duggy's build thread: 1998 Land Cruiser #SAS100 (2 Viewers)

[duggy]

Axle housings are off to powder coating today. I should expect them back by Thursday/Friday nice and shiny. The plan is to get them nice and shiny, primed to protect from surface rust and then start modding brackets. I already purchased the following:

• Front axle rebuild kit with Koyo bearings
• Rear axle rebuild kit with Koyo bearings
• Hawk HPS front pads (100 series)
• Toyota OEM rear pads
• OPOR wheel spacers
• Trail Gear knuckle gussets with shock mount
• Front diff cover
• ABS Tone rings
• Nitro 4.88 gears

After everything gets back is when the fun starts. I've been trying my best to document the journey.

 

[duggy]

Got the axles back from sand blasting today. They look mighty fine!

Before and after

 

[pkelly72]

I wish I had the knowledge, skills and abilities to do this.

 

[duggy]

@pkelly72 knowledge, skill and ability can always be acquired. The will to dive in and do it is probably the hardest part. I'll get off my high chair now, but after seeing @40Habits SAS, I'm inspired and am actually having tons of fun doing it.

I am doing the SAS in the pursuit of reliability of the front end, but in the end I think it's really about the adventure of getting the axle under the 100, sitting back and smiling that it was completed.

 

[LEX]

You're moving too fast. Slow down!

Keep up the good work.

 

[Trist]

I spend about 45 min going through this thread haha! What an awesome build and nice job with tackling all of those mods yourself, truely inspirational. I think I am going to paint my side trim and door handles black because they are both fading very badly.

 

[duggy]

Axles got back from sand blasting and boy do they look pretty. I am pretty amazed at how well it got the flakey rust off the axle. This should make working and welding on the axle much easier to keep a clean environment instead of rust being knocked off every time I hit a hammer. I did some cleaning in the garage and moved a few things around for more room when I pull the Cruiser in and place it on jack stands. The duct tape/saran wrap idea worked really well but one thing I would change is to remove the sensor from the e-locker housing when sending to get blasted. The pressure is so strong that the sensor has some damage.

 

[duggy]

I started down the rabbit hole of cutting/grinding brackets off of the front axle. This was all done with a 4.5" angle grinder and plenty of cut off wheels and flap discs. It took me a few hours to do, but it got done without any damage to the axle so I'm good with that!

 

[duggy]

While working in the garage, I found a set of 37x12.50x17 MTRs that I could not pass on. A Jeep guy had these on his JK and then upgraded to 40s while these only had 1,000 miles. They came with Discount Tire certificates so this was pretty much a no-brainer for me since they're the perfect size. You guys think these will fit on a 100 series with no lift?

 

[duggy]

More work on the axle to get the spring perches off of each side. I have 2 Makita grinders, a 4" air cut off disc.

Left the panhard bracket on

 

[duggy]

After grinding everything smoothly (as much as needed), I started to tack on the shock mounts. These from Trail-Gear have built-in knuckle gussets packaged with a shock mount. Very slick.

 

[duggy]

I heard about clearance issues with the knuckle ball wipers hitting the knuckle gussets so I tore partly into the knuckle rebuild kit I got from Cruiser Outfitters. I have to thank Kurt from there to take the time with me on the phone and discuss all of the parts I needed. He really offers a full package from quality products and great customer service.

I posted the diagram on my workbench wall just so I can reference it as needed.

I bought one of the race driver kits from Amazon which really makes easy work of driving races and seals.

Also these seal pullers make easy work of pulling seals also

 

[duggy]

I have to comment on how much I love Daylight Savings Time and how it gives me an extra hour of daylight after work hours. I really think that the fun of researching Mud and Pirate all day at work and then going home and executing on what I learned in the day is what really excites me. DST really allows me to spend just a little bit more time in the garage everyday so I can keep at it and not let this project sit.

I've had various people ask me why I am tackling this project and even though I've given a few answers such as I'm tired of breaking stuff in the front end, or I just want to prove to myself it can be done by a guy in his garage, I really enjoy doing the actual work and tearing into something new. The garage is my peaceful place and I really enjoy working in there and getting my hands dirty. I'm an IT nerd by day but I can't wait to leave work and work on the 100 SAS project.

 

[duggy]

Today's agenda:

• Get the garage cleaned up in preparation to pull the 100 in
• Replace the races in the front and rear hubs
• Pack all 8 (!) bearings (by hand )
• Pull the 100 in and get it in jack stands

I had it on my list to buy a bearing packer but it slipped my mind so I just did them by hand. It's not THAT bad but can be a messy job without one.

Hubs cleaned up and painted. Races not yet pulled

I raided the kitchen drawers for this rubber spatula which works really well for packing grease into the hubs. I hope she doesn't find out.

Nice new shiny bearings before and after being packed

 

[duggy]

I got the garage cleaned up and reorganized. I really enjoyed having a couch inside of the garage but it had to go to make space for me to work on the SAS 100.

A comparision of the 100 vs 80 series brake calipers. They are the same size. 80 series in my hand, 100 still mounted to the rotor.

 

[bucfl]

I have to comment on how much I love Daylight Savings Time and how it gives me an extra hour of daylight after work hours. I really think that the fun of researching Mud and Pirate all day at work and then going home and executing on what I learned in the day is what really excites me. DST really allows me to spend just a little bit more time in the garage everyday so I can keep at it and not let this project sit.

I've had various people ask me why I am tackling this project and even though I've given a few answers such as I'm tired of breaking stuff in the front end, or I just want to prove to myself it can be done by a guy in his garage, I really enjoy doing the actual work and tearing into something new. The garage is my peaceful place and I really enjoy working in there and getting my hands dirty. I'm an IT nerd by day but I can't wait to leave work and work on the 100 SAS project.

Well said. Im in IT as well, and its relaxing for me to tear into things not network related. It takes my mind away from all the BS.

 

[duggy]

If you'll see in the last picture above the shock has been disconnected from the upper mount. I only found this out when I put the Cruiser on jack stands and pulled the wheel off. This would explain my broken front diff as I was noticing some weird suspension unloading and offloading (bouncing) when I was climbing this hill

I needed to keep momentum but usually try to keep a very keen sense of breaking stuff in the 100 front end. It happened anyways because of the broken shock bushing/washer. It solves a piece of the puzzle now on why I broke. I now need to find out what actually broke. My bet is on the R&P as I had some pretty nasty grinding/clunking/"OMG STOP DRIVING ME" noises.

 

[duggy]

Well said. Im in IT as well, and its relaxing for me to tear into things not network related. It takes my mind away from all the BS.

I'm in Service Desk and Server Infrastructure and although I love figuring out complex IT issues and services, I love working on cars and Cruisers more

 

[savirc]

Duggy we are very a like in that sense, love working on cars. IT by day grease monkey by night, totally use up every bit of that day light savings. I miss it dearly when it goes away.

 

[baldilocks]

Over from the 80's forum looking for just this thread. A 100 is becoming more interesting to me but I really want the solid front axle durability and articulation. Basically, I would like a 100 that can run the Rubicon and other rocky trails here in west.