Front Suspension Complete...
So I tore it apart and welded it up. Added some more bracing. I was running out of time, so Jer came over and helped out by fitting some tube braces for the shock hoops. Thanks again Jer. I was going to add a small truss bar to the bottom of the D60, but ran out of time. So I’ll explain what all I have and comment on any pictures if something else comes to mind as I go along.
Keep in mind some of these pictures were the initial assembly, then I had the shocks changed to remote rezis because the tires could collide with the piggybacks. At the same time I added the flanges to remove the engine crossbar and cutout and installed the inner fenderwells. So there is a few pictures in here where it's not quite done. Disclaimer, all brackets are hand cut with a plasma and ground with an angle grinder, and some of the welds aren't as pretty as I would like but I am confident in the strength. So go easy on me.
At the rear is the custom tranny crossmember that holds the 3” ballistic joints, they are bolted to the crossmember with ¾” bolts, then threaded into tube adaptors with a 1.25” threaded shank. From there the 2” x .250 wall DOM is welded to a .250 wall DIY4X bushing with a 9/16” bolt into the axle bracket. In the middle of the main arm there are short 1.75 x .120 wall DOM upper arms. Those are connected to the lowers with 7/8” heims in tube adaptors, to brackets I custom made and welded to the lower arms. These are thin for tire clearance, thinner than the 2” tube, but the 9/16” bolt head does stick out slightly more than the tube. The other end is the same .250 wall DIY4X bushing with a 9/16” bolt as the bottom. This crossmember is also held in with 3 bolts on the bottom of each side, for a total of 14 size 7/16" bolts through to the frame with only 4 new holes.
Both the trackbar and draglink are 1.25x.250 wall DOM, cut, bent, and threaded by ORD to my measurements, all one piece. The draglink uses 7/8” tie rod ends for long life and smooth operation, but the ends BARELY have enough angle for full droop. I got the angles and lengths as close to parallel as I could. I even did some trig calcs and made simple solid computer model to simulate the bump steer and determined it was satisfactory. In my modeling I was considering slightly offsetting it to improve the slight error in bumpsteer, but determined I was just trading error at one end for the other, and decided I would rather have it more accurate where it was used the most, at ride height. In the end I don’t notice any bumpsteer anyway, it works great. The bumpstops are angled in slightly on purpose to help with coilover clearance during articulation. I tried to keep the track bar high for a better roll axis in the front as well. Also, since I rotated the pumpkin up quite a bit, I wanted to be able to raise my gear oil level to make sure the pinion bearings are oiled, so I cutout a rectangle around the fill hole including more area around the top, then flipped it upside down, and welded it back in. Raised it over an inch, done.
The axle brackets were hand cut and ground from ¼ plate with the plasma and angle grinder. The have two side plates, and a brace connecting the two at the top, bottom, and middle. At the top each axle bracket also holds the lower shock mount, and the limit strap connects with the upper bushing bolt. The top/front brace on the passenger side that connects everything together is 5/16” plate, and also extends up to form half the panhard(track) bar mount. The other side is 5/16” late as well, all boxed in with ¼” plate. The track bar is held to the axle by a 7/8” heim joint using a 5/8” bolt. The other end connects to the frame with a 5/8” bolt as well, but with a rebuildable 2.63” ballistic joint with a 7/8” threaded shank. This picture was huge for me, I had a big smile on my face because the truck was sitting on the axle for the first time in weeks. The big jackstands on the front frame are lowered!
The track bar frame mount is 5/16” plate, custom cut and welded and “batwinged” to the frame. It is also braced to the shock hoops with some 1.75 x .120 wall DOM. The track bar batwing also holds the support pivot for the intermediate steering shaft since I had to add a 3rd u-joint to clear the coilover. I also had add in the weld in brace since I found a crack in my frame when I tore it all apart. I already had the bolt in brace, so I fixed the frame and added the weld in brace.
I don't have a tubing bender, so I couldn't of made the shock hoops or engine crossbar without dunejump and his help with his bender. The shock hoops are all custom bent 1.75 x .120 wall DOM, including the engine crossbar, which also has DIY4X flanges, and the upper shock mounts are DIY4X mounting angled mounting tabs. Those are such a great price it’s not worth making them yourself. I’m all about engine maintenance and keeping it up, so I kept the shock hoops out and away from the engine for easy plug and header access, and all around easier access to the engine and accessories.
