So I bought this truck almost 5 years ago with the intentions of swaping the IFS out for a solid axle... I have been reading on this board for a long time now, and credit alot of what I know to the great write ups here... I appreciate the time ya'll spend on write ups and builds..

A little history of the truck... I bought it in Sep 2000 for a lot of money. The notorious head gasket on the 3.slow caused an eairly engine replacment. The previous owner had installed a 4" trail master lift and had it regeared to 4.88.. When I bought the truck it was clean.. Like new clean, and I paid for it.. 13k to be exact... As clean as it was, with the new engine, lift, new 33's, gears, system, and other goodies I was happy but wanted more...

I went out with my buddies that wheeled and it did alright.. The IFS just has limits that you find quickly when wheeling in rough terrain. I never broke anything in the front but the rear is a different story.. I blew the rear end up within the first year.. Since I was going to a solid axle and bigger tires I replaced the rear end with a detriot locker and 5.29's.. (rear only).. So I took the front drive shaft out at that point..

After having fun spinning donuts I started hearing some nasty noises, and I realized I had ripped the rear spring perch off the axle tube.. The rear springs that were giving me the 4" of lift had a bad case of axle wrap.. no flex and they just sucked.. So after some reading I called up AOR and got the 5" longer 5" lift springs with orbital eye (hard mount only)... and I got a one piece drive shaft made.. This cured my axle wrap issues and gave me a lot more flex..

http://img.photobucket.com/albums/v208/skipstr71/Solid%20axle%20swap/random4003.jpg

http://img.photobucket.com/albums/v208/skipstr71/Solid%20axle%20swap/random4004.jpg

I do have a question.. I have a bad rear shackle angle.. Its restricting my flex .. In a search I read that 45 degrees is the angle to shoot for... Is that what most of you have..?

http://img.photobucket.com/albums/v208/skipstr71/Solid%20axle%20swap/random4036.jpg

At this point I needed new tires... Still counting on the SAS to begin soon I went with 35" MTRs.. Love those tires by the way.. but needed more room up front as I almost shreaded my flares off when I was just "kinda" wheeling.. So I cut some 1" aluminum plate up on the water jet and made a 1" body lift.. Plenty of room now.. but with the IFS there was no real flex going on..

http://img.photobucket.com/albums/v208/skipstr71/Solid%20axle%20swap/random4039.jpg


So I called AOR again and ordered the orbital eye (front and rear) front springs.. 5" of lift and 2.5" forward axle location.. Got the SAS kit and then a couple months later I went to order a few more things and they were gone.. I am not sure if AOR even exists anymore.. I tryed for 2 weeks leaving messages, and emails getting no responce.. So I had spent quite a bit of cash getting what i thought was high quality parts and then they just dissapear.. I am still pissed.

I mean what happens if I need a orbitol eye replaced.... make one..? Remember these spring hangers are 3.75" wide to accept the orbital eye. So I have first hand exprience with AOR... DO NOT buy from them.. unless they can show some sort of contact with the public..

At this point I still needed a high steer kit.. So I called up Sky and Sky manufacturing and got great service when I picked up his high steer, steering box relocation kit, shock hoops, and other stuff.. I can't say enough about Sky's quality and support.

So I asked my buddy Rob for a second hand on the conversion.. and we got started yesterday.. Here is what it looked like when I brought it over to his house.. I took the bumper off a few weeks ago so I could look at the mounting for the front spring hangers...

http://img.photobucket.com/albums/v208/skipstr71/Solid%20axle%20swap/random4014.jpg

We got the torsen bars off and the top Aarms unbolted so I could get to the IFS brackets with the torch.. And no this is not how I will be holding the truck up.. I just didnt get the taller jack stands out from under my sammy...
http://img.photobucket.com/albums/v208/skipstr71/Solid%20axle%20swap/e8091f07.jpg

I do have another question.. and I have searched... I am hoping to see someones boxed in 3.0 V6 motor mount.. I have seen the 4 banger ones in person but the V6 is a little different..

http://img.photobucket.com/albums/v208/skipstr71/Solid%20axle%20swap/random4033.jpg

