1993 Splash in SC

[Uncle Gump]

What fun is that?

But I totally understand.

 

[Curious Hound]

The last details of my new truck bed installation revealed.

 

[Curious Hound]

Finally started working on installing the new spring buckets for the front coils, so I can get ride height and front end geometry fixed right. I basically needed to raise the top of the spring 1 inch (I hope). Here is what I'm starting with.

I had ordered the tall spring buckets for F150's and full size Broncos from James Duff since I am now on F150 style coils. I measured, remeasured, calculated, recalculated, checked and double checked everything. Then, second guessed my work and measured, calculated and double checked some more. Finally removed the old bucket and clamped the new one in place on the passenger side.

Then I added a bracket for the brake line/hose connection. And constructed an upper shock mount. Finally drilled some holes and got it temporarily bolted on. The frame had a little bit of rust. So I'll get out the Rustoleum on Friday before I start the final assembly.

 

[Curious Hound]

Well, dang it! So I built a lower spring seat and put it on the axle beam. Temporarily bolted the new bucket in place. Put the spring in and let the weight of the truck down on it and found that I still need to raise the spring bucket about another 1.75" higher.

The tech article recommends having the center of the outer end of the hub about an inch lower than the axle pivot bolts. So made sure the truck frame is the same height off the driveway on each side so I can use the driveway to measure from. When I did that, I found that the 2 axle beam pivot bolts are at different heights. So. What do I do? Use an average? I have the new bucket off again. I'll drill new holes and mount it. And that's where it will be.

Something isn't making sense. I don't think I have good data for Skyjacker spring rates. The 6" coils from my lift kit supposedly have 435 ppi. They were about 15.5" installed. That should be about 1468 pounds if compression on each one. My new F150 Skyjacker springs are supposed to be 452ppi. Divide 1468 by that and I get 3.25" of compression. The new springs are 21" long unloaded, so that load should bring them to 17.75". But they held at 19" when I put them in. Anyway. Where's my drill?

New bottom spring seat. The coil wraps around the outside of that sleeve.

 

[Curious Hound]

Got that corrected. In the morning, I can clean and paint the parts and frame on the passenger side. Then, while paint is drying, I can work on the driver side. That should go a little bit better since I have dimensions and design worked out. But the frame is funky on the driver side. So that will involve a little bit of extra engineering.

New, improved passenger side bucket.

 

[Curious Hound]

Where's that thread where we sarcastically thank engineers for the stupid crap they do? I got the driver side IEM coil bucket removed. Here us just exactly how funky the frame is on this side. The scribe marks show the center and edges of where my new bucket needs to be. At the forward side, the top of the frame bulges out an inch. That is where the frame is boxed to mount the steering gear on the other side. This should be fun to overcome. I can't just space the bucket out that far because that will screw up how it meets up with the axle beam. The flat side of the frame on this side is about 3/4" inch closer to the bolt for the lower spring mount than it is in the passenger side.

Holy asymmetries, Batman!

 

[alwaysFlOoReD]

Time for cutting and welding....

 

[alwaysFlOoReD]

Where's that thread where we sarcastically thank engineers for the stupid crap they do? I got the driver side IEM coil bucket removed. Here us just exactly how funky the frame is on this side. The scribe marks show the center and edges of where my new bucket needs to be. At the forward side, the top of the frame bulges out an inch. That is where the frame is boxed to mount the steering gear on the other side. This should be fun to overcome. I can't just space the bucket out that far because that will screw up how it meets up with the axle beam. The flat side of the frame on this side is about 3/4" inch closer to the bolt for the lower spring mount than it is in the passenger side.

Holy asymmetries, Batman!
View attachment 76041

Without actually being there I would look at cutting and welding the bucket to fit the frame.

 

[Curious Hound]

Time for cutting and welding....

I think I'm going to modify the bucket. I'll space it out 1/4" by adding plate on the back. Then I'll cut away what I need to clear the bulge in the frame. Then strengthen the side rib of the bucket with more 1/4" plate. It's going to take some time.

 

[Curious Hound]

Proposed cutting.

 

[Curious Hound]

So, I got this tacked up. I was able to do ot without adding 1/4" plate on the back to space it out. I think this will work fine. Once I drill the 1" hole in the top part of the shock bracket, I'll tack that on and weld it all up.

Passenger side is assembled. I just need to finish bending and fastening the brake line. Plus, I bought new hoses for the brakes.

 

[sgtsandman]

Is the spring going to clear that hump in the frame when the suspension cycles up and down?

 

[Curious Hound]

Is the spring going to clear that hump in the frame when the suspension cycles up and down?

I'm 93.174265% sure it will. The hump, at the centerline of the spring is barely protruding into the bucket - maybe 1/8"-1/4" at most. And the hump has such a gradual slope that the curvature of the circumference of the spring opens the clearance pretty fast. If that makes any sense. Best way I can describe it without drawing a picture.

 

[sgtsandman]

I'm 93.174265% sure it will. The hump, at the centerline of the spring is barely protruding into the bucket - maybe 1/8"-1/4" at most. And the hump has such a gradual slope that the curvature of the circumference of the spring opens the clearance pretty fast. If that makes any sense. Best way I can describe it without drawing a picture.

Ok. Just hard to tell from a picture. It just looks close enough to cause me to have a doubt but I'm working from a picture and not seeing the real thing in 3D.

 

[Curious Hound]

Ok. Just hard to tell from a picture. It just looks close enough to cause me to have a doubt but I'm working from a picture and not seeing the real thing in 3D.

I had my concerns. I measured it out and also held the disc for my lower spring seat up there to help visualize. I'm not out of the woods until it's finished and tested. That bolt head protrudes more than the hump. That's in an existing hole. Thought about not using it. But I want fasteners without drilling too many new holes in the frame.