The springs are 300/450 Eibachs. 12/16 inch for a total of 28 inches on a 14” travel 2.5” FOA remote reservoir coilover shock. The funny thing is I just ordered the 4 springs and when they arrived they were the same colors as my truck, half silver and half red. I was laughing.
The engine crossmember I custom made from 1 piece of 6x6x.250 wall square tube, I cut it lengthwise on opposite corners to produce two 6” angled pieces with a bend at the bottom. These were cut and bolted to the frame. Then I cut and notched a piece of 2x2x.250 wall square tube to make the cross bar. This was originally done because I wanted to drill and tap it to cross the compressed air over to the other side, but determined that wasn’t going to be the best solution after there wasn’t much room when I got it all done. Anyway, I bent it together and welded the notches to create the overall bent shape, and then cut the top flat to fit the angled plates. Tack welded that in place after jacking it against the plates. Then made braces for the engine mounts. Also mounted the 2” x 4” travel FOA air/hyd bumps to that and braced that as well. I used mostly holes in the frame that were already there for this crossmember. If I were to do that over the only thing I would change is I would probably just bend a round tube for the crossbar instead of using the square one since I didn’t tap it for pipe fittings anyway.
Brake lines were moved and angled down just outside the frame. New hard lines were ran and the braided flex lines I bought previously were reused.
The limit straps are from poly performance and attach from the lower bushings to the engine crossmember. I tightened the bolts on the strap tabs when they were pulled taught from full droop to keep them at even tension in the tabs. The limit straps will stretch so I ordered them two inches shorter than full shock extension.
The front driveshaft is now a HAD 1350 CV for high angle with a 1350 front u-joint and u-bolt yoke. The slip is only 3” because the radius arms are so close to the driveshaft pivot it only uses just over an inch of slip throughout the suspension travel.
I have to mention that I wouldn't have this axle, or the rear 14BFF, or the trans, or the tcase, without my Dad and brothers help. They are always finding parts and parts trucks and hauling things for me and I couldn't of built this thing without them or the parts. So I had already put the Detroit locker and all new bearings and seals in the axle, so when it was time for final assembly I got to put together the rest of the parts for the last time.This included all new kingpins and assemblies. The ORD crossover arm with ARP studs, new Spicer life u-joints with the stock large35 spline inners, and 35 spline stub shafts along with Warn Premium 35 spline hubs. I also had to replace the spindles since the seal surfaces were no longer serviceable. I drive this thing on the street as well as to and from the trails, so I definitely wanted to be able to unlock the hubs. I kept the stock plastic kingpin bushing and spring design. I believe that this helps absorb impacts if the 550 lbs axle comes crashing down on the tires and then the truck crashes down on top of that with large bumps and small jumps. Also, although I admit the bronze bushing and set screw design are stronger and eliminate the spring, what is the next weekspot on impact? The knuckle? The spindle? The inner C? I would rather be able to easily replace a bushing and spring than any of those pieces. Death wobble has been non existent so far in the driving I have done, everything from offroad, to city driving, to 80 MPH on the freeway. I aligned the toe myself with a piece of tape on each tire rotating them front to back.
Initial driving impression was, holy crap this steering is tight. With all new intermediate shaft, all new axle components, steering, track bar, tie rod, drag link, everything, it was VERY precise. The most precise I have every felt my truck at all, night and day, it was the first thing I noticed when I drove it the first time. And I had already replaced everything 7 years before that, so it's not like I haven't felt it all new before. Road manners are great, except one thing I didn’t expect is, coilovers with dual springs and a slider are kind of loud. The springs shift and slide up and down the coilover body and it travels right through the frame and into the cab. Nothing I can’t deal with I just didn’t expect it.
Offroad it is much better, absorbs bumps better, articulates better, ride smoother, steers better, has more traction with the front locker. I love it.
There is only one problem, I like the front so well that the back sucks now. The front will be soaking up everything and the back will bounce around like Tigger from Winnie the Pooh. And with the new carb on the big block I also have wheel hop in the rear now, even on sand. Also, this carb has more power, but on super steep hills at low load, low RPM, it goes pig rich and wants to die on me. Then I have no power steering or brakes, which is worse yet.
It really makes me want to 4 link the rear, and add EFI. The 4 link is happening, don’t know if I can afford the EFI yet.
In the meantime, I did some more stuff to the tranny and gauges a couple weeks ago, so that is next.