So far the only issue I ran into was the spring perch on the passenger side of the 85 front axle.. As I got this out of the junk yard I am unsure what exactly happend, but the leaf spring center bolt was munched.. The Ubolts must have been loose and it made the perch unuseable.. So I torched off the bad perch, made a new one and tacked it on...

http://img.photobucket.com/albums/v208/skipstr71/Solid%20axle%20swap/d1d14bb1.jpg

http://img.photobucket.com/albums/v208/skipstr71/Solid%20axle%20swap/60ff78d9.jpg

http://img.photobucket.com/albums/v208/skipstr71/Solid%20axle%20swap/eab375e9.jpg

http://img.photobucket.com/albums/v208/skipstr71/Solid%20axle%20swap/random4053.jpg

More to come in the next week....

Looks good, here's my boxed in motor mount.

My AOR springs were WAY WAY WAY WAY arched and horrible shackle angles when new, after alot of steet and trail miles the shackles sit perfect and the springs nearly flat ;-)

Your rear shackle angle should be alright. I don't have a side profile but, mine was pretty close to yours.

808toy.. Thats the pic I was hoping for.. Thanks a bunch.!

As far as the shackle angle in the pic.. Those springs have been on for 2 years now, around 20k or so.. They ride nice but when the tire is stuffed the shackle isnt that flat.. I'll get a pic of it and I think you may agree that it needs to be forward a little..

what time are you trying to start tomorrow?

right on. your truck looks like mine kinda. check this out if youd like http://www.pirate4x4.com/forum/showthread.php?t=330565

nice.

If you need another orbit eye, they can be obtained from Alcan Spring.

Looks like its coming along good bud. Any other plans in the works. Body protection, dual cases, bed bob? Keep the pics coming.

TIME FOR NEW TIRES!!! Talk about a safety hazard...

http://img.photobucket.com/albums/v208/skipstr71/Solid%20axle%20swap/random4004.jpg

It's interesting how many leafs are in those AOR packs. It seems like they would ride stiff, but I am no expert. Maybe it's time to move the shackle hanger around if the springs haven't settled enough to get it proper.

Good luck with your build and thanks for doing a good writeup yourself. Makes for good reading and pictures are always cool to look at.

your shackle angle looks sweet u dont want it too far back becuase that will limit your flex it looks ideal to me

TIME FOR NEW TIRES!!! Talk about a safety hazard...

http://img.photobucket.com/albums/v208/skipstr71/Solid%20axle%20swap/random4004.jpg

It's interesting how many leafs are in those AOR packs. It seems like they would ride stiff, but I am no expert. Maybe it's time to move the shackle hanger around if the springs haven't settled enough to get it proper.



AOR/Alcan spring packs use alot of thin leaves, that is the key as far as I know. I have very similiar Alcan spring packs and they ride so smooth. not sure what shocks you plan on running, but definitely get some quality shocks with those leafs and it will ride awesome.

AOR/Alcan spring packs use alot of thin leaves, that is the key as far as I know. I have very similiar Alcan spring packs and they ride so smooth. not sure what shocks you plan on running, but definitely get some quality shocks with those leafs and it will ride awesome.


I highly recomend the Bilstein 5125's from marlin. Im running those and they are super smooth. $75 a shock but well work the price. Ill be running them in the rear as soon as I can make time to fab up a mount for the rear to run them triangulated.

http://img.photobucket.com/albums/v707/erikdoreen/CIMG3091.jpg
i recommend 7100 they are fully rebuildable and you can get the valving you want. alittle pricey ($170) but well worth the $$$.theyll ride like a cadalac.

Pigs BBCS

kiyul4130.. Nice write up bud.. I enjoyed reading and looking at your pics..

AlaskaToy.. Alcan has the orbital eye's.. Man thats some good info.. thanks.!

GETTINTHERETOY.. Thanks, and yes I have alot still on the "to do" list. I have some All Pro rocker protection but I think they stick out too far.. Also I dont like where they end up needing to be welded... I dont have much experience with bidy work but I would like 10" cut out of the bed.. You may have seen my CAD design for a front bumper.. That will be my first project with my bender... I have plans to get some dual gear driven cases under it and a selectable locker up front.. Right now I am only locked in the rear...

