What's your timeframe / goal for having it done?
looking forward to the completed pics!
looking forward to the completed pics!
Mojave Suspension System Build Thread
- Thread starter Bandicoot
- Start date
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- Thread starter
- #22
At this point, I'm hopeful to be close to complete by the end of this week. I have all the parts with the exception of the Bilstein 5125 shocks. After I get the basic suspension installed then I can flex it out and see what issues if any come up and measure for my shocks and final placement of the Ford shock towers. There is some debate if the front drive shaft needs to have a longer spline installed and I want to see if a high steer would be beneficial. Since I don't carry lot's of weight in my 60 all the time, lift will prolly be fairly high 4+inches. So I don't know what unplanned articulation issues may arise. I'm fairly confident after talking with Steve at Man-a Fre that these issues may not occur, but we will see.
Edited because I'm an idiot...so DISREGARD
http://www.man-a-fre.com/technical_info/shackle_reversal.htm
Pix of the SR stages are much appreciated (before, during, with and without bumper re-installed, after...).
http://www.man-a-fre.com/technical_info/shackle_reversal.htm
Pix of the SR stages are much appreciated (before, during, with and without bumper re-installed, after...).
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- Thread starter
- #24
Tackled the Front First
Today was a good day. Got old grey in the air and supported, got the front springs off and got driver side front spring hanger and bottom stock gusset removed. Ground and cleaned metal in prep for welding and test fit the new 4+ SR spring hanger.
Some preliminary measurements prior to stripping the front end down: Truck height to top of inner fender well on front 34-3/8", rear at 33-1/8".
All shackle pins came out in three light hits with drift and hammer, soaked all hardware the week prior with liquid wrench, made it easy! Cutting the welds and removing the front spring hanger and stock bottom cross member gusset was not bad, just tedious. Takes time if you want to have a nice looking job and you do not want to damage the frame rails. 4" metal cutoff grinding wheel on a pneumatic grinder makes for fast and precise cuts.
Today was a good day. Got old grey in the air and supported, got the front springs off and got driver side front spring hanger and bottom stock gusset removed. Ground and cleaned metal in prep for welding and test fit the new 4+ SR spring hanger.
Some preliminary measurements prior to stripping the front end down: Truck height to top of inner fender well on front 34-3/8", rear at 33-1/8".
All shackle pins came out in three light hits with drift and hammer, soaked all hardware the week prior with liquid wrench, made it easy! Cutting the welds and removing the front spring hanger and stock bottom cross member gusset was not bad, just tedious. Takes time if you want to have a nice looking job and you do not want to damage the frame rails. 4" metal cutoff grinding wheel on a pneumatic grinder makes for fast and precise cuts.
I may have missed it, I know I zone out sometimes during long installs, so maybe you missed it, maybe not....but don't forget to sandwich the new front shackle bracket between the frame and the front bumper mount that you had to drill the 4 rivets out of then bolt the 3 together (frame, front shackle mount, bumper mount). Just in case you were towards the end of a long day is all....I notice on post #24 the bumper bracket wasn't bolted on with it all.
Keep the write up coming. It is much appreciated and although the detailed write up isn't out there for you, thank you for making one for us (me). I am gonna be ordering this kit and your write up makes spending money I barely have, that much more tolerable.
Keep it up.
Keep the write up coming. It is much appreciated and although the detailed write up isn't out there for you, thank you for making one for us (me). I am gonna be ordering this kit and your write up makes spending money I barely have, that much more tolerable.
Keep it up.
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- Thread starter
- #28
THX Bosljeff. No I did not forget about the bumper bracket. But I could see at the end of a long day forgetting :O
Today was just a dry fit. I will tack the SR hanger in place, run the perm beads then add the bumper hanger bolts and weld all together. The big thing with the SR hanger is getting it perpendicular and hanging properly in relation to the frame rail. This is a priority above all else, it will save on wearing bushings out.
Today was just a dry fit. I will tack the SR hanger in place, run the perm beads then add the bumper hanger bolts and weld all together. The big thing with the SR hanger is getting it perpendicular and hanging properly in relation to the frame rail. This is a priority above all else, it will save on wearing bushings out.
Did some needed cleaning of front axel, frame and steering linkages though.
nice work man,
looking forward to seeing the stance when shes all done!!
looking forward to seeing the stance when shes all done!!
Weird, wheres all the rust 
. Wish I could find em like that up here.
. Wish I could find em like that up here.
LandBruiser69
It feels good to be lost in the right direction.
Looks Killer Man!!! Keep it mooooovin...
- Thread starter
- #34
Today was a down day. Needed to go out and earn $ to pay for the rest of the upgrades planned!
Thanks guys. I was hoping the thread will help others. I was kinda nervous to do it but figured it could not hurt, I know these type of threads helped me.
Rust? What's that? I have to admit 100% California wagon and was garaged for the first 16 years of its life. What can I say...
Going to hit it hard Thursday. Removing the passenger side stock front shackle hanger and bottom gusset and prep for welding in the SR hanger. Friday I hope to start welding SR hangers and all the front crossmember gussets.
