Project Du - Deconstruction / Reconstruction (56k Beware)

[du510]

So I've collected a couple of parts to install this weekend:
- SJ 6" Coils (To swap with my RC 4" coils)
- SJ 6" Leafs (to swap with my stock leafs, 4" RC block)
- SJ Sway Bar End Links (to swap with stock links)

The front went pretty smoothly - I did it last minute so I was alone... I am running with 4" drop brackets so I had to compress the springs pretty tightly to get them in. Drivers side went in easy, passenger side was a f'ing PITA. Does anyone else notice SO much less articulation on the passenger side? It was unbelieveable. The sway bar end links - if anyone gets them just be careful, gotta cut the bushing the bottom end shorter to fit.

So I ran outta daylight (big storm, got dark early) so I saved the rear springs for Sunday. No big deal, get it all disconnected. Plan was to swap out my stock + 4" RC lift blocks for the NO blocks, and the springs with a shackle. Well comes time to disconnect at the front hanger, and I see the massive crack. Just plain unsafe to drive, youll see the picture below. It was widening anytime there was pressure on it, to about 1/4". The passenger side is starting to rust away too, so Ill just fix em both. Plan is to get the hangers from FORD and after some grinding & rivet-punching, install the new ones. Also, the rear hanger area on the frame is starting to rust away, so I am going to fab up a gusset for those.

I dunno when Ill be able to get to it, but Ill post up some pics of that when I do. Enjoy the photos.




Some of the parts:
http://img266.imageshack.us/img266/8531/picture001toolsofthetraya7.jpg

A pre-work, as-is photo...
http://img138.imageshack.us/img138/955/picture002blankcanvasdd2.jpg

Feeling Disconnected...
http://img90.imageshack.us/img90/205/picture003feelingdiscondv2.jpg

Compare & Contrast...
http://img266.imageshack.us/img266/8793/picture004comparisonshouk4.jpg

Back Together
http://img138.imageshack.us/img138/2175/picture006reconnectedwr6.jpg

Looks Good, right?
http://img90.imageshack.us/img90/8159/picture007lookingoodux4.jpg

Old on the left, new on the Right
http://img138.imageshack.us/img138/7452/picture008oldvsnewmq1.jpg

Enough blocks to build an adobe
http://img138.imageshack.us/img138/6698/picture009blockspc7.jpg

Oh shit..
http://img266.imageshack.us/img266/1940/picture010rippedfronthakb7.jpg

As she sits right now..
http://img266.imageshack.us/img266/5254/picture012asshesitsqo6.jpg
http://img90.imageshack.us/img90/8422/picture013asshesits2oq6.jpg
http://img138.imageshack.us/img138/6015/picture014onbucketsaz7.jpg

The drivers side hangar, cut away
http://img138.imageshack.us/img138/5194/picture016cutawayrm4.jpg

[metalmacguyver]

yeah, those things have a habbit of rusting out. good thing you found it before it put a hole in your bed. they are not to expensive either. looks good!

[PaleBlue90]

:icon_welder::agree: looks really nice, nice truck:woot:

[aj1493]

looks like a sweet rig

[chico4554]

shoulda put them axle drop brackets in when you had the coils out. Its much easier. And when you do put the coils in, take the sway bars off, and step on the hub. You can get plenty of room to slide the coils in after that.

[chico4554]

is that your shop? If so, thats nice!!

[du510]

shoulda put them axle drop brackets in when you had the coils out. Its much easier. And when you do put the coils in, take the sway bars off, and step on the hub. You can get plenty of room to slide the coils in after that.

I wanna paint em red first :drool:

But I did have the sways disconnected, and still the issues?!?! The drivers side was AOK, no issues really. But the passenger side was 100% a different story.

[chico4554]

thats odd, did u try to step on the hub?

[du510]

thats odd, did u try to step on the hub?

Yea - very strange
everything was disconnected
i was standing, in the air, on the hub

all i can think is that the radius arm held it back, nothing else should have...

[chico4554]

that is odd, i had pretty much the same setup when i put those coils in, and had plenty of room. maybe my radius arm bushings were more worn out, so it flexed more. who knows.

[du510]

Quick update here...

This weekend I am hopefully finishing putting it back together, at least the rear. Ive got the following parts, also:

- Duff Traction Bar (they sent me two I am hoping a combination of parts will work for me
- Skyjacker Shocks, all around
- Skyjacker steering stabilizer
- Skyjacker double-front shock kit

It was like christmas today:
http://img211.imageshack.us/img211/4323/attachmentqs9.jpg

[du510]

A little deconstruction / reconstruction today...

Started off on the passenger side, grindin away at the stock front hanger. Took some time but no issues. Then moved on to measuring/cutting some steel to use as a gusset on the inner side of the frame, inside where the rear leaf spring handers bolt in (The frame is starting to rust away under the hanger plate). Got that all squared away, then started to put things together when we ran outta daylight.

Couple issues:

- The Duff traction bar doesn't fit flush with the ubolt top plate. Ive got 2 sets (they sent me the wrong ones) and neither fit. Pretty upset about that.