As far as the rear springs go.. I have had them on for a couple of years and I had the pro comp shocks back there untill a month ago. When I had shocks on there the springs rode great.. I am completly happy with the ride they offer.. I just need shocks pretty bad.. I have been set on getting the 5125's from marlin like SAC KID suggested.. I know the piggys are most likely a better ride but I have a bugget and the pigs are twice as much.. Do you think they offer twice the ride..?

I guess I'll keep the shackle where its at for now.. Maybe some pics of it flexed may show that it needs to be moved.. I'm not looking for a better ride, I am looking for more flex...

As far as my tires go... Yea they are hurting bad..! The detriot in the rear really chews up tires.. I was holding out getting new hoops untill I did the swap so I could go with a larger tire.. I'm still eyeballing the maxxis creepy crawlers... Anyone want to flame them..?

I know the piggys are most likely a better ride but I have a bugget and the pigs are twice as much.

I'm still eyeballing the maxxis creepy crawlers... Anyone want to flame them..?

Aern't the creepy crawlers a lot more expensive than swampers or even MTRS? You said you're on a budget, but crawlers don't seem very budget minded.

I would spend my money on the big black um... cool shocks :D

http://img.photobucket.com/albums/v707/erikdoreen/CIMG3091.jpg
i recommend 7100 they are fully rebuildable and you can get the valving you want. alittle pricey ($170) but well worth the $$$.theyll ride like a cadalac.

what valving did you select for mounting you shocks 30 degrees from vertical? i don't see the point in spending big money on shocks if you mount them so they are only 86% effective unless you take that into account when ordering them.

As far as my tires go... Yea they are hurting bad..! The detriot in the rear really chews up tires.. I was holding out getting new hoops untill I did the swap so I could go with a larger tire.. I'm still eyeballing the maxxis creepy crawlers... Anyone want to flame them..?

what detroit are you running?

I said I was on some kind of a buget meaning that a $80 shock compared to a $180 shock is a big difference. If there was a huge difference in ride then I could squeeze it in.. I am just not sold on a $700+ set of shocks... I would rather spend that difference on tires.. I just have never read anything about the maxxis tires. I like them and I also like the sizes they offer.. I am looking for at least a 36" and the maxxis has a 37"x14.50" ...

The rear third is stuffed with a detroit locker.. The ratcheting, clunky, but 100% locking diff.. Still looking for a selectable locker for the front. I have 3 opens sitting in the garage..

Well after getting strep throat for the second tiome this year and moving as soon as I was better, its been too long since I made progress on my truck. So we got the IFS torched off and the rails cleaned up.. boxed in the motor mount, and got started on the spring hangers.. My 6 years of wanting to do this is finaly coming true and I couldnt be happier. Of course this is my first one but I just picked up an 85 ext cab so I can try to keep this truck fresh and thrash on "Old trusty"...


http://img.photobucket.com/albums/v208/skipstr71/Solid%20axle%20swap/64e9d80a.jpg

http://img.photobucket.com/albums/v208/skipstr71/Solid%20axle%20swap/4845491545.jpg

http://img.photobucket.com/albums/v208/skipstr71/Solid%20axle%20swap/a5b91665.jpg

The brackets are not fully welded and I have not started on bracing them up with gussets...

http://img.photobucket.com/albums/v208/skipstr71/Solid%20axle%20swap/b1c5a9a0.jpg

Oh yea some new hoops..! Gotta love the look of 22's with 5" of lift.. dont be jealous...

http://img.photobucket.com/albums/v208/skipstr71/Solid%20axle%20swap/9ae03f76.jpg

just fawking kinding... I think I have decided on TSL 36x14.5... flame on...

GETTINTHERETOY.. You may have seen my CAD design for a front bumper.. That will be my first project with my bender...

As far as the rear springs go.. I have had them on for a couple of years and I had the pro comp shocks back there untill a month ago. When I had shocks on there the springs rode great.. I am completly happy with the ride they offer.. I just need shocks pretty bad.. I have been set on getting the 5125's from marlin like SAC KID suggested.. I know the piggys are most likely a better ride but I have a bugget and the pigs are twice as much.. Do you think they offer twice the ride..?

I guess I'll keep the shackle where its at for now.. Maybe some pics of it flexed may show that it needs to be moved.. I'm not looking for a better ride, I am looking for more flex...

