Factory Dodge front shackles leave a lot to improve on...

They're thin - 3/16 or so?
Are narrow.
Bend easily.
Are only 3.75" eye to eye.


Well I wanted some bomb-proof shackles that were cheap and simple so I made my own for less than $10.00. Maybe less than $5.00, but I bought so much steel that day I can't remember what 2" strap costs.


Here's what I did:

1. Basically I bought four pieces of 3/8" cold rolled 2x7.25" steel. This will make the eye to eye measurement 5" and allow some room for grinding. Also I like to leave my shackles a little below my bushings - an 1/8 inch or so. This keeps me from tearing up bushings as much because the shackles won't grind the bushings on rocks.

2. Took one of the bushings ( source - www.offroaddesign.com) and traced its outline on both sides of one end.

3. Ground off carefully with bench grinder and kept remarking with bushing outline until grinding was complete. Took a belt sander and smoothed off the edges.

4. Drilled holes with drill press - 9/16" Bolts.

5. Painted so they would look nice for my write up. :flipoff2:

Ryan

Bent factory front shackles.

This should fix the problem.

Makes the factory stuff look really flimsy. :eek:

Side view.

Those sure are purty!!!
:D

Good job man, those look like they will last you a while.

Sources:

Offroad Design - Bushings and bolts.

I have the older Grade-5 Greaseable bolts, but the new bolts should all be Grade-8.

http://www.offroaddesign.com/catalog/greasebushings.htm

GU38002 kit for 1 1/2" shackle $66.00

These fit my custom spring pack and upper shackle mounts.


Metal Supermarkets

www.metalsupermarkets.com

These guys are great for small stuff. They'll cut it for free, and there's no minimum. So if you want 6" of 2" DOM with 1/4 wall they'll sell it to you. Can't beat that. Also they sell small stuff as scrap by the pound.

Ryan

Originally posted by The Adam Blaster
Those sure are purty!!!
:D

Good job man, those look like they will last you a while.

Thanks.

You should see the rest of my truck. Rust city :).

Ryan

Hey, those look just like mine! :) Nice job. Just wish I'd done the larger upper shackle bushings like yours to go with the larger GM spring eye bushings. Still not too late. ;) Very good stuff.