2.5in lift YJ's front and TJ coils rear, between the rear steer and the fact the front didn't flex 1/8 of what the rear did unless it was backed up something as seen here, it didn't work to hot...


ok here's a before pic...

ok after a nice crash of my comp i'll try to finish this thread tonight!

here's the front Waggy D44 all gutted and cleaned and narrowed to 58in and getting ready to install teh spring over plate on teh pass side ;)

ok here's the new D44 front all narrowed and sprung over... ready to get stuffed up in the beast...

since the springs have been outboarded so far, we had to include the rear shackle hanger into a new body mount at the same time..

the front spring bucket's also sat outside the frame... so we made a pretty heavy gusset for it...

since we didn't want to change the master/booster, and we were using ford 5 on 5.5 hub's we mounted the stock sami rotors to the ford hub's (perfect fit) and modified the caliper bracket accordingly...

the offset of the zuk calipers was perfect to use a small piece of 3/8 plate and adapt them right together :)

well here she sit's under the rig... 58in wide D44 5.38's and a Lock-Rite, all from Randy's ;)

the tie rod is the stock waggy cut down 3in and sleved with pipe, and it was a DAMN tight fit to pund in there... the drag link is similar material with hyme's for ends


the spring's are 5 leaf YJ's with the 2nd leaf from the 2.5in lift YJ's added as a 2nd leaf to these packs...

he wanted to lower the ride from before, we got approx 1.5in drop, it's perfect :D

and the rear offset D44 was 58in wide already, and 5 on 5.5, so all we did for it was add some 5.38's and a spool (welded)

for the brakes we adapted the sammi caliper's to the flange for the axle, total bolt on deal and the rotor's slid perfectly over the axle flanged using the studs for centering...

and another angle of the rear brakes...

and here's a pic of it all finished, minus shocks and flexed up on teh stair's at the neighbors, actually gained some travel and at 53degrees with 3 ppl pushing against it it would not go over, granted we could have pushed alot harder, but it was damned stable...


the rear spring's are 5 leaf YJ's with the main leaf from a 2.5in lift YJ pack cut down and used as the 2nd leaf


all 4 corner's will be roudned out with RS9012's sicne that's what he had on it before, a lil sawzall action is in order for some more clearance on teh fender's...

the brakes will lock the tires up no problem, and it handles 10x better at road speeds than before... not to mention it travels alot farther!!!

Shit, well i guess we won't have all those :beer: breaks waiting on him to change is broken axles anymore. :flipoff2:

Originally posted by AMJ
Shit, well i guess we won't have all those :beer: breaks waiting on him to change is broken axles anymore. :flipoff2:


to bad i seriously thing the next weak link is gonna be the t-case...

:flipoff2: :flipoff2: :flipoff2: :flipoff2: :flipoff2:

How far did you have to outboard the springs in comparison to the stock spring mounts?

Thanks for posting all those pics !!! I'm doing a toy swap with leaf fronts and coil rears but I know when I was researching my options it was hard to find several shots of one rig to see the whole picture... Looks cool !!! I dig the custom brake parts.... This board rules !

-yag

Originally posted by weezman1
How far did you have to outboard the springs in comparison to the stock spring mounts?

the front spring's are stock toy width @ 29in center to center, and the rear's are set with the frame in the rear @ 31in center to center, stock zuk front is 28 and rear is 37 :D

the wheelbase is also 86in :D

Very nice work....

Who is doing the work?

hay fatty


dave (dsi) and i did all of it we started last tusday or wensday and done with it drove it out of the shop on sunday after noon the thing is sweet stable as all heck i have a thouse steps in my back yard and shit i have drove over them like 20 times when i had the coils was scared shitless to even go up that far its kinda giving me a new look on things :)


Dan :massey:

DSI


thanks for all your help now i get ot go play on the rocks trails what ever and not have to worry about thouse stupid sammi axles :mad3: :mad3: but trust me im not going to be easy on those 44 :)


Dan :massey:


o i think i need to go and find about those 37x13 :):)

Originally posted by moto261
i think i need to go and find about those 37x13 :):)


Bogger's = :rainbow: :rainbow: :rainbow: :rainbow: :rainbow: :rainbow: :rainbow: :rainbow: :rainbow: :rainbow:

two questions.

Which ranchos are you using (part number) ?
How much up travel do you have ?

Hank

Originally posted by Hank
two questions.

Which ranchos are you using (part number) ?
How much up travel do you have ?

Hank


9012's (were on it before) the rear's are angled back 35degrees and have 5 1/4in showing, the front's are angled back 8 degrees and have 6 showing, the bump stops are set with 1/4in compression left...