Haven't seen your front bumper CAD design, make sure it has room for a winch mount ;) I'd like to see that...looks like you're taking the time to do it all cleanly and correclty!

Piggys are nice, but more important on the front where most of your everyday weight is.

Leave the rear shackles for now and after it gets hard wheelin a few more times with a full camping gear load it'll settle a bit more. The more vertical shackles control spring wrap and therefore wheel hop bettter but don't ride or flex quite as well...not a huge difference though. The will settle more so you're good for now. Some flexed pics would be nice though.

Lookin good so far.

EDIT: Checked out your bumper drawing and left a few comments in that thread. I like it.

36x14.5....

why not just get the 38.5x14.5 SXs...you'll be able to fit them with alittle fender trimming but it will be worth it.

http://img.photobucket.com/albums/v707/erikdoreen/CIMG3091.jpg
i recommend 7100 they are fully rebuildable and you can get the valving you want. alittle pricey ($170) but well worth the $$$.theyll ride like a cadalac.

I will be getting some short body 14" 7100s soon that I found a good deal on but I'll be definitely mounting them as vertical as possible. As 300sniper stated, you'll get much better performance out of the shocks if you mount them more vertically.

Running Orbit eyes on both ends of the spring is going to limit your steering radius by a lot. I'd recommend building a panhard bar:D

Nate... Thanks for the imput and kind words.. I am taking my time.. as I do have some fabrication experince I have never done anything like a SAS before.. This is only my second time using a torch for that matter.. I havent had anything yet that is tough, just time and $$$..!

I really want to keep the best ride I can.. I will most likely run a quality shock up front.. piggy bilstien.. The rear rides nice when i have just a little weight in the rear.. That plate that holds my spare battery, air compressor, and tank weighs about a 100lb.. and it bolts to the old tire carrier.. What that is back there it rides like a cadilac.. I just know that the live axle up front wont have the ride of my ifs and I am fine with that.. I just want to make my on road ride as good as possible..

I will be leaving the rear shackle alone for now.. I'm sure the more I get into wheeling I will have a few things I want to change and maybe the way it is now will be all good...




36x14.5....

why not just get the 38.5x14.5 SXs...you'll be able to fit them with alittle fender trimming but it will be worth it.

Westy... I really do want the biggest tire I can get on.. just a few things hold me back from going to 38's.. A: I have the 3.slow and even with the 5.29's my truck is just a dog on the hills of nor cal.. B: is that I think that I would have to do a lot of trimming to fit them.. even when I had the fresh 35's and I flexed it out, the rear got into the fender and mangled it up a bit.. I have plans to hack the fenders up as my truck progresses. Right now its a pretty clean truck when its all together... but I am really trying to find some used tires so if I come across some 38's I would jump on it and deal with it..

generalee7.... Can you explain what the reason is, and how that is true.. I cant figure it out how the orbitol eye will affect my turing radius.. ???

Basically because of how the orbit eyes work, as you steer, the axle will shift side to side. Running an orbit on one end is fine but you will see that your axle will move side to side. A friend of mine has this on his Tacoma and his turning radius isn't good.

[QUOTE=skipstr


Westy... I really do want the biggest tire I can get on.. just a few things hold me back from going to 38's.. A: I have the 3.slow and even with the 5.29's my truck is just a dog on the hills of nor cal.. B: is that I think that I would have to do a lot of trimming to fit them.. even when I had the fresh 35's and I flexed it out, the rear got into the fender and mangled it up a bit.. I have plans to hack the fenders up as my truck progresses. Right now its a pretty clean truck when its all together... but I am really trying to find some used tires so if I come across some 38's I would jump on it and deal with it..

[/QUOTE]

I think you'll find you can do some trimming and still make it look VERY good and clean. I agree, Toy motors and 38s arent a great combo but you can always modify the engine if need be, but it definitely depends if this is a DD or trail only rig...etc. btw 38.5 " SXs measure about the same as a 37" MTR.

Heres Roc Dog's old 4runner on 38s - example of the trimming needed without having a huge lift -
http://www.pirate4x4.com/forum/attachment.php?attachmentid=59074&stc=1&d=1049960376
http://www.pirate4x4.com/forum/attachment.php?attachmentid=59075&stc=1&d=1049960407

I have plans to hack the fenders up as my truck progresses. Right now its a pretty clean truck when its all together...

