux/Suspension%20build/DSC00584.jpg
And here's pretty close to what it should look like when completed... BUT...
I've actually run into several issues and she's probably going to be down for another month. The first 2 issues were the most severe. My original front axle has a bent passenger knuckle that is preventing the D44 shaft from entering the housing. This also explains why the truck was pulling hard to passenger when braking. So I did an emergency tear down on my 83 axle I had for a spare in the shed and found out that my driver's side knuckle is bent on that axle. Right now I'm waiting on my new axle housing to come in from Diamond axles. It's about a month build/ship time to get it in. They are going to recess the passenger side spring perch into the housing, add the knuckle gussetts and clock the hawg's head 6 degrees up to compensate for the lift and dual cases. I rehung the 83 axle just so I could get it turned around and start working on the rear. I got 1 forward spring perch welded in with the leaf spring hung, the 87 axle cleaned and painted and both axle shafts setup with new bearings and seals as well as the back plates removed for the rear disk brake conversion. Then 2 weeks ago I went in for my PRK eye surgery. That took me out for the week of the 8th thru the 12th. I decided not to push my self and take an extra 2 weeks beyond that to make sure my eyes are healed and let my vision stabilize a little better. Well on tuesday the 16th I had a minor set back. While at work we were moving an aircraft out of the hanger to spot it for launch and when I went to put my safety goggles on they snapped back and gave me a corneal abbrasion. When this happend it also took that weeks worth of healing and rippled the entire cornea. :eek::mad: So they had to scrape off the damage and I ended up down for another week. I'm hoping that my luck will change here soon and I'll get back to it but I feel my health is a little more important. But don't worry more is coming.

Paul G.

[locknload]

I would of or if you still can, shave those axle housings and get rid of those drain plugs. I wish I would of done that when I built my front. Now it's going to be alot of extra work.

[tbd85hilux]

As often as I change my diff fluid I'll just let the rocks do it for me... they've done a pretty good job so far.

Paul G.

[tbd85hilux]

Well I've finally got a couple hours to work on her. Here's the rear suspension.

http://i102.photobucket.com/albums/m93/tbd85hilux/Suspension%20build/DSC00016.jpg
I didn't like the mounts that came with the kit so I made my own. Here's how I held them apart to set the width of the shock as I welded the back brace on.

http://i102.photobucket.com/albums/m93/tbd85hilux/Suspension%20build/DSC00017.jpg
The pieces that I cut to form the sides

http://i102.photobucket.com/albums/m93/tbd85hilux/Suspension%20build/DSC00020.jpg
The middle set are the ones I made. The outside set are the ones that came with the kit. I'll reuse those on the front axle when it comes in.

http://i102.photobucket.com/albums/m93/tbd85hilux/Suspension%20build/DSC00021.jpg
The upper shock mount that got welded into the frame above the axle.

http://i102.photobucket.com/albums/m93/tbd85hilux/Suspension%20build/DSC00023.jpg
The final setup.

Hopefully tomorrow I can start cutting some square tubing that I have to make a new mid frame brace so that I can cut the horse collar out of the frame and start setting up the new gears. I'll keep you posted.

Paul G.

P.S.
Hey moderator could you move this thread to builds? I think I originally placed it in the wrong section.

[tbd85hilux]

Well I got a little more done today. Didn't get the gears setup but I did get my new cross member built and installed. I also got my transfer case e-brake installed. Tomorrow I'll set up the gears and try to get most of the rear axle put back together.


http://i102.photobucket.com/albums/m93/tbd85hilux/Suspension%20build/DSC00024.jpg
took some 2x2 square stock I had lying around and the chop saw to make the cross member. Here's laying it out ready for welding.

http://i102.photobucket.com/albums/m93/tbd85hilux/Suspension%20build/DSC00025.jpg
Welded up!