Nice work guys! I think the 37's sound adequite!

no the 37"mtr


:flipoff2: :flipoff2: :flipoff2: :flipoff2: :flipoff2:



dan :massey:

Originally posted by moto261
no the 37"mtr


:flipoff2: :flipoff2: :flipoff2: :flipoff2: :flipoff2:



dan :massey:


so in otherwords a BIG pack of sawzall blades to clerance the bastage will be in order :flipoff2:

not needed :flipoff2: :flipoff2: :flipoff2: i got it going on :rasta:



Dan :massey:

Originally posted by DSI



Bogger's = :rainbow: :rainbow: :rainbow: :rainbow: :rainbow: :rainbow: :rainbow: :rainbow: :rainbow: :rainbow:

Lick me
:flipoff2:

hay ever one thoes tires are for sale $800 payed $1000 three weeks ago:)

Dan :massey:

BTT for destroyer dychen :flipoff2:


hope tis answer's all your Q's dude..

Did you mig weld that springpad on the D44 casting ? And if so has anyone had problems with the pad welded on the cast ?

First, great work. Looks very clean.

But I don't "get" something.

Why downgrade the brakes to Mickey Mouse Suzuki stuff? Surely adding a new MC for the big brakes isn't that big a deal?

Or am I missing something else?

r@m

Originally posted by Root Moose
First, great work. Looks very clean.

But I don't "get" something.

Why downgrade the brakes to Mickey Mouse Suzuki stuff? Surely adding a new MC for the big brakes isn't that big a deal?

Or am I missing something else?

r@m


the reason was simple... budget... Dan had about 10 set's of zuk rotors and calipers sitting around, and the rig is very light, and the zuk brakes proved to be 110% adequate, the thing stop's HARD on demand...

and no one else has done it so why not be origional :confused:

With the Sam brakes front and rear, did you use the stock brake distro block or do something else?

r@m

Originally posted by Root Moose
With the Sam brakes front and rear, did you use the stock brake distro block or do something else?

r@m


with the exception of line lock's everything's exactly as it was from suzuki...

Hey DSI do you have any more pics of the front passanger side knuckle before you welded the perch on?

Also, how did you get your the area flat enough so that your angles would be correct

I.E. did you use a combo of sawsall and grinder, or just straight grinding.

Also, did you chop some tube off the passanger side of the housing so you could rotate the pinion up and still keep your stock camber angles on the knuckles. I can see some tack welds on both knuckles.

Thanks

8 months and a buggy later....:rolleyes:

Originally posted by MuddMachine
Did you mig weld that springpad on the D44 casting ? And if so has anyone had problems with the pad welded on the cast ?

I have had no problems MIG welding spring pads onto cast housings. I grind the cast until it is nice and shiney shiney and weld it on.

Originally posted by moto261
dave (dsi) and i did all of it we started last tusday or wensday and done with it drove it out of the shop on sunday after noon the thing is sweet stable as all heck i have a thouse steps in my back yard and shit i have drove over them like 20 times when i had the coils was scared shitless to even go up that far its kinda giving me a new look on things

Thank god you let dave snap the pics...:flipoff2:

I love it! You guys do some sick work. When do you get to test it out on the trail moto? Looks bad ass!

Originally posted by Lav25
Hey DSI do you have any more pics of the front passanger side knuckle before you welded the perch on?

Also, how did you get your the area flat enough so that your angles would be correct

I.E. did you use a combo of sawsall and grinder, or just straight grinding.

Also, did you chop some tube off the passanger side of the housing so you could rotate the pinion up and still keep your stock camber angles on the knuckles. I can see some tack welds on both knuckles.

Thanks


THIS IS DSI... I can't seem to log kris off her computer!

anyhow..

we used a 7in angle grinder with a cutoff wheel to smooth that perch, just cut it nice and flat at the angle we needed after setting the axle in place and checking it... if you check the date's on this origional post you'll see it's a year old now, so i highly doubt there's any pic's left :(

the knuckle welds were ground off, and a big hammer used to rotate them back to 6 1/2 degree's

Originally posted by heshers3
I love it! You guys do some sick work. When do you get to test it out on the trail moto? Looks bad ass!

DSI again...

check the date on the origional post ;) this thread is a year old :flipoff2: it's been trail thrashed for a year now, even ran the last calROCS last season... first thing he broke on it was yesterday, and it split a stubshaft...

Originally posted by RocKrawler


Thank god you let dave snap the pics...:flipoff2:


dan wasn't smart enough to use a camera a year ago :flipoff2:


BTW, when the DSL comes back up and i can use my computer again, i've got a pic to prove just how smart moto isn't :D

Originally posted by heshers3
I love it! You guys do some sick work. When do you get to test it out on the trail moto? Looks bad ass!

My bad. I'm retarded. Maybe i should try reading next time... :D

Originally posted by BrewCrew
8 months and a buggy later....:rolleyes:


12 months... and being as this is moto's rig, not mine... the only change since then has been an upgrade in tire size... so if you could please do a bit more looking around before posting stupid shit, i'm sure the rest of the world would be a much safer place.

thank you :flipoff2: