Project: Old Bumpy (3rz xcab 3-link)

[Philfab]

Formerly known as: Tacoma 3-link my way

Why not start a build thread on a Tuesday?

Specs:
-'96 x-cab 3rz/w59, 186K mi, buncha motor bolt-ons, (leaving as-is)
-Chevy leafs out back, single shackle conv., bilstein 5150's, relocated x-member, lunch box locker, removed LSBPV, 3.55's
-Clocked t-case, clocked x-member, twinstick, LCE short shifter
-Dual batteries and OBA 1/2 way complete

Going in:
-Typ. D44 out of a GWaggy, (free, so I'm gonna use it until I make up my mind, which might be a while)
-pre '80 Saginaw box ported for hydro,
-XJ coils (thinking about ditching), 5100's
-2" x .25" square links, bushings on frame end, Ballistic joints on axle, links will all be pretty long @ 42" each.

Had leafs ready to go, but changed my mind at the last minute figuring that I wanted to be different for the sake of being different and go to a linked setup.

From this:


To this:


To this:


I've lurked on this board for a LONG time, finally got my red star when I was ready to get serious about my axle swap.

BTW: Constructive criticism is ALWAYS welcome. Seriously.

[Philfab]

Need to add plating extension toward and finish the welding.

[Philfab]

Cannibalized steering components:



Firewall plate is uglier than a mudfence but keeps the elements out.


Steering angles are fairly good:

[Philfab]

Crossmember evolution:

[Philfab]

Current issues:

- XJ springs were WAY cheap, so I bought them. Got them mounted up and starting to think that they are just too damn big. 24" free height and nearly 6" in diameter. These are fairly soft, but I'm still considering going with something like a Ballistic Fab/blue coil 18" tall 200-250 lbs spring as those are merely 3" in diameter.

- 4x 3/4" bolts through a 1/2" of A36 plate holds the x-member on right now, I should probably do the calcs (yes, I am a field engineer very slowly working on getting his P.E.), but I just don't think that it's quite enough. Comments, ideas, suggestions?

[THESOFTTACO]

whered you get that sick girll!! that thing looks sweet!!! i want one for mine!

[Booger Weldz]

did you make the adjustable coil buckets?? if so, youre a genious and should market them!!! if not, they are still cool and so is your truck

[generalee7]

Originally Posted by Booger Weldz

did you make the adjustable coil buckets?? if so, youre a genious and should market them!!! if not, they are still cool and so is your truck

Ballistic used to sell those but I can't find them on their website anymore.

[Philfab]

Originally Posted by THESOFTTACO

whered you get that sick girll!! that thing looks sweet!!! i want one for mine!

I made it with about $20 worth of bondo, fiberglass and metal mesh. It's a slightly different version of the "satoshi grill mod". There's a an old write-up on a toyota site somewhere. One of those arts and crafts projects that you can stave off boredom with during the winter.

Originally Posted by Booger Weldz

did you make the adjustable coil buckets?? if so, youre a genious and should market them!!! if not, they are still cool and so is your truck

Sadly, I did not make them, Ballistic fab did. I may offer a kit for an :angry: version later though. Thanks for the complements, I gotta admit the Silver Bullet build thread (among others) was definetely an inspiration to get this thing going.

Originally Posted by generalee7

Ballistic used to sell those but I can't find them on their website anymore.

I know that your rig is leaf sprung, but just in case you change your mind:
http://www.ballisticfabrication.com/...p_32-1183.html

[Mawnov]

Originally Posted by Philfab

Current issues:

- XJ springs were WAY cheap, so I bought them. Got them mounted up and starting to think that they are just too damn big. 24" free height and nearly 6" in diameter. These are fairly soft, but I'm still considering going with something like a Ballistic Fab/blue coil 18" tall 200-250 lbs spring as those are merely 3" in diameter.

Comments, ideas, suggestions?

Ive always liked the idea of going with the smaller coils your mentioning. It should still do the same job, its smaller and should fit well. Its not to common.

[Philfab]

Test fit the links, seeing if I need to clearance the driveshaft. Should be alright.


Finished the Driver's side frame plating (finally).


For this weekend:
-Finish mounting steering box and hook up plumbing lines. I need to plug the hydro-assist ports for the time being.
-Finish link ends and get axle located.

[Philfab]

Cut off the end of the stock pressure line, bored out a -3AN fitting and welded it on. It doesn't leak but I'm still going to go back and braze it.


Hooked up the steering lines, filled the res and called it good.


Ballistic Fab shock towers didn't come with the bungs, and rather than spend $25+ shipping I decided to make my own from some 3/4" pipe and extra thick washers.



Had to trim the towers slightly to fit, in addition to massaging the inner fender to allow the bolt to clear. 12" travel 5100 from TimBhudda.


Couldn't contain myself, so I welded up a temp muffler and used my commuter Saturn to crank her over. Video here:http://s157.photobucket.com/albums/t...t=PA100350.flv

[generalee7]

You are running a Waggy axle? I'd love to do a setup very similar to yours once I can afford it

Can't wait to see it on tires!

[Philfab]

Originally Posted by generalee7

You are running a Waggy axle? I'd love to do a setup very similar to yours once I can afford it

Can't wait to see it on tires!

Aiyup, D44 out of an 88 Grand Wagoneer.

