Thought I'd post up this project here as well since it has some cool shit involved and some of you don't wander out of this forum much. This thread for the most part will be copied/pasted from the existing thread on my site.

PD's Drivetrain Upgrade

This project has been long in the making and with the arrival of the Scout yesterday afternoon via transporter from Tennessee we can now begin the progress.

Most would be very happy with this Scout as it already has a SOA lift with reverse shackle, front ARB differential, rear Warn full float axle kit, a 'built' 727 Torqueflite transmission, an Atlas transfer case, and more. Take a look at the pictures as this Scout is no slouch. But where theres a will, theres a way and we at IH Only North know how to take any vehicle to the next level.

So here is the list of upgrades that will be performed on this Scout while it is here -

1. The 727 TorqueFlite transmission will swapped out in favor of a B&M Racing GM 700R4 transmission using a Blackwood Labs transmission adapter.

2. A Klune-V will be installed between the transmission and Atlas transfer case.

3. A Curry Rock Jock Hi-Pinion Dana 60 will be installed in the rear set-up with a ARB differential, 4.88 Yukon gears, 35 spline Curry shafts, and 12" Wildwood disc brakes w/ internal drum style parking brake.

4. We are going to build what is called a '609' front axle(not to be confused this is not a Unimog 609 axle). The center section will be a Hi-Pinion 9" from Hi-9 set-up with 4.88 reverse cut gears and a ARB differential. The center section will be mounted into a SpiderTrax housing equipped with Dedenbear/Reid Racing 'C's and kingpin type knuckles. 4 piston Wilwood aluminum calipers will be installed on custom 5 lug hub/rotors.

5. All new custom exhaust.

6. Rear 4-Link Coil suspension.

7. Front 3 Link Coil-Over suspension.

Below are pictures of some of the products that we will be using on this build.

http://www.ihonlynorth.com/forums/attachments/ih-only-build-ups/1212d1201384239-pds-drivetrain-upgrade-img_1018.jpg

http://www.ihonlynorth.com/forums/attachments/ih-only-build-ups/1213d1201384239-pds-drivetrain-upgrade-img_1052.jpg

http://www.ihonlynorth.com/forums/attachments/ih-only-build-ups/1214d1201384239-pds-drivetrain-upgrade-img_1053.jpg

http://www.ihonlynorth.com/forums/attachments/ih-only-build-ups/1215d1201384239-pds-drivetrain-upgrade-img_1054.jpg

http://www.ihonlynorth.com/forums/attachments/ih-only-build-ups/1216d1201384239-pds-drivetrain-upgrade-img_1059.jpg

http://www.ihonlynorth.com/forums/attachments/ih-only-build-ups/1217d1201384239-pds-drivetrain-upgrade-img_1063.jpg

http://www.ihonlynorth.com/forums/attachments/ih-only-build-ups/1218d1201384239-pds-drivetrain-upgrade-img_1065.jpg

http://www.ihonlynorth.com/forums/attachments/ih-only-build-ups/1219d1201384239-pds-drivetrain-upgrade-img_1067.jpg

http://www.ihonlynorth.com/forums/attachments/ih-only-build-ups/1220d1201384239-pds-drivetrain-upgrade-img_1210.jpg

Thats a Tall Boy can by the way and yes we plan on using the larger flex joints on this build.

http://www.ihonlynorth.com/forums/attachments/ih-only-build-ups/1222d1201384449-pds-drivetrain-upgrade-img_1262.jpg

Jeff Ismail
WWW.IHONLYNORTH.COM
Authorized Scout LightLine Distributor
Custom Built Scout's and Components. Performance Parts, Service, and Custom Fabrication.
CPT - Crawler Proven Technology
Online Store, Photo Gallery, and now FORUMS!
WWW.ALLTERRAINCARTS.COM
Suspensioned Mig Welding Carts

Pic of the Scout arriving from its long journey.

http://www.ihonlynorth.com/forums/attachments/ih-only-build-ups/1223d1201385438-pds-drivetrain-upgrade-img_1384.jpg

Pics of the Scout before we start.

http://www.ihonlynorth.com/forums/attachments/ih-only-build-ups/1226d1201386694-pds-drivetrain-upgrade-img_1397.jpg

http://www.ihonlynorth.com/forums/attachments/ih-only-build-ups/1227d1201386694-pds-drivetrain-upgrade-img_1399.jpg

http://www.ihonlynorth.com/forums/attachments/ih-only-build-ups/1228d1201386694-pds-drivetrain-upgrade-img_1403.jpg

http://www.ihonlynorth.com/forums/attachments/ih-only-build-ups/1229d1201386694-pds-drivetrain-upgrade-img_1401.jpg

http://www.ihonlynorth.com/forums/attachments/ih-only-build-ups/1230d1201386694-pds-drivetrain-upgrade-img_1400.jpg

http://www.ihonlynorth.com/forums/attachments/ih-only-build-ups/1231d1201386694-pds-drivetrain-upgrade-img_1402.jpg

http://www.ihonlynorth.com/forums/attachments/ih-only-build-ups/1232d1201386694-pds-drivetrain-upgrade-img_1404.jpg

http://www.ihonlynorth.com/forums/attachments/ih-only-build-ups/1233d1201386694-pds-drivetrain-upgrade-img_1405.jpg

http://www.ihonlynorth.com/forums/attachments/ih-only-build-ups/1234d1201386694-pds-drivetrain-upgrade-img_1406.jpg

Teardown is slated to begin in the next two weeks so stay tuned.
________
Jeff Ismail
WWW.IHONLYNORTH.COM
Authorized Scout LightLine Distributor
Custom Built Scout's and Components. Performance Parts, Service, and Custom Fabrication.
CPT - Crawler Proven Technology
Online Store, Photo Gallery, and now FORUMS!
WWW.ALLTERRAINCARTS.COM
Suspensioned Mig Welding Carts

Nice starting point.
Looking forward to the build.

this one made me wonder...

http://www.ihonlynorth.com/forums/attachments/ih-only-build-ups/1217d1201384239-pds-drivetrain-upgrade-img_1063.jpg

Is this scout going to be used as a wheeler after this build?
Interesting build but seems like a waste of good parts that won't be used if it's a pavement pounder.

Is this scout going to be used as a wheeler after this build?
Interesting build but seems like a waste of good parts that won't be used if it's a pavement pounder.

Double duty so to speak. The owner wants to be able drive it to the trail, wheel it, and drive it home.
________
Jeff Ismail
WWW.IHONLYNORTH.COM
Authorized Scout LightLine Distributor
Custom Built Scout's and Components. Performance Parts, Service, and Custom Fabrication.
CPT - Crawler Proven Technology
Online Store, Photo Gallery, and now FORUMS!
WWW.ALLTERRAINCARTS.COM
Suspensioned Mig Welding Carts

Im diggin the CAROLINA sticker in the backgorund, its bound to be a great build on that point alone. :D:D.

http://www.ihonlynorth.com/forums/attachments/ih-only-build-ups/1217d1201384239-pds-drivetrain-upgrade-img_1063.jpg

I will be following this build, great start Jeff.

Those parts pics have some serious bling. Looking forward to the 609 axle build, among other things. Why the 5 lug? Keeping the current wheels and tires?

Hmmmm......I'm from TN.....who does that belong to? Well...at least what county in on the license plate...

Can't wait to see how this comes together.

bling bling for sure.

http://www.ihonlynorth.com/forums/attachments/ih-only-build-ups/1217d1201384239-pds-drivetrain-upgrade-img_1063.jpg

Oooooo.... dual torque converters.... cool. :smokin: :flipoff2::flipoff2::flipoff2:

Those parts pics have some serious bling. Looking forward to the 609 axle build, among other things. Why the 5 lug? Keeping the current wheels and tires?

