Another update, not quite driving but nearly there!
After the last update, the main remaining task was the front suspension. I ended up ordering some coilovers from Viking which didn't show up until a couple days ago.
I still had to address the passenger side being bent, and it turned out the LCA I ordered on
eBay actually had been sold already. I tried to track down another one, but in the mean time did MORE MEASURING and pulled the driver's side off to bolt back to back with the passenger side to confirm the LCA was bent.... and it wasn't! At least not a meaningful amount. After MORE MEASURING what I concluded was that the UCA seemed to be in the correct location, but the LCA certainly was not, and the bump stop was not in the correct spot either. What I think happened is that the entire subframe kind of rotated around the axis of the hub, with the UCA staying in the right spot and the LCA getting shoved backwards. I also think the frame deformed since using the front tow point location seems extremely inconsistent between the two sides.
With all of that in mind, what I decided to do was to cut up the LCA mount and make it adjustable so the LCA could be moved back to the correct position relative to the body mount at the rear of the wheel well. The body mount there seemed far enough back that it was the same between both sides and would serve as good reference geometry. I then took the huge bolt/pivot for the LCA and chopped it up and welded some brackets to it with slotted holes so I could rotate the LCA, move it front to back, and to some extent in and out so caster and camber could all be adjusted. I don't have any before pictures, but this is how the passenger side is now:
Not sure if this will be strong enough and I'll need to run a brace between the two sides, but I think it should be fine. As for maintaining alignment, I may end up tack welding the plates to the subframe once I get it on an alignment rack. I used a tape measure to the body mount and a level gauge on the spindle to approximately set the LCA to the same position as the driver's side (hard to see much in this photo since everything is the same s*** color).
That photo was from the final mockup and torquing. After making the LCA mounts, I mocked up the coilovers which seemed to fit beautifully! The first thing to change was the new coil springs were too small for the coil buckets, but too big for the spring perch to properly seat at the end of the coilover. The coil bucket is tapered, so you can't fit the coilover in as a fully assembled unit, and instead the coil spring has to sit in a feature inside the bucket but that feature is meant for a much larger spring if that makes sense. This was easy to fix though, I took the spring seat for the coilover and machined a lip around the outside, which then aligns with the stock coil spring seat:
This works out very nice, the bottom of the coil spring still sits on the coilover, but the top of the coil spring sits against the stock coil bucket and the end of the shock eyelet goes through the stock eyelet hole. It ends up being a bit of a hybrid between a stand alone coilover and a coil and shock factory setup.
The lower coilover mount took a bit of thinking, but I ended up with a very elegant design. The bottom mount sat just below the LCA, and if you could run a rod through the eyelet and drill two holes where the factory retaining bolts are, you would be done! But the factory retaining bolts are nearly the same size as the 1/2" rod for the coilover, so that doesn't really work. What I ended up doing was using a small 1/2" rod, and then a bracket that wraps around it and holds it up tight against the LCA and retains it from sliding out either side.
This is a beautiful solution that is really simple and and really easy to assemble. The coilover ends up being the absolute perfect length where it tops out the same time the factory droop stop engages, and has plenty of up travel so the factory bump stop works.
Not a lot of work, and this is a 100% bolt in solution for the truck. It's now on coilovers with spring adjustment as well as compression and rebound adjustment, and uses the factory bump and droop stops!
With all of that said, two current issues to solve. The springs are WAY too soft, I think I multiplied instead of divided somewhere
I ordered new springs today, the 250 springs up front are getting swapped for 750s. And then the suspension seems to be bottoming out on something besides the bump stop.
I think the coilover body is hitting the upper spring perch. I did open up the center bore on the spring perch in anticipation of that---to be clear, what I think is happening is since the upper spring perch is essentially "floating" around the shock shaft (since it's located on the stock frame spring perch) as the suspension cycles the shock shifts over but the spring perch doesn't move with it like a normal coilover, so the shock body ends up hitting the spring perch and that's what's bottoming out I think. This should also be easy to solve, I just machine out the center bore of the upper spring perch more. As I said, I DID do that, but just an arbitrary amount thinking it didn't really need to happen. I have a LOT more material I can remove, something like opening the inner bore to here:
It does work out that I had such soft springs in, since I would not have found this bottom out issue without driving and bottoming the suspension dynamically. I had considered buying super soft springs (like tender springs) just so I could cycle the suspension with the upper perch and make sure it clears (can't really cycle it by hand since you have to hold the upper perch up inside the coil bucket). Sucks I bought the wrong springs, but works out it helped reveal another issue.
Another thing I did was I threw some big gussets on the front crossmember since it was cracking off of the subframe. I have a rear gusset that goes vertically up towards the engine mount, and a forward gusset that ties in along the length of the subframe. Some pretty nasty welds (somehow this picture makes them look worse than I thought hahaha) since everything was gross and I could barely reach any tools in to clean it, but I got good enough welds up in there for the time being. Both sides are gusseted and I think this will make a huge difference for the front end.
Other minor things I've done, the rear relays have been replaced since they had been destroyed. I added limit straps that just mount janky style to the shock bolts. Rear axle has gear oil in it. I ran AN3 brake lines from the master to the rear (will do that up front eventually too). At this point the rear end is completely done and just waiting on the driveshaft.
I should have the new front springs by the end of the week. Fingers crossed I get the driveshaft this week too! Then she's ready to drive I think. And since it's been awhile and I don't think a full engine bay photo of how it's currently configured was ever posted, here is the good ole 2JZ
I didn't expect to go from the engine build phase to the suspension phase so quickly, but there are a LOT of upgrades over the past couple months and the truck should be in a very good spot now. Hopefully it will be back to the point of being reliable and fun like it was a year ago!