I agree with Westy. You can do a really clean job of fender hacking if you take your time. I haven't looked at a pickup bed, but it's gotta be easier than a 4Runner. I cut my 4Runner rear fenders (http://www.pirate4x4.com/forum/showthread.php?t=386066)and if I put a little trim on the edges I think it would look factory. If I can do a decent job with my complete lack of experience, you should be able to do a great job. :)

Looking very good so far.....You might wanna start thinking about a "panhard bar" to keep it centered under the truck. I would also be looking for the front to have the "wandering" effect......I think I would only keep the orbital eyes on the rear spring not on the front on a street driven truck....just my 2 cents... :cool2:

Basically because of how the orbit eyes work, as you steer, the axle will shift side to side. Running an orbit on one end is fine but you will see that your axle will move side to side. A friend of mine has this on his Tacoma and his turning radius isn't good.


Ah... I understand.. I am hoping it isnt that bad.. cuz this is going to be more of a DD for now than a trail rig.. As time goes on that will change but the truck is still kinda nice.. I may have to take up Shaker's idea of a panhard bar if it is a wondering fool...

Westy.. I love the look of the 38's and the addes ground clearence of 38's over 36's is what i want... (for referance those are 35" mtr's in the pics).. The thing is its gonna be more of a DD than trail rig for a little bit.. I am wondering if he had to tub the inner fenderwell... Its obvious he trimmed the fenders and thats not to big to do... I'm trying not to trim the wall between my cab and the wheel well... for now anyways... Also I am concerned about breakage. Yea I am only locked in the rear so the birfeilds may be saved for now but they will get thrashed with the 38's.. I agree that Roc Dogs truck is what I want mine to sit like though.. I love the low lift big tires look..

Well I got it to sit on all fours.. The front axle is now 2.5" forward.. and it shows.. Its just slightly higher in the front which is ok cuz the rears are broken in, and there is still no bumper or weight up front..

http://img.photobucket.com/albums/v208/skipstr71/aa5e2a74.jpg

http://img.photobucket.com/albums/v208/skipstr71/5439f249.jpg

I'm wondering if this is what angle it should look like.. I obviously have to trim the body mount for the movment of the shackle..

http://img.photobucket.com/albums/v208/skipstr71/41297618944.jpg

Now I see that my tie rod is going to make contact with my oil pan.. With the 4"+ lift and 2.5" forward axle location I am suprized.. So I may have to massage it with a hammer, ar cut it up and moddify it... Its close but I can see its just not gonna clear.. other than than and the suprizingly soft front springs I am happy so far.. Skys wheel widening kit was tight but went on with a 20 ton press... The truck should be going by the end of the week.. without shocks anyways..

Thanks for all your help guys..!

I have high steer on my 93' 3.0 V6 pick-up, and my drag link hit my oil pan at times. To cure this I got an oil pan, windage tray and oil pump pick up from a 2wd 3.0 pick-up and It works great because the sump is in the rear of the pan, way more drag link clearence. Cost about $250 for parts from the dealer. You might be able to find them used for cheaper.

I think you'll find you can do some trimming and still make it look VERY good and clean. I agree, Toy motors and 38s arent a great combo but you can always modify the engine if need be, but it definitely depends if this is a DD or trail only rig...etc. btw 38.5 " SXs measure about the same as a 37" MTR.

Heres Roc Dog's old 4runner on 38s - example of the trimming needed without having a huge lift -
http://www.pirate4x4.com/forum/attachment.php?attachmentid=59074&stc=1&d=1049960376
http://www.pirate4x4.com/forum/attachment.php?attachmentid=59075&stc=1&d=1049960407
that pic is funny to me cause that is my truck in the backround:laughing: or how it used to look a long time ago:D

Skipstr,

You're welcome...looks great so far. Wow hadn't thought about the wandering with orbit eyes on front springs...personally if it's a problem, I'd just runn regular poly bushings in the front springs and leave the orbit eyes in the rear springs only. Panhard bar is just one more thing to break! They look great when they tear off the frame out in the boonies, seen it too many times.

36" tires are plenty big for DD...38"s will kill your birfields, mileage (even worse than my 36 tsl sxs :D )