93 X-cab buildup

[Kaptain]

I've been wheeling IFS for several years now and my rig was good enough
while i was on the 4xWire forum. Then I started lurking at this forum for
about a year and now my ifs no longer adequate, in fact it's now sitting on
the garage floor in a mangled heap of torched metal.

Anyway, a few goals of this project are...
*Capable daily driver
*Somewhat legal
*Reliability

Specs
*Rebuilt 22re (40 over, EB cam)
*Marlin HD clutch (1200lbs)
*V6 4.88 diffs front\rear
*Rear Spool
*3" TG springs - hybrid fronts and frenched rears
*Vertical Rear shocks through bed
*Dual Cases - Marlin Adapter - stock gears
*Front range crossmember
*TG 12" spline clearanced CV front DS \ IFS one piece rear
*Bed-bob 12 inches
*2" Gas tank lift


09 plans
DONE *Remove bottom leaf from front springs
DONE *Modify front bumpstops and bumpstop extensions
DONE *Modify shock hoop to raise front shocks
DONE *Shorter shackles f\r
DONE *French rear hangers and mount shackles through frame?
DONE *Rear Bumper
*Front Bumper

2010 Winter plans
DONE Finish rear discs
DONE Fix bed
*In Cab Cage
*Buy or build Sliders
*Thick wall\DOM rear DS
*Chromoly birfs
*Finish Half-doors


Bought - 84k
SAS'd - 125k
Tires - 135k
Engine Rebuild and clutch- 137715
Current - 149k

[Kaptain]

Here it is before pulling into the garage.. (2" body, 1 1/2" BJ spacers,
2" Shackles, 33" TSL's)

[Kaptain]

This should help with the SAS... Lincoln 140, and a bunch of scrap steel.. (Thanks Mike!)


I bet this will help too... (Axle is from an 85 p/u.. yeah, auto hubs do suck)

[MUCHADO]

Hey looks like a cool project, I'm lookin forward to watching this build. BTW, I bobbed my bed 14" and it seems just right. Take it down as much as you can!

[Kaptain]

IFS getting torn down. Mainly just unbolting some of the junk
(3rd, Cv's.. blah, blah blah)



Now im getting serious... Never used a torch before, what a good way to
get some practice

[Kaptain]

Well I'm happy with my progress so far.. Pulled into the garage at 5pm, and
this is what it looked like at 12



And every SAS has to have the IFS pile-o-shit picture, right?



Thats enough for today. Tommorow I plan on finishing the cutting of the
IFS crap as well as smoothing down the frame. Maybe I'll get around
to welding the front hanger and rear shackle tube.

[cdub350]

Looks familiar. Here's mine

[hammerdown 4]

looks like it is coming along good. post up some more pics. was this your first SAS?

[Kaptain]

I'll have some more pics up tonight. Yup, this is my first SAS.

[Kaptain]

I spent alot of time cleaning up the frame today..
(Thanks Josh for the extra grinding help)
Gawd that was time consuming, and I still have a few
spots to touch up.

Ran out of o2 in the torch so I'll prolly end up using a
cutting wheel for the IFS Diff mounts and the torsion
adjuster thingi. Definitely not doing that tommorow.
However, I'll try to finish welding up the front hanger,
primer/paint a few things, and figure out what I'm doing
for the Rear shackle hole. I think I'll try the hole saw
route since the torch is no workie right now.

A few pics from today

[greasyjeep]

Originally Posted by Kaptain

I've been wheeling IFS for several years now and my rig was good enough while i was on the 4xWire forum. Then I started lurking at this forum for about a year and now my ifs no longer adequate, infact it's now sitting on the garage floor in a mangled heap of torched metal.

I think that is the very deffinition of web wheeling

looks like a nice project
I'll keep an eye out for ya at PAP.

now get 'r done

[paulwhat]

Sweet. Another garnet pearl x-cab.

