Chevy 63" and FZJ80 FF Swamp

[Randy88FJ62]

It starts today. After going to the junk yard over a year ago and pulling springs then buying an axle off a club member I am ready to pull / cut the rear out today. I bought the ruffstuff chevy swap kit to use with the spings.

A friend in my club works at a tow company and days before this lift he mentions he has spare leaves from a 2004 Chevy 3500HD. He then offers me the extra overload spring, spring pack clamps, and spring long leaves.

Trying to see how I'll assemble the pack so it may be interesting. The springs he gave me do not look like the ones I have off an older vehicle. So either the design changed over the years or the initial springs I bought aren't 1 ton. Internet shows these as the 2004 chevy springs which don't match the old ones I have:
http://www.sdtrucksprings.com/bmz_cache/0/0f63c91043e581e6d98344fbcb9cc354.image.750x249.jpg

Pics of the springs and the back of my truck. Heading to my friends shop after work.

 

[Output Shaft]

Now THAT is ambitious

 

[Spook50]

Gonna follow this thread. These are two things I want to do with my 62.

 

[Randy88FJ62]

Tore down front and rear springs since I was using some of the chevy leafs up front as AAL springs. Front packs back together.

FZJ80 axle cleaned and ready for perches.

The hard work begins tomorrow. This work cant happen without an off-road club that brings this many friends together.

 

[Randy88FJ62]

 

[cruisermatt]

80 rear axle is one of my favorite 60 series mods. Lots of grinding required.

 

[cruisermatt]

And if you haven't already, I'd delete the factory LSPV and plumb in a manual proportioning valve in the rear circuit. And I'd look into the 92-94 FZJ80 non-ABS Disc/disc master cylinder. There's a whole thread in the 80 section with all the different BMC part numbers.

 

[LAMBCRUSHER]

mine is just fine with a 4runner booster/master/prop valve.... That is on my fj55. I want to do the same to the 62 some day...you're going SOA?

 

[Randy88FJ62]

13 hrs in today with 2 helpers half the day and two of us going at it for the full day.

Perches and leaf spring mounts welded. Axle assembled (not fully rebuilt). Rear custom packs assembled.

Tomorrow is shocks and rear assembly. Custom brake lines will be done Monday by a a local shop. Too lazy to run em myself this week.

 

[Randy88FJ62]

Pardon all the bad shots. More work than photographer.

 

[Randy88FJ62]

Some thoughts while they are fresh.

I'm running a T100 master cylinder so the rear disk brakes should be fine for my brake system.

The rear FZJ80 axle brake lines are too long for a spring perch setup. Their rear brake line termination is in the center where my 62 was passenger side. Custom hard brake lines seem like the best bet.

My friend had spare chevy leafs so I made a custom pack that is probably too stiff. I'll see how it does and then adjust accordingly when I tear down rear axle to rebuild bearings and brakesanother time.

My front axle was cut and turned years ago when I went SOA by proffits cruisers. They put square stock and a stud as the shock mount. This allows the shocks to articulate well and I'll be copying it for my rear brake mounts. I'll use the stock top shock mounts.

 

[MANUCHAO]

Looking good eh...!!

An 80's FF axle with its wider stance, e, and disk brakes...is a great upgrade...
Will you be beefing up the axle studs later on?

Rear Axle Hub Stud and Dowel Pin Upgrade

Full Floater Hub Stud Upgrade write up

 

[cruisermatt]

I have a T100 master right now without a proportioning valve and the rears lock up. I'm installing a Wilwood manual proportioning valve in the rear circuit next weekend.

This is what my rear brakeline on the axle looks like, I put the 60 junction on the 80 housing (don't remember if there was a hole there already or not but I definitely remember tapping it) and plugged the 80 breather hole which is on the other side of the housing. I also made a couple tabs with captive nuts to mount the 60 hardline "P-clips"

 

[Randy88FJ62]

Finished in 27 hours total over three days with lots of help from friends.

The rear shackle angle looks good but the main spring doesn't look good. Maybe a different main leaf or an aftermarket military wrap leaf?

 

[boots4]

If I'm seeing it right your rear shackle angle doesn't look good to me. I think that angle is putting too much stress on your rear main leaf. If it was "\" instead of "/" that should help (in reference to the pic above in previous post). I think you need to move your rear shackle frame mount forward a couple inches so that that you've got closer to a 45-60* angle at ride height. I imagine your rear ride is really stiff and not really working the pack as a unit.

 

[Randy88FJ62]

Balls.

 

[cruisermatt]

Yeah dude, I've never seen a shackle angled towards the leaf spring like that.

 

[Randy88FJ62]

Back to the drawing board.

 

[Spook50]

At least it's a quick fix.

 

[Dynosoar]

Front shackle angle looks good