I'm running Heim joints on my Hysteer steering setup now, but thinking of going to either Fj-80 or dana 60 ends. Which are stronger and which have the most articulation? anyone know what angle taper reamer I'll need to use to modify the steering arms to fit these tie rod ends?

Heim Joints belong on Airplanes....that is what they were designed for!

They have and get too much slack in them to be used in steering and suspensions unless changed or bebuilt frequently.

FJ-80 ends are stout! I use F-450 tie rod ends on my Cruiser and they are "Hell for Stout"

Personally, I've not problems with the QA-1 rod ends on my steering. They are pretty cheap, easy to replace, and their quality is great. I ran a couple other brands initially, and changed them yearly due to slop. 2 years so far on the QA-1 and they are still as tight as new.

I won't diesagree with the strength of the 80-series ends, but cust for them and the cost for either a custom tie-rod or the taps themselves makes them expensive. FEW shops carry metric taps in that size, especially wrong-thread. Most any shop will have SAE in left and right hand and be a quick replacement for a junked tie rod.

Actually, what IS the sizing for 80-series ends (thread-pitch)? My buddy just bought a lathe last night, and got a pile of cutters with it....maybe he got that size....

23mm x 1.5.

Yes, the FJ-80 TREs are stout. At 23mm (0.9") they are almost as large as the 1" units used on 1 ton domestic trucks. The 1 ton TRE is 1" x 18 (TPI) and the left-hand version of that tap is as difficult to find as the metric ones (I have been looking for three days, and just found a source). The SAE taper is 1.5" per foot. I don't know what the taper is on the FJ-80 TRE.

One issue with the big TREs is that you need big tie rods to hold them. The 45 truggy project is getting the 1" TREs and the tie rod and draglink are 1 3/8" DOM with a 3/8" wall -- heavy and spendy.

Thanks Medusa that's the info I was looking for . Would you also happen to know approximately what size the hole in the steering rods would need to be at the largest dia? Kinda like to know before I buy the T.R.E.'s only to find out I don't have enough meat around the existing holes for the 1 ton ends. Also you might want to check with a tool company back east for that 1"-18 L.H. tap , It's called MSC Ph.# 1-800-645-7270 . They also have a web site with a catologe, their catologe is huge almost 4" thk., www.mscdirect.com
I order most of the tools for work from them, almost always get them delivered in two days . There prices are pretty good too.

MSC has the 1x18 RH tap but NOT the LH version. I also buy most of my tools from them. With their new warehouse in Reno, I can usually get stuff within two days. I don't have a 1-ton TRE with me right now, but if memory serves the diameter at the narrow end is 0.67" and at the wide end approximately 0.7". I know it is definitely less than 0.75"