[flexin81]

Nice build up thread. I will be watching since I'm doing the same thing as we speak. Here's my shit pile.

[pr0ject42]

Hey dood, while you have everything out from under the truck, now would be a good time to brace your steering box.

It would suck to rip that sucker off on the trail then have to cobble something up to get home THEN have to fix it to take it to work the next day.

You're making excellent progress though!

[Po' riggity]

Truck looks like its coming along good.. For some reason, even though I am a jeep guy I really enjoy seeing these SAS threads...
Nice truck dude.
Scott

[toy4x4boy]

Nice job man. I've got an 89 Xtra Cab that's being sas'd, getting a flatbed, and rock sliders currently. I need to start a buildup thread.

[Kaptain]

I made some more progess today.. Thanks for all the feedback
BTW! Decided to take a break from the frontend and
do some other things. Plus a few of my friends stopped by
and were feeling ambitious and helped me take the bed off.
(They have projects they are starting in the near future, go
figure )

Here's a few shots from today...

I knew this was going to happen sooner or later, I hate rust
(That's a fuel line btw)



Dropping the tank, Wanted a better look at that side of the
frame since the drivers side has a nice crack in it (I'll post that
some other time)



Took the bed off. I have alot of cleaning up to do

[Kaptain]

About adding a brace.. I actually wasnt going to do that until
I ran tires big enough to force me to move my steering box
forward. But after thinking about it, I have sheets of 1/4 and
5/16 big enough to make my own, so I might as well do it.

[Kaptain]

Got a little bit more done last night..I'm still waiting
on o2 to cut holes for the shackle sleeve. Oh well.

Front Hanger fully welded



Front axle getting beefed up, not quite done yet
(Front range knuckle gussets on the way)





Weekend plans.. Brace frame for steering box, Hang
the springs, finish tearing the front axle apart, and cut off
torsion bar mounts.

[TheBandit]

Interesting idea with the nut for the steering stop. What size is that?

[Kaptain]

Stole that idea from TNToy.. It's 5/8's

[93yota]

people have been doing that, but I just closed up the steering stop on mine, just a heads up you'll have to fab up some new front shock mounts to use the fror gussets

[Kaptain]

I've haven't gotten as much done as I hoped to (It's spring, but it's
still f-in cold in the garage). But here's what I did since last time.

Sleeves installed and painted up.





Front springs installed.





Axle stripped and getting primed.



Side shot

[Kaptain]

Finished up the SAS this week, I have a few minor things to
take care of.. (Bumpstops, brake lines, hubs.. etc) Even with
the 3" springs it seems to sit higher then I expected.. Oh well,
I'm sure they'll settle an inch or two. Here are a few shots of
what I did up front.

Shock hoop welded and gussetted



Fabbed front shock mount to clear the knuckle gussets



Steering box reinforcement (Both plates are 1/4 thick)



The 'completed' SAS







I've been working on the rear in the meantime, mainly just cleaning
up all the damn rust. I'll have a few shots of what I'm doing back
there in the next couple days.

[Kaptain]

A few things that are being done to the rear section of frame

-Cut out/Replace Spare Tire carrier crossmember (Or the rusted
piece of crap adding useless weight in my case)
-Cut out/Replace Tube crossmember
-Frame Repair
-Eliminate LSPV
-Fab shock mounts to new tube crossmember


Spare tire carrier carrier gone, and a look at the rust I had to
deal with.



Both sides were filled with mud/dirt and started to rot through, I cut
out as much as was needed. Then shop vac'd the rest of the 'stuff'
that was lying in there. The rest of the frame is in great shape
surprisingly.



I cut a piece of 1/4 angle iron, slid it in the hole, and rotated the iron
once it was inside the frame rail. It didn't go in as easy as it looks.





After fully welding that in I cut a section of 3/16 plate to make it flush
with the rest of the frame.



Then that's fully welded and then ground down smooth. Seemed to turn
out rather well, and will add some strength.