Project Du - Deconstruction / Reconstruction (56k Beware)

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:


A pre-work, as-is photo...


Feeling Disconnected...


Compare & Contrast...


Back Together


Looks Good, right?


Old on the left, new on the Right


Enough blocks to build an adobe


Oh shit..


As she sits right now..




The drivers side hangar, cut away

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!

looks really nice, nice truck

looks like a sweet rig

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.

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

chico4554 said:

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.

Click to expand...

I wanna paint em red first

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.

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

chico4554 said:

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

Click to expand...

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...

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.

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:

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!


old rivet versus new Grade 8


a little torch work


almost-finished product


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

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.

JFA_Spyderman said:

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.

Click to expand...

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.


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

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