HotRodLarry's Epic SAS Project (1 Viewer)

[Hotrodlarry]

Months down the line I did have to modify the steering arm. After talking with someone who has done this before, he indicated the stock Toyota ball joints were not holding up to the large tires. I then modified and offset the arm to take GM 1 Ton ball joints. (this did not work as planned I will go over that in another post) a recurring theme is solve one problem, create another. In the photo of the outside of the wheel you may be able to see the lip I machined out of the bore.

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Yes, I some of the porosity in the weld!

 

[Hotrodlarry]

The rear axle was fairly simple. It needed a complete rebuild but it is still a 100 series rear axle with the original e-locker. I pulled the axle shafts and replaced all the bearings and seals, then re-geared it to 4.88. The only real change was the modification to the track bar (Panhard bar) mounts on both the axle and frame. When I flexed the stock suspension it was very obvious that the factory bar with rubber bushing would bind up very quickly. It was the primary limiting factor in reducing suspension travel in the back. Barnes 4WD was my primary source of fabrication parts. I would order something close and then modify it (hack it up). I then fabricated a new bar out of 1.5" diameter stock with rod end bearings

 

[Hotrodlarry]

Moving forward, I was near the 13 month of the project and I looked at all the videos to rebuild the transfer case. I then call Cruiser Brothers (Roark Richards) for a price. I had watched a video of them rebuilding a transfer case. It was very obvious to me that they had been doing this for a long time. I admitted defeat and sent my case to them. The turn around time was amazing. 5 days to his shop, 1 week to rebuild and 3 days back. I now have a fully rebuilt case with new bearings, seals, 10% reduction on the high side, 25% reduction on the low range. This matched with the 4.88 gears in the axle puts me back very close to the factory ratio's. The truck accelerates very good with the big heavy tires. I used a ATV jack to remove it. (hint: the transfer case does have a differential as part of the all wheel drive. To align the spline with the transmission grab both the front and rear output flange at the same time and you can rotate the input shaft)

 

[MongooseGA]

. I was picking my way down the trail when this 80 series with big tires, floaty suspension, driven by a 25 year old girl just passed us as if we were sitting still. I thought to myself, I want one of those....

I see no pics of 25 year old women.

Thread fail.

 

[MongooseGA]

Just kidding. This is an awesome build!