- I am trying to go without using stock blocks (ie: have the springs sit on the pad, no block), but the damn ubolts dont have enough thread. May have to have the stock blocks in there, in the end.


aint it a beauty!
http://img261.imageshack.us/img261/90/img0784or5.jpg

old rivet versus new Grade 8
http://img61.imageshack.us/img61/5527/img0786pe6.jpg

a little torch work
http://img61.imageshack.us/img61/2507/img0787gy1.jpg

almost-finished product
http://img402.imageshack.us/img402/7678/img0788la7.jpg

So tomorrow, I am hoping to bang out the driver side nice & quick, hoping for an early start!

[JFA_Spyderman]

Yo,
you diddnt have the old shocks connected when you tried to fit the new coils in, did you? My guess is that you were hitting the end of the shocks to get the new coils in.

The only reason i mention it is because we were pulling coils out and i couldnt figure out why this coil wouldnt come out. The shock was maxed out.

[du510]

Yo,
you diddnt have the old shocks connected when you tried to fit the new coils in, did you? My guess is that you were hitting the end of the shocks to get the new coils in.

The only reason i mention it is because we were pulling coils out and i couldnt figure out why this coil wouldnt come out. The shock was maxed out.

Glad to see I am not the only one still up thinkin trucks at this hour of the night.

Nope, the shock was disconnected. That got me the first time I took apart the front end, but now I've done it 3-4 times. :icon_welder:


Edit: NM, I see youre out west. Its a bit earlier for ya.

[red85]

How much was that leaf spring hanger? My 94 needs one and I'm terrified to call Ford to hear the price LOL

[littleredrangerhood]

Go on ebay. They will run you about $40 for the pair of hangers including hardware.

[du510]

How much was that leaf spring hanger? My 94 needs one and I'm terrified to call Ford to hear the price LOL



I almost bought through ebay, but instead listened to the following advice:

Check out this site. They have all the brackets, bolts, and other suspensions parts you could want; and they are great on the phone re: information. www.stengelbros.com:bye: Click on SPRING ACCESSORIES to see front and rear hangers & shackles, etc.for Fords.


I ended up calling them up to talk to em about what I needed, and they were great. No problems whatsoever, and the parts are great. No complaints, at all!

[du510]

Today's work:

After a big ol breakfast, went to work on the passenger side front hanger. Stuffed the space on top of the gastank with old clothes soaked in water, then hosed it down for good measure. Also set up a towstrap from my truck to another truck, ready to pull me out if we got lit up!

The grinding went fine, no problems whatsoever. Popped the little suckers out, and realized how little room there is to work on the backside of the frame, between the frame & the gastank. So after much pondering and angry words, we decided to notch the bolts, and run them out from behind. Worked great! You can see it in the photo.

Put in the gussets in the rear, put it all back together. Did my best to install the Duff traction bar, but none of the brackets fit. So, thatll be going back to them.

Here are some photos:

The driver side front hanger. Note the notched grade 8 bolts.
http://img116.imageshack.us/img116/7109/driverfronthangerel3.jpg

The gussets, drivers side first, then passenger:
http://img132.imageshack.us/img132/9747/drivergussetok5.jpg
http://img206.imageshack.us/img206/6843/passengergussetqp4.jpg

A few general photos:
http://img206.imageshack.us/img206/2632/truckuv7.jpg
http://img206.imageshack.us/img206/5598/truckcorneryh4.jpg
http://img263.imageshack.us/img263/5385/rearunder2jn1.jpg

So the bulk of my work is done. It is driveable! But the list is still there:

- 1pc drive shaft, ASAP
- Longer rear brake dropline
- SJ front drop brackts
- SJ extreme drop pitman arm
- Steering Stabilizer
- Dual shocks up front
- Swap out the shocks all around
- Get this damn duff traction bar to work!

:icon_welder::icon_welder::icon_welder:

[du510]

Reposting the driver side hanger, so you can see:

http://img261.imageshack.us/img261/7648/driverfronthangergq2.jpg




EDIT: making it just a link so it doesn't F-up my thread, the pic was too big.

[du510]

Just a cool pic I took tonight, of my truck next to my wife's new FJ Cruiser.

http://img119.imageshack.us/img119/4281/attachmentla1.jpg

[zainyD]]

Looks good so far, but man, your truck has a lot of cancer.

[du510]

;43067']Looks good so far, but man, your truck has a lot of cancer.


Ya there is... its the product of New England winters. I have taken care of a LOT of it, but there is still so much to go.

Just FYI - behind the brackets is brownish spraypaint, not rust. I didn't have any other color, and just wanted to get it done.

[du510]

Got a little bit done this holiday weekend:

Swapped out a buddy's LCA's: (thats me underneath)
http://img261.imageshack.us/img261/8291/photo002jp1.jpg

And I am obviously no painter:

http://img20.imageshack.us/img20/7821/photo009gi3.jpg

And I ordered longer radius arm drop brackets (till I make the jump to longer arms), and the extreme drop pitman arm. Should be good to go this comin weekend!