Painted up


Still on stilts


Exposed shock shaft. I need shorter, softer coils and 10" shocks. I figure I can swap out the 12's I have out back that are absolutely beat to shit for the one I have up front, and just buy some new 10's.

[Philfab]

Oil pan kit shows up tommorow, and if my joints aren't shipped I am going to come un-fucking-glued (potential scathing review but I will give folks the benefit of the doubt).

Whats left...
Short term (This week):
- Install panhard after oil-pan is mounted
- Swap shocks for 10" travel units
- Swap springs for 18" x 175lbs ones
- Finish welding, grinding, painting, etc.
- Bleed brakes.

Long term:
- Gears and locker for the 44, (going with 4.88's and an Aussie)
- Re-gear rear-end (locker already installed, 4.88's sitting in the garage)
- Install double-ended hydro ram and cooler (lines are already made)

Really long term:
- Crawler
- 3-link rear

[Philfab]

Just in time...

2-5/8" Ballistic joints, square tube inserts, poly bushings and jam nuts.



Little irked that they don't come with set screws or zerk fittings like they show in the ad. Oh well...


Slightly disappointed that the square tube insert isn't threaded all the way through, so the there's about 2" of stud still showing. That was clearly stated on the site though, so I can't really bitch, I mean, they build all kinds of other pimp shit, can a brother get another 1/4" of threads for his $17 + S&H?


I'm praying to every known deity for good weather tommorow, keep your fingers crossed, and we might just see Bumpy rolling.

[toy86]

ballistic is cool but good luck with those joints, every one ive seen personally run has ripped the stud off but they'll hook you up with a new one

[Philfab]

I haven't read any bad reviews about them, but thanks for the heads up, do you have any pictures of a broken one?

I did notice that the welding is ever-so slightly undercut in a couple places, I should take them into work and let the Con-Am guy take a couple shots, he's got to be getting tired of x-raying concrete.

[Booger Weldz]

throw some numbers from this bad boy in the link calcualtion census thread!! undercut and lack of throat(enough filler) on those welds maybe? hard to tell, the whole thing could have been beveled and filled with weld and those could just be light cover passes to make it 'pretty'? i buy stuff from ballistic like every other week...they make cool shit! i actually wish they would expand theyre product line so i could just shop there for everything...

[Philfab]

Easiest part of the build:


Nothing fancy here:


It's not quite ready to roll, but oh, what a feeling:



I did manage to get the flex joint stuck in the last tube adapter I welded up, made the vast assumption since the other ones didn't need the threads chased, and I was a bit excited to get the thing together. Fought with it for about 10 minutes and realize I should've been a bit more patient. Oh well, worst case is that I'm out $20. Lesson learned.

[generalee7]

It looks as though your coils are doing a little bit of this action \ / . Is there anyway to fix that on a Waggy axle?

[Philfab]

Originally Posted by generalee7

It looks as though your coils are doing a little bit of this action \ / . Is there anyway to fix that on a Waggy axle?

Correct, they are in a V shape. Taco frames are kinda wide up front. The lower coil buckets are crammed next to the C's and the uppers mounts hang to the outside of them by an inch and a half on either side. I thought that I could get away with redrilling the upper mounts but the coils are just too damn big. I'm going to be switching to a 18" long 2" ID coil which will free up all kinds of room to get things mounted inline.

Daylight:


Upper link tucks in...


I managed to salvage the jammed flex joint and tube adapter through the process of piling about 3/4" of weld to get it cherry red, bathing it in penetrating oil and an enourmous pipe clamp in conjunction with a wrench on a cheater bar. I collapsed 20 minutes later in the yard with the link in one hand and the salvaged joint in the other. Little bastard may have won the battle, but I won the war.

"There is no mechanical problem so vast that it cannot be solved through brute force and ignorance."

[Philfab]

wheelbase: 123"
weight: 4,200
true tire diameter(at 25 psi): 32.5"
rolling radius:15.5"
Center of Gravity(top bell housing bolt): 36"


front suspension:

antisquat(dive): 102.56
roll axis angle: 8.34
roll center height: 16.71

seat of the pants comments: It's getting there...

[laproscopic]

love your build

I buy stuff from balistic all the time. I am ising 16 of their balistic joints right now.

they do come with the zerc and set screw. you got screwed and I would give them a call and have them send you the parts they owe you.

And the square tube adapters that dont go all the way through are simply bulshitty machining. they owe you new ones of those also.

I like the balistic stuff and it is all over my truck but they do cut corners on their machining. My biggest complaint is how rough the treads have been cut on their tube adapters in my past orders. just sloppy. you want nice machinework get the adapters made by evolution machine.

rant over.
keep it coming

[Philfab]

Originally Posted by laproscopic

love your build

and the square tube adapters that dont go all the way through are simply bulshitty machining. they owe you new ones of those also.

I like the balistic stuff and it is all over my truck but they do cut corners on their machining. My biggest complaint is how rough the treads have been cut on their tube adapters in my past orders. just sloppy. you want nice machinework get the adapters made by evolution machine.

rant over.
keep it coming

I'll give 'em a jingle about the zerks, I have to order mo' stuff anyways.

I figured that I had to buy a tap anyways to chase the threads after welding, so I don't feel like I've been had.