http://i102.photobucket.com/albums/m93/tbd85hilux/Suspension%20build/DSC00026.jpg
Cleaned ready to install

http://i102.photobucket.com/albums/m93/tbd85hilux/Suspension%20build/DSC00027.jpg
There's how it sits. I'll go back when I redo the bed and add some additional support to it to go all the way to the top of the frame. But that will do for now.

http://i102.photobucket.com/albums/m93/tbd85hilux/Suspension%20build/DSC00028.jpg
The Transfer case Disk for the E-brake

http://i102.photobucket.com/albums/m93/tbd85hilux/Suspension%20build/DSC00029.jpg
The e-brake installed. I need to get a new cable cause mine is worn and binding but otherwise it should hold me on a 45 deg slope.

Paul G.

[BeaterToyota]

P.S.
Hey moderator could you move this thread to builds? I think I originally placed it in the wrong section.

Done.

[tbd85hilux]

I finally got Ol' Red out of the garage last night. I still need to get a new proportioning valve for the rear to adjust the disk brakes and I need to drop the body lift so that I can fit it in and out of my garage without running the tires flat. I'm still waiting for the front axle housing to come in from diamond axle so I'll start working the body lift today. Here's the pics I've clicked since the last time You saw it.

http://i102.photobucket.com/albums/m93/tbd85hilux/Suspension%20build/DSC00032.jpg
The rear gears set up.

http://i102.photobucket.com/albums/m93/tbd85hilux/Suspension%20build/DSC00033.jpg
My makeshift RTI ramp.

http://i102.photobucket.com/albums/m93/tbd85hilux/Suspension%20build/DSC00034.jpg
a second shot of the truck flexing.

I'll also be making some new rock rails as soon as the body lift is off and doing some further undercarriage changes.

Paul G.

[tbd85hilux]

Just got back off vacation friday so I started work again. Here's a couple shots of the new axle vs. the old axle.

http://i102.photobucket.com/albums/m93/tbd85hilux/Suspension%20build/DSC00035.jpg
http://i102.photobucket.com/albums/m93/tbd85hilux/Suspension%20build/DSC00036.jpg

I've had to get creative with the mounting of the u-bolts. The passenger side inside perch is integrated into the housing so I'm having to make some bracketry to mount the spring plate. I also have to finalize the shock mounts too. Hopefully later today I'll have the final welds burned for the spring plate mount. (gotta get a couple grade 8 bolts) and then it will be just a matter of bolting everything back together. I'll keep posting as I make progress.

Paul G.

[tbd85hilux]

At the end of last weekend I finished up the Yota project and it just so happend that this weekend there was some wheeling at Crozet. Well over all it was an interesting trip. My buddy Jon had issues on the way up with his Dodge not being able to go over 2k rpms then I ended up shooting a brake master cylinder out around 200yds up the trail which killed my weekend. After 5 stores I finally found a replacement but we still couldn't get the brakes back. I'll start trouble shooting it again after I get the garage cleaned up. Also while I was running for parts I found out that I have a caliper sticking on the Dodge that I'm going to need to replace. And finally Jons friend Tony bent his Tierod twice... bad enough for the tires to both hit the front bump stops pointing twords each other. Over all it was an interesting and fun trip. I wish I could have got more wheeling in but that's the way it goes sometimes. Here's a few pictures. I'll post up some more once I get them.

Paul G.


http://i102.photobucket.com/albums/m93/tbd85hilux/Crozet%2013DEC08/DSC00598.jpg
http://i102.photobucket.com/albums/m93/tbd85hilux/Crozet%2013DEC08/DSC00596.jpg
http://i102.photobucket.com/albums/m93/tbd85hilux/Crozet%2013DEC08/DSC00593.jpg
http://i102.photobucket.com/albums/m93/tbd85hilux/Crozet%2013DEC08/DSC00592.jpg
http://i102.photobucket.com/albums/m93/tbd85hilux/Crozet%2013DEC08/DSC00590.jpg