Longer Rear LCA's for the 80.

[Rice]

This really belongs in the 80-tech section but opted just to share with "family" instead. JFZ80 and I both had slightly bent rear lower control arms, wanted to make a pinion angle correction, and to add some strength. Below are a couple pics of the process.

costs: 4 bushings were about $100, Tubing $145 (That's total cost for a 22' stick so only about $6.60/foot and have enough tube for 3 more sets), The looks we got from Brodi - priceless.

The LCA's we opted to work with are the "early" style. Outside diameter = 1.68" and roughly .120 thick. The plan was to cut and sleeve these using 2.00" outside diameter DOM tubing with 0.120 walls. That leaves about 0.030 clearance between the inside wall of the new and the outside wall of the OEM. Thus the large number of rosettes to get a strong join.

 

[Rice]

Page 2

First job is removing old bushings. We had access to a 30 ton press but it could only manage 15 tons for some reason and old bushings wouldn't budge. Cutting them out only took about 5 minutes each. Drill the rubber, carefully sawzall the bushing sleeve, and tap it out.

 

[Rice]

OEM control arms with bushings out. Now time to clean.

 

[Rice]

Once clean, measured out the original length. Then cut. We set up a template to increase length by 0.450". The pics of the "whole" arm are mock ups of the sleeves slid over the cut ends.

 

[Rice]

Next was marking and drilling the rosettes and then some tube cleaning to make sure we get a clean weld. Somewhere in here we worked in a or two.

A note to others who wish to try this ... I've been wrenching for a pretty good while but have never drilled metal with a step bit. Jason brought some over and I am sold. At least 8x faster than any brand new high quality drill bit. I now own a set. We drilled 48 1/2 inch rosettes thru 0.120 wall on each set of LCA's (96 holes total) in about 30 minutes (plus time for another )

 

[Rice]

Welding time. Strapped everything together so it wouldn't slip, triple measured the length, tapped the ends on flat surfaces to be sure they were aligned, measured again, tacked it together, and measured again.

 

[Rice]

Finish the welds, polish down the rosettes, paint, , install new bushings. While the 15 tons we could "squeeze" out of the press was not enough for the old bushings it was enough for the new. Barely.

 

[Rice]

Installing onto the rigs would have to wait until another day. Brodi was ready to go home.

 

[Rice]

And finally the install. Have not had the 80 on any trails but at least while on the road was able to lose the vibration (worse on deceleration) that came from having my front and rear ujoints at different angles. I have not measured my angles yet but they now look in line. Jason says his are right at 10 degrees and 10 degrees.

For anyone else wishing to make a set I still have left over tubing provided this is the way you wish to go. If it sits around too long I'll take Jason's suggestion and make myself a super heavy duty wind chime.

If you have to ask about the green driveshaft it's obvious you don't wrench with a 4 year old little boy named Brent.

 

[GLTHFJ60]

Jason was telling me about this last weekend. Tons of rosette welds = tons of grinding time, but man the end result is beautiful!

How did you come up with the amount to increase the LCA's link by?

 

[jfz80]

search feature

 

[lt1fire]

Pretty cool, been thinking about doing something similar, but with adding some angle iron to the bottom for more protection.

 

[jfz80]

ok couldnt resist......

buuuuut its true and every post led to 3/8'' to 1/2'' longer. Nay and LCphil have good post
Landtanks are .55'' over stock for a 4'' . We did all the same lengths to have a spare amongst us.

Definately considered the angle iron, wanted it, didnt have it, were 10 hrs in...... you know how it goes.
May do it in the future and not weld it solid but good 1'' spots along the way slowly so as not to melt the brand new OEM bushings installed.

 

[Mtbcoach]

I'll be up for some of the tubing to do to mine. Please save me a hunk and/or I'll take the rest off your hands, I can always use another piece of tubing around my garage.

Let me know what you want for the rest and/or enough for a set for me.

Thanks...

 

[jfz80]

Jerry, You would have to source some earlier 80 series LCA's

the 91-94's are thicker and hollow vs our later solid thinner ones.
many moons ago i paid too much to mention for this early set that use to be thought of as an upgrade worked out 8yrs later that I had them so we could order the same size tubing

 

[NCFJ]

Jerry, you could also use 1.5" or 1.75" .250" wall DOM. Cut the sleeves off the links you have and use them on the new links. Avoids the rosette weld and you get 1/4" solid walls.

Just food for thought.