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Discussion Starter #1
Figured I'd cross post this over here for those who don't venture to some of the other forums.

Vehicle originally had ICON coilovers in the front and their shocks/coils in the rear. Lefty and a whole bunch of other goodies to boot.


Out goes the old axle






In goes the Total Chaos 2" Long Travel setup.










Rear Axle



Misc Parts all over the place

 

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Discussion Starter #2
More of the front and rear comming together.








Old link to frame mounts gone.









Trying to keep the link mounts from being too low while still targeting the #s on the calculator





For reference here is how low they normally hang on an OEM/normal currie 4 link setup.

 

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Discussion Starter #3









Lower link position when upper link contact crossmember.




Upper link tack'd on frame.




Track bar looks like it will need to be bent a bit.




Ride height



New frame mounts



Link clearance at frame at full uptravel



Some stuff just gets in the way




 

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Discussion Starter #4
Wheel position @ full uptravel (I think...can't remember when I took the photo).




Coils & Jounce Shocks in place




So close to being finished, and then things changed. I didn't like the fact that I wasn't getting the travel #s advertised on the front. UCA uniball would have to go through the fender (and LCA uniball through the rotor) to get those numbers.












The advertised rear numbers weren't accurate either once taking a closer look at the spring. Definitely weren't getting as much use out of a 14" shock as I had hoped. So we are starting to tinker around with some other options. Since the axle is 4" wider than normal it freed up a bit of space at full uptravel.





Still a bit tight though at full articulation. Although I think some spacers should take care of that. But if I'm going to be 3.25" wide or more on each side in the rear, I'm going to have a bit of headache with law enforcement in Houston....already were checking how far out my wheels were with respect to the fenders the one time I got pulled over.

So fiberglass is in order. If I'm doing that in the rear I might as well toss them on in the front. And if the are on in the front I might as well shoot for a wider front setup to match the track width...plus I could go with another kit which actually is supposed to meet their advertised numbers. :D
 

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Discussion Starter #5
Front locker/gears going in.








Thought I had also snapped a few pictures of the rear end parts order that showed up Friday, but apparently my memory card is full and or didn't grab them. Basically we'll be notching the the frame and possibly coming up through the wheel wells if needed with a tower to run a 14" coilover with reservoir.

Rear interior and storage system removed in case the fender wells need to be modified a bit.

 

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Looks great, glad to see someone really going for it. It is very difficult to make the triangulation #'s work on an FJ given the frame width and shape and the body being a limmiting factor. I would be interested in seeing your #s in the calculator. Did you wiegh your wheels individually? Did you find your exact COG or dod you just use your center bell housing bolt? I'm not sure using wheel spacers is the right choice for getting the clearance you need. I think this will effect your calculations as you would have to increase the axle width. I have heard that back spacing on wheels will actually effect the #'s.

It apears that you have about 10" between upper and Lower Link CL at the axle. Is that what you started with? I think running your uppers to the frame instead of to a cross member could be thowing your 3's off because the difference between the frame connection points of uppers and lowers is minimal compared to the difference in thier lenghts. Well, not sure, I'm still studying the math involved in this and could be completely wrong.

The Rear shock towers are a cool idea and the fab work looks great. Keep us up to speed this is the sort of thing that need to be on here instead of what color your FJ is.
 

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Discussion Starter #9 (Edited)
No, race scales weren't used to determine CG, so there's not a whole lot of use tossing the numbers out there since assumptions were made for the CG of my FJ from the get go.

The three link "kit" was from Metal Tech and I've seen the calculator numbers that they ran, but I'm not going to speak to their #'s since I don't know their accuracy (or how they determined their CG). What I did know was that I wanted the IC location further forward to reduce the AS #s that they were getting and based on what I got on the calculator (assuming both our CG estimates were close (which they may or may not be)). Since I'm planning on using this for high speed stuff and playing in the rocks we aimed to modify the design to hit ~50% AS and keep the RA below the assumed CG. There is still some modification to be done to the links themselves, but that will be addressed in due time.


You are close on the link seperation(~8-9", have to go back and check cause I don't have anything on this computer). I'm not really sure what you are saying in your statement though. There is only one upper since its a 3 link suspension and the length difference between the upper and lowers is 4". Modifying width or backspacing would change the numbers, but not much more than a few % on the AS perhaps (calculator #s were run with a 4" wider axle as is, so you'd add 2.5-3" to that).


I'm always open to ideas or suggestions, still learning this myself (surprisingly I didn't have any classes on suspension design for my ME degree, so this is all fairly new to me).


If I actually get access to some scales I'll post up the true calculator numbers (rather than those that are based on assumptions from the get go).
 

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Discussion Starter #15
It hits cleanly in those photos. When articulated and loaded at some different angles it might not make as clean of contact. Likely end up welding on a pad for it to land on.
 

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Discussion Starter #17
New front came in. Camburg setup is much nicer than the Total Chaos all around. Definitely no regrets going with Camburgs over TC's 3.5"kit. Right now it looks like we are getting about 13.375" of wheel travel. Have to figure out how we can eek out a bit more cause the shock still has travel left. Flipping the LCA spacer will buy a bit of travel. Uptravel could be gained by chopping the fender well and reframing. Waiting for a call back from Camburg.


For comparison purposes - upper uniball on both kits.

















 

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just a tip... reinforce the lower control arm mounts

Thicker material and brace them across to one another, they will not stand up to much stock
 

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Hmmm.....this rig looks familiar! Didn't know there was a thread on here for it.

The LCA mounts will be boxed, I'm just playing with the alignment of the lower arm before we make anything solid.

Just got the Trailer Products front fenders sitting in place, and threw one of my Krawlers on for fitment.



 
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