Yes, for now the 15" wheels are going to be reused.

Hmmmm......I'm from TN.....who does that belong to? Well...at least what county in on the license plate...

Montgomery. The Scout belongs to Paul3 on this board and BB.

Can't wait to see how this comes together.

Me too!

bling bling for sure.

:smokin:

http://www.ihonlynorth.com/forums/attachments/ih-only-build-ups/1217d1201384239-pds-drivetrain-upgrade-img_1063.jpg

Oooooo.... dual torque converters.... cool. :smokin: :flipoff2::flipoff2::flipoff2:

Yup! Were going to mount them before and aft of the tranny:laughing:
(joking)
________
Jeff Ismail
WWW.IHONLYNORTH.COM
Authorized Scout LightLine Distributor
Custom Built Scout's and Components. Performance Parts, Service, and Custom Fabrication.
CPT - Crawler Proven Technology
Online Store, Photo Gallery, and now FORUMS!
WWW.ALLTERRAINCARTS.COM
Suspensioned Mig Welding Carts

Very nice stuff. Can't wait to see it come together!

Nice budget build for sure :flipoff2:


Nice starting point.
Looking forward to the build.


Just by looking at the nice clean paint from the last upgrades, SOA and all that this is all going to waste IMHO. Plenty of bling and a owner that wont use it.

Still it will be nice to see Jeff build this thing and all those $$ parts!

Nice budget build for sure :flipoff2:

Just by looking at the nice clean paint from the last upgrades, SOA and all that this is all going to waste IMHO. Plenty of bling and a owner that wont use it.

Still it will be nice to see Jeff build this thing and all those $$ parts!

You never know if the owner has spent the better part of 3 of the last 5 years in Iraq and hasn't had the time you have to do what he'd like. Thanks for the opinion though.

Yup I've never been there, 2 Stans, Bosnia or any other place in my 14 years of service :shaking:

So welcome back. Why not wheel it before tearing it a part again? Or get another Scout for Jeff to build since this is a huge build on it's own?

Forgot: That interior is almost nice enough to eat off of. Did Bills purple Scout rub off on ya? I say this because I spent a couple years and plenty of $$ on a ScoutII almost as nice as your starter and hated it because I was too wimpy to tear it up. So after a couple years I parted most of it and started with beater Scouts as starter points and much happier. I hope you dont regret down the line starting with something that nice.

Not everyone wants there junk to look like a walnut. I have been tossing the idea around on making some jeep tape for the Scout. These would be some rear quarter skins made out of 11 ga that would provide some protection.

What up with all the small KN air filters? Axles and t/c vents?

Yup I've never been there, 2 Stans, Bosnia or any other place in my 14 years of service :shaking: Ahh Bosnia another great STX. I personally loved the overflowing blue canoes and the ankle deep mud, but at least we all got home by Christmas right? You get out or still serving? Marine Corp, Army?

Forgot: That interior is almost nice enough to eat off of. Did Bills purple Scout rub off on ya? I say this because I spent a couple years and plenty of $$ on a ScoutII almost as nice as your starter and hated it because I was too wimpy to tear it up. So after a couple years I parted most of it and started with beater Scouts as starter points and much happier. I hope you dont regret down the line starting with something that nice.
I'm not familiar with Bills purple Scout but thanks for the comment. I've been working on this Scout for 12 years now and I try to keep it looking good. I've tried to overbuild this Scout from day one. I'm not into tearing the sheet metal off of it and I'm not going to win any rock crawling event with it, but I'm not worried about it breaking on me either. The Scout is my thing that I refuse to have any regrets about...plenty of other shit in life to fill that slot.

I'd like to build an 80 or 800, using the parts coming off this build, but with the deployment schedules it's not going to happen for several years down the road. Six to retirement and then we'll see.

What up with all the small KN air filters? Axles and t/c vents? There just $2.50 generic filters from Advanced Auto Parts for breathers. Got the idea from someone on this board awhile back.

I'm in the guard now so basicly out. 5AD Army tanker, 7.5AD USAF Security forces, rest is Air guard, biomedical. Part of that is AD but Texas may suck but it still isnt Iraq. I'm trying to make it but I've dodged the last 4 volunteer Iraq missions and our AEF rotation is comming around again :shaking:. So hopefuly less then 2 more deployments before I retire.

Enough sidetracking however, back to the ScoutII.


What tire size are you going to run?

Cage plans?

Next set may be 37's. Full 6 point cage.

For a truck in TN that's been off-road, there's surprisingly little body damage. Perhaps it's only been off-pavement?:flipoff2:

Edit: And...Thanks for your service! :smokin:

I'm not familiar with Bills purple Scout but thanks for the comment. I've been working on this Scout for 12 years now and I try to keep it looking good. I've tried to overbuild this Scout from day one. I'm not into tearing the sheet metal off of it and I'm not going to win any rock crawling event with it, but I'm not worried about it breaking on me either. The Scout is my thing that I refuse to have any regrets about...plenty of other shit in life to fill that slot.

I'd like to build an 80 or 800, using the parts coming off this build, but with the deployment schedules it's not going to happen for several years down the road. Six to retirement and then we'll see.

Comparing your truck to Bill's is a major compliment. He took a PILE and made a very nice DD/wheeler out it while driving it to work each morning during its rebuild. He then shipped it across the ocean and drove it and wheeled all over that part of the world. That scout has seen more sights than most of us will ever see.

So in 6 years you and Bill can enjoy your bling/built trucks while the rest of us try to find the time or the parts to be able to wheel our junk. Time being my major hurdle!!

Gonna be a crazy build!! Love it.

Thanks for your service to our country!!!

Nothing too exciting yet. We got the Scout running first before tearing it down as it was delivered to us with a fuel injection problem. After a test drive the drivetrain was removed, a bunch of brackets were ground off, and some mocking up has started. Tedious time consuming work so not a whole lot of excitement yet.

http://www.ihonlynorth.com/forums/attachments/ih-only-build-ups/1319d1202675795-pds-drivetrain-

Nice pile of parts.

http://www.ihonlynorth.com/forums/attachments/ih-only-build-ups/1325d1202677976-pds-drivetrain-

The Blackwood labs adapter was bolted in.

http://www.ihonlynorth.com/forums/attachments/ih-only-build-ups/1326d1202677976-pds-drivetrain-

We started mockup of the 700R4/Klune-V/Atlas.

http://www.ihonlynorth.com/forums/attachments/ih-only-build-ups/1329d1202677976-pds-drivetrain-

Dan from RuffStuff delivered to us a bunch of the link brackets that we are going to use for the suspension.

http://www.ihonlynorth.com/forums/attachments/ih-only-build-ups/1330d1202677976-pds-drivetrain-

Look for more progress next week.
________
Jeff Ismail
WWW.IHONLYNORTH.COM
Authorized Scout LightLine Distributor
Custom Built Scout's and Components. Performance Parts, Service, and Custom Fabrication.
CPT - Crawler Proven Technology
Online Store, Photo Gallery, and now FORUMS!
WWW.ALLTERRAINCARTS.COM
Suspensioned Mig Welding Carts

http://www.ihonlynorth.com/forums/attachments/ih-only-build-ups/1319d1202675795-pds-drivetrain-




This pic scares me. How steady is that thing with the jack stands so close together? I'm sure its totally safe and what not, its just a freaky picture.

This pic scares me. How steady is that thing with the jack stands so close together? I'm sure its totally safe and what not, its just a freaky picture.

Its hard to see but if you look towards the front of the Scout I have my extra heavy duty steel cart also under the front of the frame supporting the weight. Better angle of it seen here.

If someone could photochop out the jackstands it would look like a hoverscout.:homer:
________
Jeff Ismail
WWW.IHONLYNORTH.COM
Authorized Scout LightLine Distributor
Custom Built Scout's and Components. Performance Parts, Service, and Custom Fabrication.
CPT - Crawler Proven Technology
Online Store, Photo Gallery, and now FORUMS!
WWW.ALLTERRAINCARTS.COM
Suspensioned Mig Welding Carts

that was way to easy, no shadows to even copy.

One hover Scout

had to brighten the pic to make it look better:laughing:

http://www.ihonlynorth.com/forums/attachments/ih-only-build-ups/1222d1201384449-pds-drivetrain-upgrade-img_1262.jpg


I could sure use 6 of those. How much info would you share on the front 3 link? Calc #s ? Thanks

Sweet! Looks like a fun project Jeff. It sure is nice when they are that clean to start with and not a complete resurection from the grave or grease pile. You separating the frame from the tub to allow easier access for welding or powder coating after mocking up and tacking?

Good Times:cool2:

had to brighten the pic to make it look better:laughing:

Does it have a flex capacitor too? :p

Updates?

Sorry for not updating this build. Honestly not much has been done on this project since the teardown. We made a final decision on rear coils, shocks, and front coilovers and ordered them in with a promise date of three days for delivery. I even paid extra as this one vendor said he had everything in stock. Its been close to a month and I'm still waiting for the rear coils and shocks:mad3:.

We did get in the front Bilstein coilovers and the rear Curry bridge. We'll get hustling on this project soon as the remaining parts arrive.
________
Jeff Ismail
WWW.IHONLYNORTH.COM
Authorized Scout LightLine Distributor
Custom Built Scout's and Components. Performance Parts, Service, and Custom Fabrication.
CPT - Crawler Proven Technology
Online Store, Photo Gallery, and now FORUMS!
WWW.ALLTERRAINCARTS.COM
Suspensioned Mig Welding Carts

Were the choices of axles and such Pauls, Jeffs, or both? Im just curious as to how you decided the 9 in front and 60 rear. I was leaning to hi9 rear and hp44/60, hi9/60, or just a hp60 front

Were the choices of axles and such Pauls, Jeffs, or both? Im just curious as to how you decided the 9 in front and 60 rear. I was leaning to hi9 rear and hp44/60, hi9/60, or just a hp60 front

This is one of those projects that started with a short list of modifications/upgrades and then grew into what it is today. Originally Paul was slated to bring in his Scout for the 700R4 conversions that we have been performing as of late. Then he talked about wanting a rear Dana 60 and so that was added to the list. Then Paul mentioned that he wanted a Klunve-V installed so we switched the rear low pinion Dana60 in favor for the Curry Hi-pinion 60. I then asked Paul what his plans were for the front end(since the Scout would already be here) and he told me he's always wanted a D60 front. I then told Paul how I always wanted to build a 609. He liked the idea so we added that to the list. I forget how the link suspension came into play but then it was added along with a complete cage and power window conversion.

So to answer your question the choices were both of ours.
________
Jeff Ismail
WWW.IHONLYNORTH.COM
Authorized Scout LightLine Distributor
Custom Built Scout's and Components. Performance Parts, Service, and Custom Fabrication.
CPT - Crawler Proven Technology
Online Store, Photo Gallery, and now FORUMS!
WWW.ALLTERRAINCARTS.COM
Suspensioned Mig Welding Carts

looking great keep up the good work

We made some progress on this so I thought I'd update the thread.

The B&M 700R4 was installed next along with the Klune-V and Atlas transfer case. With no body lift there was just enough room for the whole combo to fit without any cutting of the floor.

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1538&stc=1&d=1206999239

More parts started rolling in. We got the rest of the RE joints in.

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1540&stc=1&d=1206999239

Darren started mocking them up in some of the various RuffStuff brackets.

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1545&stc=1&d=1206999239

With the rear housing setting under the Scout we had a better idea of what we needed to do.

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1542&stc=1&d=1206999239

Which was strengthen the frame so frame reinforcement plates were made out of 1/4" strap.

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1543&stc=1&d=1206999239

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1544&stc=1&d=1206999239

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1546&stc=1&d=1207000339

We decided to go with Bilsteins new 14" RC9100 Rock Crawler Series Coilover. These are about as good as it can get. They have a real nice digressive valving that according to Bilstein this valving will greatly enhance vehicle stability while reducing impact harshness. Utilizing the digressive valving, wheel hop, front to rear/side to side weight transfer, erratic spring unload, and sway will greatly be reduced.

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1547&stc=1&d=1207000339

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1548&stc=1&d=1207000339

We also ordered in the matching Curry truss to make mounting the top links a little simpler.

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1549&stc=1&d=1207000339
________
Jeff Ismail
WWW.IHONLYNORTH.COM
Authorized Scout LightLine Distributor
Custom Built Scout's and Components. Performance Parts, Service, and Custom Fabrication.
CPT - Crawler Proven Technology
Online Store, Photo Gallery, and now FORUMS!
WWW.ALLTERRAINCARTS.COM
Suspensioned Mig Welding Carts

Darren started installing the frame plates by first tacking them on.

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1550&stc=1&d=1207003601

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1551&stc=1&d=1207003601

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1552&stc=1&d=1207003601

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1553&stc=1&d=1207003601

Once they were tacked in place Darren spent the better part of a day welding them completely on.

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1554&stc=1&d=1207003601

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1555&stc=1&d=1207003601

Next Darren started the mockup of the upper axle link mounts.

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1556&stc=1&d=1207003601
________
Jeff Ismail
WWW.IHONLYNORTH.COM
Authorized Scout LightLine Distributor
Custom Built Scout's and Components. Performance Parts, Service, and Custom Fabrication.
CPT - Crawler Proven Technology
Online Store, Photo Gallery, and now FORUMS!
WWW.ALLTERRAINCARTS.COM
Suspensioned Mig Welding Carts

With measurements made Darren began tack welding on all the various links and link mounts. We used HREW tubing for the mockup of the links and will replace with the actual DOM when all measurements are finalized.

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1557&stc=1&d=1207004129

We mounted the lower links to frame outriggers from RuffStuff Specialties.

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1558&stc=1&d=1207004129

Some last minute adjustments were made before we cycle the suspension to check fit.

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1560&stc=1&d=1207004129

Suspension at full droop. Pinion angle still looks good!

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1561&stc=1&d=1207004129

Pic of the upper links and mounts.

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1562&stc=1&d=1207004129

Once we remove the electric fuel pump and filter that is currently mounted above the axle we should be able to cycle the suspension upward another 2"-3".

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1563&stc=1&d=1207004129

Darren then tack welded in the coil spring mounts and popped in the coils.

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1564&stc=1&d=1207004129

And with the springs in we were able to set the Scout down on the coils for the first time.

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1565&stc=1&d=1207004129
________
Jeff Ismail
WWW.IHONLYNORTH.COM
Authorized Scout LightLine Distributor
Custom Built Scout's and Components. Performance Parts, Service, and Custom Fabrication.
CPT - Crawler Proven Technology
Online Store, Photo Gallery, and now FORUMS!
WWW.ALLTERRAINCARTS.COM
Suspensioned Mig Welding Carts

How do you like your Ruff Stuff brackets?

You know Jeff you should sell some frame rail protectors. More of a contoured angle iron with some speed holes, made out of 1/8" Angle (save a little weight).

My frame looks like a $10 whore, beat to piss, and tore up.

Nice, that is lookin good ! I thought I was the only one welding in shorts :grinpimp:

Great work on this.

What are the rear coils?

Nice, that is lookin good ! I thought I was the only one welding in shorts :grinpimp:


Shorts and flip flops! Propper PPE is #1 priority! :flipoff2:


Looking good Jeff.

Jeff if I promise not to tell anyone you once got arrested for stalking Barry Gibb would you work over my scout for me?

Jeff if I promise not to tell anyone you once got arrested for stalking Barry Gibb would you work over my scout for me?

Why you're too busy playing with little boys to wheel.

What is the axle widths wms/wms, and how did you decide on the width?

How do you like your Ruff Stuff brackets?

They are top notch!

You know Jeff you should sell some frame rail protectors. More of a contoured angle iron with some speed holes, made out of 1/8" Angle (save a little weight).

My frame looks like a $10 whore, beat to piss, and tore up.

Definitely doable. If the market is there we can have them made.

Nice, that is lookin good ! I thought I was the only one welding in shorts :grinpimp:

Thanks.

Great work on this.

What are the rear coils?

4.5" 400# 18" tall to start with but this may change.

Shorts and flip flops! Propper PPE is #1 priority! :flipoff2:


Looking good Jeff.

Thanks.

Jeff if I promise not to tell anyone you once got arrested for stalking Barry Gibb would you work over my scout for me?

Sure. Just keep the Boy George thing quiet :bender:.

What is the axle widths wms/wms, and how did you decide on the width?

We planned on 63" wide axles but that is already changing. We first decided on the 63" wide axles as Paul really liked the stance on the fancy orange Scout we built last year which had 63" wide axles front/rear. As we mocked things up we have come to the conclusion that the front is going to have to be at least 67" wide in order for everything to fit. Once we finalize this measurement I will be ordering in another rear housing/shafts since it was built at 63" wide.
________
Jeff Ismail
WWW.IHONLYNORTH.COM
Authorized Scout LightLine Distributor
Custom Built Scout's and Components. Performance Parts, Service, and Custom Fabrication.
CPT - Crawler Proven Technology
Online Store, Photo Gallery, and now FORUMS!
WWW.ALLTERRAINCARTS.COM
Suspensioned Mig Welding Carts

With the mock up of the rear suspension complete Darren then moved on to the mock up of the front suspension.

First the Tru Hi-9 third member was temporarily bolted on to the Spidertrax housing.

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1615&stc=1&d=1208734081

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1616&stc=1&d=1208734081

Darren then placed the housing under the Scout and began mounting of the axle housing brackets.

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1614&stc=1&d=1208734081

In order to fit the housing Darren made a few cuts on the custom made link bracket.

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1617&stc=1&d=1208734081

At this point Darren and I couldn't decide on whether to make the front suspension either a 3, 4, or 5 link. We played around with some different setups but in the end I did not like the way the brackets looked on the housing and how big they were. The size of the brackets alone was making it difficult to locate the trackbar mount and with the huge size of the Reid Racing Dana 60 knuckles it was leaving no room to mount the front coilovers.
http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1618&stc=1&d=1208734081
________
Jeff Ismail
WWW.IHONLYNORTH.COM
Authorized Scout LightLine Distributor
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Suspensioned Mig Welding Carts

So these brackets were scrapped and smaller ones were tacked in place. At this point we made up our mines that the front suspension would be set up with what is called a 'missing link'. Follow along as Darren puts it all together.

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1619&stc=1&d=1208735126

Next Darren fabbed up the track bar mount.

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1620&stc=1&d=1208735126

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1621&stc=1&d=1208735126

The front Bilstein coilovers were set in place to make sure there was going to be no fitment problems.

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1622&stc=1&d=1208735126

At this point the suspension was manually flexed to check how good the setup was going to work. At this point ignore the pinion angle change as the mock up driveshaft we were using was too long and was forcing the pinion upward against the yoke. So far everything was looking good.

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1623&stc=1&d=1208735126
________
Jeff Ismail
WWW.IHONLYNORTH.COM
Authorized Scout LightLine Distributor
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Suspensioned Mig Welding Carts

Happy with the overall lengths of the mock up links Darren began cutting the actual 2"x.250 wall DOM that is going to be used.

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1624&stc=1&d=1208735840

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1625&stc=1&d=1208735840

Darren also began welding on the threaded inserts.

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1626&stc=1&d=1208735840

The third link mount was tacked on and the suspension flex retested.

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1627&stc=1&d=1208735840

This picture clearly shows why this suspension setup is known as a "missing link" since there is no upper link on the driver side of the axle.

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1628&stc=1&d=1208735840

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1629&stc=1&d=1208735840
________
Jeff Ismail
WWW.IHONLYNORTH.COM
Authorized Scout LightLine Distributor
Custom Built Scout's and Components. Performance Parts, Service, and Custom Fabrication.
CPT - Crawler Proven Technology
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Suspensioned Mig Welding Carts

One problem with our setup was the trackbar was hitting the third link mount on top of the housing upon suspension compression so each end of the 2"x.250 wall DOM that was going to be used for the trackbar would need about a 20* bend. Being that .250 wall tubing let alone 2"x.250 wall DOM was way beyond Protools recommended maximum wall thickness (even for our heavy duty Super Bender that we use here in the shop) it didn't take much to break the bender die.

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1630&stc=1&d=1208736917

So Darren turned up the heat on the welder and burned the piece back on and then added a huge 1/2" thick gusset to it.

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1631&stc=1&d=1208736917

After heating the DOM tube to slightly under 400* we quickly slid the tube into the bender and began bending. Success!

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1632&stc=1&d=1208736917

Darren then cut the bar to size and tack welded on the threaded ends. With the trackbar in place the suspension flex was retested.

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1633&stc=1&d=1208736917

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1634&stc=1&d=1208736917

At full stuff the trackbar tucks nicely under the oilpan. There is now plenty of room between the trackbar and third link mount.

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1635&stc=1&d=1208736917

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1636&stc=1&d=1208736917

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1637&stc=1&d=1208736917

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1638&stc=1&d=1208736917
________
Jeff Ismail
WWW.IHONLYNORTH.COM
Authorized Scout LightLine Distributor
Custom Built Scout's and Components. Performance Parts, Service, and Custom Fabrication.
CPT - Crawler Proven Technology
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WWW.ALLTERRAINCARTS.COM
Suspensioned Mig Welding Carts

Darren made the third link mount on the lower link permanent. He fabbed up some pieces of 1/4" plate and then welded/molded it all together.

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1639&stc=1&d=1208738223

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1640&stc=1&d=1208738223

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1641&stc=1&d=1208738223

More threaded inserts were welded into place as well as the third link which was finished off with the poly bushed end.

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1642&stc=1&d=1208738223

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1643&stc=1&d=1208738223

Darren then removed all the brackets which were tacked onto the frame and finished welding them all up.

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1644&stc=1&d=1208738223

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1645&stc=1&d=1208738223

And more of the DOM links were prepped for welding on of the threaded inserts.

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1646&stc=1&d=1208738223
________
Jeff Ismail
WWW.IHONLYNORTH.COM
Authorized Scout LightLine Distributor
Custom Built Scout's and Components. Performance Parts, Service, and Custom Fabrication.
CPT - Crawler Proven Technology
Online Store, Photo Gallery, and now FORUMS!
WWW.ALLTERRAINCARTS.COM
Suspensioned Mig Welding Carts

With all the link and coil mounts welded up Darren then began permanently welding them on to the frame.