:3gears:

[Dishtowel]

I noticed your running some very nice looking shock boots on your old shocks. I can't recommend installing them on your new Skyjackers, this is what I found in mine when I was doing some front end work. I decided that shock boots are not for offroad trucks.
http://memimage.cardomain.net/member_images/1/web/2929000-2929999/2929003_109_full.jpg http://memimage.cardomain.net/member_images/1/web/2929000-2929999/2929003_110_full.jpg
If you didn't have this grossness then keep by all means keep them on!

[du510]

I noticed your running some very nice looking shock boots on your old shocks. I can't recommend installing them on your new Skyjackers, this is what I found in mine when I was doing some front end work. I decided that shock boots are not for offroad trucks.
http://memimage.cardomain.net/member_images/1/web/2929000-2929999/2929003_109_full.jpg http://memimage.cardomain.net/member_images/1/web/2929000-2929999/2929003_110_full.jpg
If you didn't have this grossness then keep by all means keep them on!

Mmmmm, looks like youve done some good muddin! Ill keep em on, but maybe Ill wash em out after muddin.

[Toreadorranger]

Mmmmm, looks like youve done some good muddin! Ill keep em on, but maybe Ill wash em out after muddin.


That doenst solve the problem, the boot keeps both mud/dirt AND Water trapped in it, which is bad for the shock. Just take them off, they dont look good anyways.

[du510]

That doenst solve the problem, the boot keeps both mud/dirt AND Water trapped in it, which is bad for the shock. Just take them off, they dont look good anyways.

It would work, because naturally I wouldn't tighten them back on until they drain & dry out. But in that it is my truck, and I like the way they look, they will stay on. :buttkick:

;)

[Dishtowel]

If you get your hands on a leather punch, or even a decent one-hole paper hole-punch then you could put 2-3 holes near the bottom of the shock boot, and one on the top to wash them out. I would use a pressure washer, and I would make sure to do this anytime I was in the mud.
I put mine on when I built it this spring liking the looks as well, but I've definatly grown to like the looks of shiny shock shaft as well. It has it's own bling every time I hit a bump, lol.
Good work on your build, what is a LCA ? the thing on the jeep that you helped your friend with..?

[du510]

If you get your hands on a leather punch, or even a decent one-hole paper hole-punch then you could put 2-3 holes near the bottom of the shock boot, and one on the top to wash them out. I would use a pressure washer, and I would make sure to do this anytime I was in the mud.
I put mine on when I built it this spring liking the looks as well, but I've definatly grown to like the looks of shiny shock shaft as well. It has it's own bling every time I hit a bump, lol.
Good work on your build, what is a LCA ? the thing on the jeep that you helped your friend with..?

Thats a decent idea...


LCA = lower control arm. No leaf springs - hes got a coil, then an upper and lower arm that connect the axle to the frame. Similar to how we have the radius arms up front... kinda.

[chico4554]

the only problem running bootless is then the shaft tends to get rust on it quicker. I think when i get shocks i will end up running bootless.

[du510]

Decided to move the truck yesterday, from my apartment parking lot up to the barn. Just some cool photos, I think:

http://img267.imageshack.us/img267/5108/photo1tc5.jpg

http://img296.imageshack.us/img296/4350/photo2ai7.jpg

http://img257.imageshack.us/img257/418/photo3hr4.jpg

http://img508.imageshack.us/img508/3511/photo4ck7.jpg

http://img508.imageshack.us/img508/6276/photo5cs4.jpg

http://img180.imageshack.us/img180/7231/photo6nf6.jpg

http://img508.imageshack.us/img508/4749/photo7ed0.jpg

Picked up some more grade8 bolts today, should finish up the radius arm brackets tomorrow. Hopefully!

[du510]

And just for ha-ha's, here is an old photo I came across wihle cleaning out the computer:

http://img176.imageshack.us/img176/3600/truckfrontpreliftwh0.jpg

[du510]

Radius arms are just about done. Theyre all bolted up except for the tabs that bolt to the bottom side of the frame. For those, though, Ill need to drill into the frame... so maybe next weekend. Till then, its in the shop right now for an alignment & some safety checks, maybe the longer rear brake lines too.

Here are some photos.. (I think i just like taking photos)

http://img245.imageshack.us/img245/2460/photo1vs4.jpg
http://img526.imageshack.us/img526/2561/photo2ha6.jpg
http://img526.imageshack.us/img526/2368/photo3lw4.jpg
http://img526.imageshack.us/img526/4268/photo4rk7.jpg
http://img526.imageshack.us/img526/6959/photo5ak2.jpg
http://img296.imageshack.us/img296/2966/photo7ou0.jpg
http://img518.imageshack.us/img518/7594/photo8bv0.jpg

Once this is said & done, Ill just have small projects to do:
- 1pc DS
- Swap out all the shocks
- Steering Stabilizer
- Dual shocks in front
- Rewire/reinstall the CB
- Install the sub/amp
- Install Duff Tracbars
- Install Shifter bushings
- Swap out the TTB bolts with some newer/longer ones

I think thats about it... Ill think of somethin. :icon_welder: