Gotta Few More Mods Underway...

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Bout Time For Some Updates

I've since finished up the new frame panhard mount & got the bar refabbed also. The springs, shocks, bumpstops & knuckles are on finally. Gotta fix the steering linkage too but that's after I get the brake caliper brackets to work. I'll add the panhard bar spacers later as I still hafta paint 'er up.
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Brake Caliper Brackets

I shopped around for a while lookin for D60 front caliper brackets that allow 15" wheels. I've read that *some of those brackets were close fitting or needed some clearancing/ alignment. So, I already had these brackets & decided to make mine work. I have a D60 rear bracket that uses the same calipers so I can get my hole spacings true. I cut off the mounting ears from the originals & have one side mocked up. All I need to do now is cut 2 pieces of 1/4" plate for each of the caliper mounts. Yeah I know it's time consuming, but for the prices I've seen (~$200.00 a pair) I think I can spend that somewhere else on items I can't fab :D
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Thanks man :clap: Your budget build is coming along nicely :D I'm squeezin the bucks on these mods too.

The caliper plates are "machined" & the pilot holes are drilled. I really shoulda used 3/16" for this :meh: You can see how the plates will fit, bolted to the bracket & I'll weld the plates @ the inner curve. You can also note how the plate, that will hold the caliper bolt, aligns w/ the threads. I'll need to thicken up that area before I tap it w/ 7/16" X 20 thread. The most time consuming part will be drilling & tapping the caliper bracket 12 times.
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Whew, I'm all tapped out after these..... I was going to use 3 - 5/16" bolts to secure one of the plates to the caliper bracket, but I broke the tap off flush w/ the top of the hole :bang: I tried to weld a nut & drill it out to no avail. So, I cut that end off & will use 2 - 7/16" bolts instead. Next, I'll fit it all up, align everything, then weld the plates together. Here it is mocked up again after the slight changes:
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Update.....

I have the brake lines done & have already started cutting down the old steering linkages to fit. I'll use inner sleeves, plug welds & butt welds. All steering connections get double shear mounts. I've got the pieces rough cut that I will shape & add to the steering knuckles & hy steer arm. The drag link will be 100% in alignment w/ the panhard & that is key to not having any binding issues. Pics soon.......
 
Hy Steer Arm & Drag Link

I started adding the double shear mount to the hy steer arm. I have the drag link tacked & will burn it in tomorrow. Then, I'll move onto the knuckle reinforcing & finally the tie rod.
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That should do it for the steering! 12 plug welds on the tie rod alone + 4 butt welds. I've been test fitting the 2" O.D. hydro cylinder & it's tight. I'd like to mount it to the hy steer arm so we'll see if it's the best spot for it.
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Well the hydro cylinder was just too tight & woulda hit the frame on uptravel positioned above the diff cover & mounted to the hy steer arm :frown: So, I chose to mount it to the drag link instead. I'm using 1/4" plate for the mains & 1/8" for the boxing mat'l., as on all brackets already done. The axle housing bracket will be the last one. I still hafta order the braided brake line that extends from the firewall to the top of the housing cuz I rerouted the line. Then, I'll order all my steering hoses.
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I got the tie rod connection done. HUGE heat on those 1/4" plate pieces. I got a blister cuz I had an awesome bead goin & didn't wanna stop :rolleyes: Even used my nomex welding gloves :doh: Onto the housing bracket. No more big bracket fabbin after this one........
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I've started on the housing bracket for the hydro-assist cylinder. It's just in the beginning stage as I still hafta add the top piece & add a small hole in the middle of the bracket tying it to the housing for added support. Alotta curves goin on here. I like my brackets beefay :D
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All done & ready for paint, then reassembly.
Now, for the rear of the Cruzah, all I need to do is fix the bumpstops cuz they are long & pressure from hitting the base of the stops have caused them to bend the bolt that holds each bumpstop. I'll make sure that won't happen again ;p
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Well, just as I started bolting things up, I realized my panhard bracket bolt was binding :mad: First time I welded it all up, it was binding so I cut it out. Second time I thought I had it aligned, same problem. This time I had to use a breaker bar to remove it :bang: I also checked the bracket I made for the :pig: & it's binding too :rolleyes: I think I'll just tap some 3/8" plate instead of using a bolt behind 1/4" plate. That should let me assemble them even if it's slightly misaligned.
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Updates

I finished up fixin the panhard mount w/ a 3/4" X 16 bolt tapped into 3/8" plate, works perfect. The frontend is pretty much reassembled. I'll order a few hoses for the steering & some parts to finish this rebuild. Also refabbed the rear bumpstops to be more beefy & will not bend.
 
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I ordered a custom 44" long stainless brakeline that runs from the firewall to the top of the housing. I fabbed up 2 quick brackets & got it mounted up. It's tied w/ my ARB flex line & my axle housing vent.
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I still need to get the steering lines & bleed the brakes. I'll bolt up the 3rd member & order the front inner axle shafts soon. Other than that, the front is done. I ordered a few items from SOR to finish things up. Here's a completed front axle view :meh:
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