Thanks guys. I was hoping the thread will help others. I was kinda nervous to do it but figured it could not hurt, I know these type of threads helped me.
Rust? What's that? I have to admit 100% California wagon and was garaged for the first 16 years of its life. What can I say...
Going to hit it hard Thursday. Removing the passenger side stock front shackle hanger and bottom gusset and prep for welding in the SR hanger. Friday I hope to start welding SR hangers and all the front crossmember gussets.
Not that I'm rippin on ya Bandi, but do you (or anyone else) think if dedicated to one whole weekend, with the right tools, that this could be done in 2 days?
Just makin plans.
Just makin plans.
i was able to do it less than two days ....and that was with 2 sets of hands a welder and compressor ....without them it might take longer ......but easily a sun up top sundown job
So what would any of you say would be a list of "nice to haves" when it comes to tools and making this a quick and painless as possible.
Anything you ran into that you had to stop and get mid-install?
Don't say wrench...I mean those unique tools that you wish you would have had or actually had that made this a world better.
I heard 4" cutting wheel, which is obvious, but I hadn't thought about it...
Again, just makin' plans.
Anything you ran into that you had to stop and get mid-install?
Don't say wrench...I mean those unique tools that you wish you would have had or actually had that made this a world better.
I heard 4" cutting wheel, which is obvious, but I hadn't thought about it...
Again, just makin' plans.
- Thread starter
- #38
Today was a Good Day
Removed the Passenger side front stock spring hanger, ground down all the old welds. Continue with test fit of all the 4+ SR hangers. One thing that I learned again is that despite most of this suspension is a "kit" does not mean you can just slam this stuff on and go! What's my point? Take the time to make sure the hangers are properly mounted of the frame rails. Just because Mr. Toyoda built our cruisers does not mean everything is plumb, square or in perfect alignment.
My wagon is bone stock with no damage, bends or accidents, just as the factory built it and there are differences in how well the SR hangers mount. Passenger side was fairly easy with no major alignment issues. The Drivers side for whatever reason I had to die grind the SR hanger mounting bolt holes to align with the stock bumper hanger bolt holes and sit nicely against the bottom of the frame rail so my welds will not have to span large gaps and eliminate the use of filler or backer steel.
The other item I did during the fitting process was to straighten the vertical
bolting flange on the SR hangers so they would align properly with frame rails. Now let me be clear, Dave's (4+)/ Man-a-Fre products are without compromise and extremely high quality so none of what I'm saying is a negative reflection on the Mojave suspension kit or how it's constructed. There is no question about the quality here!
By trade I am a mechanic and machinist so I am naturally picky on how well things fit and align, so I am paying particular attention to this detail. After all, once it's welded in that's it and I do not want to regret not having done something, so take your time on this phase.
Other items I did was chase the stock bumper hanger bolt holes in the frame rails to 1/2" with a Uni-bit which cuts nicely and leaves a clean beveled edge on the hole. I also test fit the gussets that will be used on the frame rail/ cross member/ SR hangers. All looks good. The the rear top cross member gusset will be a bitch to weld due to lack of room. I removed the radiator and fan but still will be a tough weld. The rest of the day will be spent grinding, sanding and wire wheeling frame members in preparation for the welding phase which I may start tomorrow. I've included lot's of pics for your enjoyment.
Removed the Passenger side front stock spring hanger, ground down all the old welds. Continue with test fit of all the 4+ SR hangers. One thing that I learned again is that despite most of this suspension is a "kit" does not mean you can just slam this stuff on and go! What's my point? Take the time to make sure the hangers are properly mounted of the frame rails. Just because Mr. Toyoda built our cruisers does not mean everything is plumb, square or in perfect alignment.
My wagon is bone stock with no damage, bends or accidents, just as the factory built it and there are differences in how well the SR hangers mount. Passenger side was fairly easy with no major alignment issues. The Drivers side for whatever reason I had to die grind the SR hanger mounting bolt holes to align with the stock bumper hanger bolt holes and sit nicely against the bottom of the frame rail so my welds will not have to span large gaps and eliminate the use of filler or backer steel.
The other item I did during the fitting process was to straighten the vertical
bolting flange on the SR hangers so they would align properly with frame rails. Now let me be clear, Dave's (4+)/ Man-a-Fre products are without compromise and extremely high quality so none of what I'm saying is a negative reflection on the Mojave suspension kit or how it's constructed. There is no question about the quality here!
By trade I am a mechanic and machinist so I am naturally picky on how well things fit and align, so I am paying particular attention to this detail. After all, once it's welded in that's it and I do not want to regret not having done something, so take your time on this phase.
Other items I did was chase the stock bumper hanger bolt holes in the frame rails to 1/2" with a Uni-bit which cuts nicely and leaves a clean beveled edge on the hole. I also test fit the gussets that will be used on the frame rail/ cross member/ SR hangers. All looks good. The the rear top cross member gusset will be a bitch to weld due to lack of room. I removed the radiator and fan but still will be a tough weld. The rest of the day will be spent grinding, sanding and wire wheeling frame members in preparation for the welding phase which I may start tomorrow. I've included lot's of pics for your enjoyment.