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1647&stc=1&d=1208738999

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1648&stc=1&d=1208738999

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1649&stc=1&d=1208738999

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1650&stc=1&d=1208738999

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1651&stc=1&d=1208738999

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1652&stc=1&d=1208738999

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1653&stc=1&d=1208738999

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1654&stc=1&d=1208738999

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1655&stc=1&d=1208738999
________
Jeff Ismail
WWW.IHONLYNORTH.COM
Authorized Scout LightLine Distributor
Custom Built Scout's and Components. Performance Parts, Service, and Custom Fabrication.
CPT - Crawler Proven Technology
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WWW.ALLTERRAINCARTS.COM
Suspensioned Mig Welding Carts

The 12" travel remote reservoir Bilstein 7100 shocks finally came in.

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1656&stc=1&d=1208739787

Darren finished up the frame side of the trackbar mount.

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1657&stc=1&d=1208739787

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1658&stc=1&d=1208739787

He also finished off the mounts on the front housing and finished welding on the lower link mounts.

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1659&stc=1&d=1208739787

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1660&stc=1&d=1208739787
________
Jeff Ismail
WWW.IHONLYNORTH.COM
Authorized Scout LightLine Distributor
Custom Built Scout's and Components. Performance Parts, Service, and Custom Fabrication.
CPT - Crawler Proven Technology
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Suspensioned Mig Welding Carts

[QUOTE=ihojeff;8160199]The 12" travel remote reservoir Bilstein 7100 shocks finally came in.

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1656&stc=1&d=1208739787

Someone is getting a sweet ride for sure. :smokin:

Those are the same shocks I am thinking about going to. I ran Bilsteins on the Vette before I went to Koni DA shocks. They were good shocks. Have they been good for you?

I'm still undecided about the valving F&R. Have an idea though. I need to re-weigh the Scout again F&R since I'm going to be performing some weight transfer mods. I have another 120# I can relocate.

Lookin Pimp!

I don't know who Darren is, but he does some damn fine work. I'm wondering how that Currie HP60 will hold up. I know the Ford HP60's don't have the best reputation when used as a rear diff in heavy vehicle.

Paul, what ratios did you go with for the Klune-atlas combo?

Darren finished up the frame side of the trackbar mount.

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1658&stc=1&d=1208739787

Jeff, I'd suggest running the gusset all the way to the top frame rail on the inside. Mine completely tore out the surrounding frame, that mount takes a lot of abuse, especially with hydro assist.

Damn why's his adapter look SOOO much better:D than mine? Looks like the current cut has more clearance for weights on flex plate? Or did you do a recut inside? Have you had those 3/8 bolts go loose or is that me and the 392/700r4:smokin:?(re: nuts and longer bolts)

I may finaly bust out $ and set up to stop shearing those 30 spliners

Thanks for posting this Jeff/Paul. Now I know how whimpy mine really is.

[QUOTE=ihojeff;8160199]

Someone is getting a sweet ride for sure. :smokin:

Those are the same shocks I am thinking about going to. I ran Bilsteins on the Vette before I went to Koni DA shocks. They were good shocks. Have they been good for you?

I'm still undecided about the valving F&R. Have an idea though. I need to re-weigh the Scout again F&R since I'm going to be performing some weight transfer mods. I have another 120# I can relocate.

Seeing that these rigs get fairly heavy in trail trim packed with gear/food/beverages/spare parts I usually just go with the heaviest valving available for the shock length we rae using.

Lookin Pimp!

Thanks!

I don't know who Darren is, but he does some damn fine work. I'm wondering how that Currie HP60 will hold up. I know the Ford HP60's don't have the best reputation when used as a rear diff in heavy vehicle.

Paul, what ratios did you go with for the Klune-atlas combo?

Darren definitely does some excellent work!

The Klune-V is a 2.7 ratio and the Atlas is a 3.8.

Jeff, I'd suggest running the gusset all the way to the top frame rail on the inside. Mine completely tore out the surrounding frame, that mount takes a lot of abuse, especially with hydro assist.

Duly noted and totally agree that this bracket takes an extreme amount of load. It doesn't look like it in the picture but that inner gusset does run 1/2 way up the inside of the frame.

Damn why's his adapter look SOOO much better:D than mine? Looks like the current cut has more clearance for weights on flex plate? Or did you do a recut inside? Have you had those 3/8 bolts go loose or is that me and the 392/700r4:smokin:?(re: nuts and longer bolts)

I may finaly bust out $ and set up to stop shearing those 30 spliners

Thanks for posting this Jeff/Paul. Now I know how whimpy mine really is.

We had to chamfer all the adapters from the last batch. We hope to get this resolved before another batch is made.
________
Jeff Ismail
WWW.IHONLYNORTH.COM
Authorized Scout LightLine Distributor
Custom Built Scout's and Components. Performance Parts, Service, and Custom Fabrication.
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Suspensioned Mig Welding Carts

[QUOTE=Shadow man;8161543]

Seeing that these rigs get fairly heavy in trail trim packed with gear/food/beverages/spare parts I usually just go with the heaviest valving available for the shock length we rae using.


Apples n' oranges here, but I run the 7100 RR shocks on my current racer, which is lighter than most trail rigs, but sees a lot more violent suspension travel.

I ran singles up front for a year or two with the heaviest off-the-shelf valving Bilstein had, 360/80.

I've since added a second set with the "normal" 255/70 valving. Plus the 2" Fox air-bumps.

It still isn't a particularly harsh ride (all things considered). Rides nice on the road without being harsh. The 360 shocks are MUCH hotter than the 255s when I stop to check 'em so I know they're doing a lot more work.

Tom this might be noob, I don't know much about shocks, why are you running different valving in the 2 shocks? ride quality, $ or ?

Tom this might be noob, I don't know much about shocks, why are you running different valving in the 2 shocks? ride quality, $ or ?

Time and money. Bought the second set with the 255/70 valving in them, and didn't want to drop the money on another set of valve stacks, and didn't have the time to do the valve swap at that point anyhow.

One accidental bonus is that if I run hard enough / long enough to make the 360/80 shocks get hot enough to fade, the 255/70 shocks will still be much cooler, and provide some damping (though the whole thing would be degraded over having it all working like it should, it's still much better than having NO damping from way-too-hot shocks)

But mostly it boils down to me being a) cheap and b) lazy. I do, after all, own a Scout.

And for a long overdue update.............

Copy and pasted

The knuckle's were tacked into place and checked for proper alignment.

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1714&stc=1&d=1210802832

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1715&stc=1&d=1210802832

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1716&stc=1&d=1210802832

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1717&stc=1&d=1210802832

With the alignment set the knuckles were welded permanently into place. Darren did the welding while Chad slowly rotated the housing.

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1718&stc=1&d=1210802832

The housing was then reinstalled and mock-up of the steering began.

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1719&stc=1&d=1210802832

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1720&stc=1&d=1210802832

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1721&stc=1&d=1210802832
________
Jeff Ismail
WWW.IHONLYNORTH.COM
Authorized Scout LightLine Distributor
Custom Built Scout's and Components. Performance Parts, Service, and Custom Fabrication.
CPT - Crawler Proven Technology
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Suspensioned Mig Welding Carts

Getting back to the front suspension the next thing we needed to do was come up with a strong and simple hoop for the coilover that would work on both the left and right sides. On the driver side we have the steering box and shaft in the way and on the passenger side the alternator was going to be problem. So a pair of hoops were bent up with the driver side being slightly different but mounting points of the coilover are the same.

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1817&stc=1&d=1213495152

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1818&stc=1&d=1213495152

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1819&stc=1&d=1213495152

For extra strength both sides of the frame were drilled so that the hoop would pass thru the entire frame.

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1820&stc=1&d=1213495152

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1824&stc=1&d=1213495518

Not sure why I don't have any pictures of the driver side hoop but I will with the next update. Also, oval mounting plates will be added to the frame around each tube for additional strength.
________
Jeff Ismail
WWW.IHONLYNORTH.COM
Authorized Scout LightLine Distributor
Custom Built Scout's and Components. Performance Parts, Service, and Custom Fabrication.
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Suspensioned Mig Welding Carts

These next few pictures are for Paul so that he can see how wide the front axle is. Total axle width is 68" and the wheel that is on the Scout is a 15" x 10" wide w/ 3.75" of back spacing.

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1825&stc=1&d=1213496749

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1826&stc=1&d=1213496749

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1827&stc=1&d=1213496749

We will probably go with wheels that have either a 4.5" or 5" of back spacing.

Some more parts have come in as well. We got in a wider Curry Rockjock60 since we initially planned on 63" and ended up at 68". We ordered this housing without ends this time in order to keep the final product as straight as can be. Once all the brackets, truss, etc are welded on we will then center and weld the ends in place.

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1828&stc=1&d=1213496749

CTM's showed up this week for the front axle.

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1829&stc=1&d=1213496749

A set of Dynatrac Dynaloc hubs were ordered in instead of the usual Warn's since these are a low-clearance type hub when compared to the Warn. Since we plan on 4.5"+ of back spacing we want to try to keep the hub in the wheel as much as possible.

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1830&stc=1&d=1213496749

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1831&stc=1&d=1213496749

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1832&stc=1&d=1213496749

And finally we ordered in some Bilstein air bumps and mounting cans. These will be mounted above the kingpin right next to the coilover.

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1833&stc=1&d=1213496749

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1834&stc=1&d=1213496749

Stay tuned as we continue on with the front suspension and axle this next week.
________
Jeff Ismail
WWW.IHONLYNORTH.COM
Authorized Scout LightLine Distributor
Custom Built Scout's and Components. Performance Parts, Service, and Custom Fabrication.
CPT - Crawler Proven Technology
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Suspensioned Mig Welding Carts

The axles and CTM's were put together.

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1931&stc=1&d=1214240112

Darren made up the struts to hold the back of the engine up. By putting these extra struts in it takes a lot of weight off of the 700R4 transmission bellhousing.
http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1939&stc=1&d=1214240112

Next up was to set the suspension height so that 37" tires would clear. We have yet to install a 1" bodylift which will help with tire clearance but may not be enough with 37's.

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1932&stc=1&d=1214240112

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1933&stc=1&d=1214240112

With max height set the air bumps were mounted in place. The suspension was then flexed out in different directions to make sure there were no clearance issues.

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1934&stc=1&d=1214240112

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1935&stc=1&d=1214240112

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http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1937&stc=1&d=1214240112

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1938&stc=1&d=1214240112
________
Jeff Ismail
WWW.IHONLYNORTH.COM
Authorized Scout LightLine Distributor
Custom Built Scout's and Components. Performance Parts, Service, and Custom Fabrication.
CPT - Crawler Proven Technology
Online Store, Photo Gallery, and now FORUMS!
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Suspensioned Mig Welding Carts

The same was done on the driver side except this hoop was a little wider in order to go around the steering box.

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1940&stc=1&d=1214240818

With the hoops main structure built they were removed from the frame and welded up. Gussets to the airbump can will be added later.

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1941&stc=1&d=1214240818

The hoops were reinstalled and for the first time the Scout was set down in the front on its new suspension.

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1942&stc=1&d=1214240818

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1943&stc=1&d=1214240818

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1944&stc=1&d=1214240818

This coming week gussets will be added to the towers/airbump cans and a crossover bar tying the two hoops together will be added in.
________
Jeff Ismail
WWW.IHONLYNORTH.COM
Authorized Scout LightLine Distributor
Custom Built Scout's and Components. Performance Parts, Service, and Custom Fabrication.
CPT - Crawler Proven Technology
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Suspensioned Mig Welding Carts

Extra tubing was added to the bumpstop cans to help strengthen the entire setup.

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1951&stc=1&d=1214691127

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1952&stc=1&d=1214691127

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1953&stc=1&d=1214691127

Teflon pads are going to be added to the top of the kingpin plates to help keep the bumpstops quiet when coming in contact.

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1954&stc=1&d=1214691127

A removable crossover bar was added next to again add additional strength and support the front coilover reservoirs.

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1955&stc=1&d=1214691127

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1956&stc=1&d=1214691127

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1957&stc=1&d=1214691127

The front hoop system was then painted and installed.

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1958&stc=1&d=1214691127

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1959&stc=1&d=1214691127

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=1961&stc=1&d=1214691470
________
Jeff Ismail
WWW.IHONLYNORTH.COM
Authorized Scout LightLine Distributor
Custom Built Scout's and Components. Performance Parts, Service, and Custom Fabrication.
CPT - Crawler Proven Technology
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Suspensioned Mig Welding Carts

Nice work! Keep the pictures coming :beer:

Im not sure I understand why you had to get a new rock jock housing though :confused:

The first one ended up too wide? You couldnt cut it back down?

Nice. I like how you ran the tubes all the way through the frame. Much stronger than the flush mount so many people do.

Jeff very nice work hats off :cool:

IMHO I'd find a way to tie the cage into the shock halo. The frame will flex a ton without a tie in.

I ran a bar through the firewall and into the legs for the front hoop, and just under the shelf on the inner fenders turning down into the frame about where the rad is. It made a world of difference.

Nice. I like how you ran the tubes all the way through the frame. Much stronger than the flush mount so many people do.

"Ditto" - running 'em through and welding it all up double-shear should make it last a lot longer, along with the extra reinforcement plates on the frame.

I'm curious about the purpose of the "air cleaner" bar of the cross over support? I was glad to see the cross-bar, but with it being a pretty straight shot across, I'm waiting to see what the air-cleaner hoop brings to the table.

Probably not a big deal for this rig, but I originally mounted my reservoirs to the engine cross-over bar, too, but eventually moved them back down to the shocks, using the nylon hour-glass mounts.

I found that with the reservoirs mounted to the cross-bar, I was *ADDING* engine heat to the shocks - they run cooler with the reservoirs mounted down by the tire, away from the radiator's heat-wash.

Jeff, this may be a dumb question buit whats the advantage of the shorter 3rd link going back to the lower instead of the full length going back to the frame?
clearance issues? or better function?

Very sweet bump stop mount. The build is coming together awesome!

Super nice work guys! That binder must weight a few tons eeh?

Super nice work guys! That binder must weight a few tons eeh?

They weight a few tons from the factory bone stock. It probably weighs multiple few tons by now! :laughing:

They weight a few tons from the factory bone stock. It probably weighs multiple few tons by now! :laughing:

The skins are heavy sheet metal, which adds a lot of weight, but you get protection from it too. I used a floor jack to reinstall my doors:eek::eek:. This ain't no zuk build up that's for sure. I going to weight my 1 ton axle beast some day, I'm guessing 5,700 as that what my chev 3/4 pickup weighs.

