Builds 86 Xtra Cab Build (4Wheelunderground 3 link front, 4 link rear and 3.4 swap) (1 Viewer)

[aztoyman]

I have another set of bolts on the way. Coming from Phoenix so might be tomorrow.

I didn't get out in the garage until about 2:30. I got the passenger side brake hose and line routing figured out.

There's a bracket for a limit strap in the perfect spot for the union bulkhead fitting. It's a 1/2" hole and the fitting is 3/8" so I used a 1/4 NPT brass fitting as a bushing. Knocked it in the hole, cut off the excess and drilled it out to 3/8".

 

[aztoyman]

It's tight. Here's full stuff.

 

[aztoyman]

Here's what I was talking about with the upper link being WAY too close to the slave cylinder. I can cut the outer tube back and have a longer section of the 1.5" inner sleeve at the end.

I can shim out the bump stop if I have to.

 

[aztoyman]

Look how close to the oil pan it gets with the panhard bar and upper link bracket.

 

[gnob]

id probably bump it and call it a day.

 

[aztoyman]

Hard to tell in the pic. It's hard against the bump and there's a 1/4" of space from the oil pan.

I think I'm in break it off territory with the slave though.

If you're saying to shim out the bump on this side, you're probably right.

 

[aztoyman]

I got the driver side brake line made and installed. I wanted both brake hoses to be identical and this is where it ends up. Clears everything including the hydro assist hoses.

I found a really thick washer with a 3/8 hole in my stash and shaped it to use as a bracket for the bulkhead fitting.

 

[aztoyman]

More pics

 

[aztoyman]

Max stuff and full turn. UPS tracking shows my bolts are out for delivery. Hopefully I can get this assembled today.

 

[aztoyman]

My bolts made it. Started assembling my outer axle parts. Hopefully FINAL assembly instead of test fitting and mockup. I still have to see if I can run a thin steel wheel spacer to clear the calipers or if I'll be grinding the other caliper. I already ground on one of them a while back.

I need to bend up a couple more limit strap brackets for the lower links and pull the links to put them on. And I need to trim the upper to clear the slave cylinder.

 

[aztoyman]

Today I cut my steel pieces for my limit strap clamps and didn't feel like cleaning the mill scale off so I soaked it in phosphoric acid for tomorrow and worked on getting some more clearance for my slave cylinder.

First I pulled the upper link, cut the tack weld holding the 1 1/2" sleeve in. Cutting back the 1 3/4" outer tube got me a little more clearance from the slave. The inner 1 1/2" tube is 1/4" wall so I don't think I'm sacrificing too much strength. I still have at least 3" of overlap into the other tube.

It's still too close for comfort so I made a spacer to put on top of the bump stop. I found a piece of Delrin in the chip tray of my lathe. It was almost a bolt in as is. I just had to drill a second hole and trim it to the needed thickness. It started at 1/2". I ended up just needing it at 1/8" . I'm good with this clearance now.

 

[88repo]

Just throwing out an idea here but if there's enough meat in the lug(s), you could add some counterbores for SHCS's.

The heads on metrics are a little bigger than their US equivalent, so you could actually turn them down a smidge to keep mass in the lugs.

And that's if the lugs are tall enough to begin with.

 

[aztoyman]

What's a shcs?

 

[ntsqd]

Socket Head Cap Screw. Viable idea. I wouldn't do it on my own truck because I want box-stock replacement parts to fit and work as-is, but if that isn't a priority it's a possibility.

 

[aztoyman]

I'm guessing that you're talking about counterboring the bolt holes on the slave cylinder? That is a good idea and I could do it if I had to.

I managed to get the clearance I need with the combination of the socket head screws I have on it now, cutting back the outer tube of the upper link and the 1/8" spacer on the bump stop. I don't drive like a desert racer but I have to be prepared for any bottom out possibility. Getting off the trail with out a functioning clutch is doable but it would suck.

I'd rather not modify the slave itself if I don't have to in case I need to change it. I actually have a new Aisin clutch slave and master on the way. The ones on now were on my 88 when I bought it back in 2006.

 

[88repo]

^^ Yes.

I agree about not wanting to mod off the shelf parts. All depends on the need, I guess.
While it is possible to keep a c'bored spare packed away with you, what just hit me was the question what is the casting going to be like on the next one you buy?
Are they going to take another millimeter or two off the perimeter of the lugs, to the point where strength now becomes an issue after c'boring them?

...your button heads are looking pretty good right now.

 

[ntsqd]

FWIW I've also thinned the heads of hex head bolts on a lathe to gain clearance. Can cut them to about the same overall height of a button head.

 

[aztoyman]

Today I cleaned and painted the caliper bracket for the passenger side. Painted the spindle as well so I can assemble tomorrow. Torqued bolts, put in cotter pins, cut the long suspension bolts to size. Basically getting stuff done that still needs to be done. I fabricated the brackets for the front limit straps and got them painted.

Can't post without pics so here's the brackets getting made.

 

[aztoyman]

And the rest.

 

[gnob]

nice work. dig your "press break"