Damn nice build Jeff and Darren. I've seen thier workmanship up close and they pay attention to the details:smokin:

...Damn nice build Jeff and Darren. I've seen thier workmanship up close and they pay attention to the details:smokin:

I can't speak for Darren's work, but I do know Jeff does quality work. I was out there for 3 days working on my junk after the '05 Rubicon run. My rig was in need of some attention so I could continue my 3 week wheel-a-thon across the western half of the states. I had never met Jeff before and he graciously opened his shop to me (on a Sunday even!!) and we pieced it back together over the next 3 days. I got to see a lot of his work as we bounced around from my rig to customer rigs during that time. Jeff and his whole family are good people too!

Rescued from page 3. Any further progress?

[QUOTE=JFoster;7882417]http://www.ihonlynorth.com/forums/attachments/ih-only-build-ups/1222d1201384449-pds-drivetrain-upgrade-img_1262.jpg


Are those tera joints? I didnt know they made such a big one?

Thanks guys for all the compliments! We are nearing completion on this project and will post up the remainder of the build when I find some spare time(which lately I can't seem to find any). I'll also try to answer all your questions at a later date. Between all the projects we have had this summer and the purchase of a new house it has left me with little to no extra time to update our build threads.
________
Jeff Ismail
WWW.IHONLYNORTH.COM
Authorized Scout LightLine Distributor
Custom Built Scout's and Components. Performance Parts, Service, and Custom Fabrication.
CPT - Crawler Proven Technology
Online Store, Photo Gallery, and now FORUMS!
WWW.ALLTERRAINCARTS.COM
Suspensioned Mig Welding Carts

Here's some more on this project(copy/pasted from my site).

The shock hoop assembly was prepainted and then permenately welded into the frame.

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=2003&stc=1&d=1216489133

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=2004&stc=1&d=1216489133

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=2005&stc=1&d=1216489133

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=2006&stc=1&d=1216489133

A tubular straight steer was bent up and welded into place as well.

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=2007&stc=1&d=1216489133

The PSC hydrualic steering assist ram was mounted to the axle.

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=2008&stc=1&d=1216489133

Darren came up with a great idea on the rear shock mounts and reservoir mounts and went ahead and fabbed everything up.

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=2009&stc=1&d=1216489133

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=2010&stc=1&d=1216489133
________
Jeff Ismail
WWW.IHONLYNORTH.COM
Authorized Scout LightLine Distributor
Custom Built Scout's and Components. Performance Parts, Service, and Custom Fabrication.
CPT - Crawler Proven Technology
Online Store, Photo Gallery, and now FORUMS!
WWW.ALLTERRAINCARTS.COM
Suspensioned Mig Welding Carts

We stopped fabbing long enough to deal with the rust issues the Scout had. A quarter panel patch was installed on the driver side quarter panel and both rear lower quarters were reapainted as they had rust bubbling under the paint.

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=2011&stc=1&d=1216489820

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=2012&stc=1&d=1216489820

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=2013&stc=1&d=1216489820

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=2014&stc=1&d=1216489820

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=2015&stc=1&d=1216489820

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=2016&stc=1&d=1216489820

As usual Mike did a fantastic job on the body work!

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=2017&stc=1&d=1216489820

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=2018&stc=1&d=1216489820
________
Jeff Ismail
WWW.IHONLYNORTH.COM
Authorized Scout LightLine Distributor
Custom Built Scout's and Components. Performance Parts, Service, and Custom Fabrication.
CPT - Crawler Proven Technology
Online Store, Photo Gallery, and now FORUMS!
WWW.ALLTERRAINCARTS.COM
Suspensioned Mig Welding Carts

Fender flares were mocked up. They were trimmed to go around the side moulding. We have not decided whether the flares will stay black or get trimmed.

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=2020&stc=1&d=1216490606

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=2021&stc=1&d=1216490606

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=2023&stc=1&d=1216491410
________
Jeff Ismail
WWW.IHONLYNORTH.COM
Authorized Scout LightLine Distributor
Custom Built Scout's and Components. Performance Parts, Service, and Custom Fabrication.
CPT - Crawler Proven Technology
Online Store, Photo Gallery, and now FORUMS!
WWW.ALLTERRAINCARTS.COM
Suspensioned Mig Welding Carts

Seeing that its been months since I've updated any threads I thought I would lock myself in a room with my computer and start updating threads. So here is the conclusion of this build which is almost done at the time of this posting.

A few more parts rolled in like the limit straps and bumpstops for the rear.

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=2731&stc=1&d=1224342179

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=2732&stc=1&d=1224342179

Darren made some special bolts that will both hold the rear coil spring in place and the bumpstop.

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=2733&stc=1&d=1224342179

Darren then notched the frame and welded in the rear swaybar mounts.

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=2734&stc=1&d=1224342179

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=2735&stc=1&d=1224342179

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=2736&stc=1&d=1224342179

Darren assembled the remaining rear suspension to perform another test of all parts.

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=2737&stc=1&d=1224342179
________
Jeff Ismail
WWW.IHONLYNORTH.COM
Authorized Scout LightLine Distributor
Custom Built Scout's and Components. Performance Parts, Service, and Custom Fabrication.
CPT - Crawler Proven Technology
Online Store, Photo Gallery, and now FORUMS!
WWW.ALLTERRAINCARTS.COM
Suspensioned Mig Welding Carts

With the designing and mock-up of the rear suspension complete Darren removed the housing, finished welding all the brackets, and then set the alignment bar thru the housing and welded on the housing ends.

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=2739&stc=1&d=1224343060

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=2740&stc=1&d=1224343060

The rear axle truss was welded up as well and tied into the rear diffy cover.

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=2741&stc=1&d=1224343060

After that the Yukon gears and ARB were installed.

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=2742&stc=1&d=1224343060

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=2743&stc=1&d=1224343060

One thing that caught us off guard was the fitting of the RuffStuff cover to the housing once everything inside was assembled. The bearing caps on the Curry housings sits up a little higher than a stock Dana 60 so the cover was modified some more for additional clearance.

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=2744&stc=1&d=1224343060

With the housing completed it was reinstalled under the Scout and all the suspension components were bolted on for the last time.

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=2745&stc=1&d=1224343060

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=2746&stc=1&d=1224343060
________
Jeff Ismail
WWW.IHONLYNORTH.COM
Authorized Scout LightLine Distributor
Custom Built Scout's and Components. Performance Parts, Service, and Custom Fabrication.
CPT - Crawler Proven Technology
Online Store, Photo Gallery, and now FORUMS!
WWW.ALLTERRAINCARTS.COM
Suspensioned Mig Welding Carts

With the rear axle back in place Darren finished it off by sliding in the Curry axles and installing the Wilwood disc brakes.

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=2747&stc=1&d=1224344043

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=2748&stc=1&d=1224344043

At this point tires were mounted on the Scout and it was rolled in the shop for the first time in six months. Even though at this point we were far from done it was nice to actually see it roll.

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=2749&stc=1&d=1224344043

Next to be installed was the front swaybar setup. Darren notched the frame for the custom machined bushing holders and mounted in the front swaybar. From there the suspension was cycled to make sure all components cleared.

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=2750&stc=1&d=1224344043

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=2751&stc=1&d=1224344043

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=2752&stc=1&d=1224344043

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=2753&stc=1&d=1224344043

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=2754&stc=1&d=1224344043

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=2755&stc=1&d=1224344043

With all clearances set Darren welded in the swaybar mounts and added gussets.
http://www.ihonlynorth.com/forums/attachment.php?attachmentid=2756&stc=1&d=1224344669
________
Jeff Ismail
WWW.IHONLYNORTH.COM
Authorized Scout LightLine Distributor
Custom Built Scout's and Components. Performance Parts, Service, and Custom Fabrication.
CPT - Crawler Proven Technology
Online Store, Photo Gallery, and now FORUMS!
WWW.ALLTERRAINCARTS.COM
Suspensioned Mig Welding Carts

Next up was fabrication of the crossmember. The crossmember was attached at two points since this drivetrain was extra long due to the Klune-V.

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=2757&stc=1&d=1224345016

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=2758&stc=1&d=1224345016

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=2759&stc=1&d=1224345016

With the crossmember complete it was on to the plumbing. Darren started running all the brakelines, ARB lines, vent lines, and hydraulic lines to the steering assist ram.

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=2760&stc=1&d=1224345016

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=2761&stc=1&d=1224345016

You can see in this picture the ram hydraulic lines running up the track bar which keeps them out of harms way.

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=2762&stc=1&d=1224345016

Fabrication of the roll cage also began. To keep welding sparks, dust, etc out of Paul's Scout we pulled out one of our orphaned Scout's from the side yard and began building the cage there.

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=2763&stc=1&d=1224345016

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=2764&stc=1&d=1224345016
________
Jeff Ismail
WWW.IHONLYNORTH.COM
Authorized Scout LightLine Distributor
Custom Built Scout's and Components. Performance Parts, Service, and Custom Fabrication.
CPT - Crawler Proven Technology
Online Store, Photo Gallery, and now FORUMS!
WWW.ALLTERRAINCARTS.COM
Suspensioned Mig Welding Carts

Getting back to the crossmember an aluminum skid plate was added to help protect the transfer case. A rubber snubber was bolted onto the skid plate to help keep the drivetrain from flexing.

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=2765&stc=1&d=1224345956

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=2766&stc=1&d=1224345956

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=2767&stc=1&d=1224345956

Next up was the exhaust system. Seeing that space was tight under the Scout we decided to go with Flowmasters Hushpower mufflers as they are a nice compact straight thru designed muffler that has a built in heat guard to keep things from getting hot around it.

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=2768&stc=1&d=1224345956

Darren then began running tubing. A crossover was added for better flow as well.

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=2769&stc=1&d=1224345956

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=2770&stc=1&d=1224345956

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=2771&stc=1&d=1224345956

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=2772&stc=1&d=1224345956
________
Jeff Ismail
WWW.IHONLYNORTH.COM
Authorized Scout LightLine Distributor
Custom Built Scout's and Components. Performance Parts, Service, and Custom Fabrication.
CPT - Crawler Proven Technology
Online Store, Photo Gallery, and now FORUMS!
WWW.ALLTERRAINCARTS.COM
Suspensioned Mig Welding Carts

Continuing on with the exhaust system......

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=2773&stc=1&d=1224348872

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=2774&stc=1&d=1224348872

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=2775&stc=1&d=1224348872

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=2776&stc=1&d=1224348872

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=2777&stc=1&d=1224348872

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=2778&stc=1&d=1224348872

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=2779&stc=1&d=1224348872

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=2780&stc=1&d=1224348872

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=2781&stc=1&d=1224348872
________
Jeff Ismail
WWW.IHONLYNORTH.COM
Authorized Scout LightLine Distributor
Custom Built Scout's and Components. Performance Parts, Service, and Custom Fabrication.
CPT - Crawler Proven Technology
Online Store, Photo Gallery, and now FORUMS!
WWW.ALLTERRAINCARTS.COM
Suspensioned Mig Welding Carts

At this point we are for the most part caught up with this build so I thought I would throw in a few random pictures.

Here's the fuel tank before installation. Darren did the normal modifications to it in order to accept an in-tank fuel pump.

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=2782&stc=1&d=1224349288

Picture of under the hood while getting things buttoned up.

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=2785&stc=1&d=1224349288

We took a few days off for the IH Sierra Fall Rallye. The Scout wasn't complete enough to make the 65 mile trek under its own power so we had it towed instead.

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=2783&stc=1&d=1224349288

http://www.ihonlynorth.com/forums/attachment.php?attachmentid=2784&stc=1&d=1224349288

So as of today there still is quite a list of tasks to still yet get accomplished. Stay tuned for the next update where we hopefully get this project completed and delivered.
________
Jeff Ismail
WWW.IHONLYNORTH.COM
Authorized Scout LightLine Distributor
Custom Built Scout's and Components. Performance Parts, Service, and Custom Fabrication.
CPT - Crawler Proven Technology
Online Store, Photo Gallery, and now FORUMS!
WWW.ALLTERRAINCARTS.COM
Suspensioned Mig Welding Carts

Really nice work. It's too tall for me, but I understand the customer wanting to keep the body uncut.

simply gorgeous!

Great work guys, what a build.

What shock travel do you have front & rear?

No updates in a while, Any truth to the rumor that it was sold for scrap:D

The Scout has been completed and and was driven back home to Tennesse a couple weeks ago. Thread to be updated eventually.

http://www.ihonlynorth.com/forums/attachments/ih-only-build-ups/3393d1229132462-pds-drivetrain-upgrade-home.jpg
________
Jeff Ismail
WWW.IHONLYNORTH.COM
Authorized Scout LightLine Distributor
Custom Built Scout's and Components. Performance Parts, Service, and Custom Fabrication.
CPT - Crawler Proven Technology
Online Store, Photo Gallery, and now FORUMS!
WWW.ALLTERRAINCARTS.COM
Suspensioned Mig Welding Carts

The Scout has been completed and and was driven back home to Tennesse a couple weeks ago. Thread to be updated eventually.

http://www.ihonlynorth.com/forums/attachments/ih-only-build-ups/3393d1229132462-pds-drivetrain-upgrade-home.jpg

Super nice. Great job Jeff.

Now we need an owner update of him scratching that pretty black paint on the axles :smokin:

friggin beautiful, that is all..

Like a Wet Dream.....

Totally beautiful, but out of reach for all but that one guy.

Like a Wet Dream.....

Totally beautiful, but out of reach for all but that one guy.

That may be true, but considering what that one guy does for a living...he deserves it. Way to go Paul, thanks for your service as well as giving us the opportunity to see this awesome rig come together.

Paul, I see you are having problems getting the Scout in the garage, hell if it were mine I would be trying to figure out how to get it in my living room.

It sure looks nice I hope we can hear from Paul after he puts some miles on it and stretches its legs

just read through the entire thread... what an awesmoe job! all i need to do is hot the lottery then it will have an identical twin after your finished with mine, lol. what an awesome build, hats off to this one!!!

Thanks guys for the compliments. The build up is complete on our website so check it out when you get a chance - http://www.ihonlynorth.com/forums/ih-only-build-ups/442-pds-drivetrain-upgrade.html

Here's a video I took while cruising up the freeway on our initial freeway test drive -

Test Drive - PD's Scout II (http://video.google.com/videoplay?docid=-9039970589544503956)

Yeah I know its a lame video as its not rock crawling but its all I got for now.
________


Jeff Ismail
Test Drive - PD's Scout II (http://video.google.com/videoplay?docid=-9039970589544503956)
Authorized Scout LightLine Distributor
Custom Built Scout's and Components. Performance Parts, Service, and Custom Fabrication.
CPT - Crawler Proven Technology
Online Store, Photo Gallery, and now FORUMS!
Test Drive - PD's Scout II (http://video.google.com/videoplay?docid=-9039970589544503956)
Suspensioned Mig Welding Carts

Any updates on truck since 08'?

any updates on truck since 08'?

x2 :d

Thanks guys for the compliments. The build up is complete on our website so check it out when you get a chance - http://www.ihonlynorth.com/forums/ih-only-build-ups/442-pds-drivetrain-upgrade.html


Any updates on truck since 08'?

Go to the actual build thread and read. The last update on this build was 12-03-2010.