My re- SAS 05 DCAB build

oh, I see. Not to sure, but maybe that was a mount for the coilovers that was cut off. Definatly don't think it was factory

 

The picture is focused on the old shock mount, to the right looks like a hideous frame plate. I completely understand wanting to redo it.

 

Ahhhhh, I see it now, the OG owner plated the whole frame from left to right. Holy shit burn that off with fire, NOW!

 

last night we looked at how bad the frame plates are. originally the plan was to just grid out as much of the welds as we could and just TIG it so the frame plates looked pretty…needless to say that went out the window

the current plan it to actually cut the face of the frame off and rebuild it from plate. we haven't decided if it will be a single 1/4 plate or a 1/8" plate with another 1/8" over it to bridge the seams. we are planing to french in some air bump cans so that will play into the decision a little I am sure.

 

After seeing that pic I wondered if you would slice it out or not. This thing is going to be sexy.

 

weekend up date…
I got a little done. I installed the Inchworm Taco Box, did the twin stick modification to the FJ case and installed that. pulled the radiator. did a little frame cleaning with my least favorite tool the grinder….oh and slid the axel under it
we are waiting on some stuff to come in. at the moment. mainly a HUGE ballistic order that was placed almost a month ago that hadn't shipped as of last thursday because they were missing one, yes one jam nut. a large order of plate and tube. I still have to extend the wiring for the engine bay fuse block. looking to do that Wednesday. David is going to finish cleaning the frame and get the NWITaco brackets mounted and should have a design for a crossmember/skid plate…with a little luck next weekend we may have the suspension linked with PVC and have some pictures worth drooling over.





ohh yeah if you were wandering if I took some kind of action about the output bearing in the Taco box. I did. I also replaced that with a bearing from MRO supply today…
this is the one I used for those who are interested (thanks Mark, again)
https://www.mrosupply.com/product/1132940-5209CG-MRC

 

No problem Josh! Looking good. Any reason you didn't clock that t-case more to get a flatter belly?

 

We need measurements at multiple locations for future reference.

 

Subscribed

 

Mmmmmm my pants just filled up with happiness.

 

Nice job man. Keep at it and never make compromises to your plan. I like the way your approaching this.

 

thanks for all the positive feed back guys. I am super excited and David is having a hard time holding me back. We made some pretty substantial progress last night since I was free and David was also we both worked on it ALL NIGHT…as in just put the tool down a few minutes ago. we were getting retarded from sleep deprivation.
things we accomplished.
-I finished the crawler, FJ case install and clocked the rear case
-extended the wiring for the t-Case sensors and terminated the no longer needed plug for the actuator motor
-The frame is completely ground and sanded of all the old shit!!!
-Installed DMZ fab motor mount gussets (frame isn't cracked but it is an '05 and I was being proactive)
-Mark's frame brackets are clean, pretty and installed.
-performed major surgery on the pass side frame plate…plasma cutter is now dead
all the brake crap under the hood including hard lines master cylinder, and ABS valve are gone.

unfortunately my phone died so I didn't get any pictures…hopefully david will log on and throw up some photo or I will get them this afternoon when I head back out there.
in addition we have a huge order of steel and aluminum tube and plate that is supposed to be delivered today

 

Can't wait to see my brackets on another rig, exciting day for me as well!

 

This better be true, otherwise this post is useless....

 

Hopefully it died from you taking so many pictures

 

Subbed!

 

picture update as promised. I have more but will share these for now
this is the ridiculous pile of trash generated from all the grinding…most have the mandatory IFS hits the ground picture. i didn't get that pleasure. to be honest I am pretty sure it would have been a hell of a lot easier if i had started with a stock rig. this pile doesn't include the brackets or the brake lines and other brake poop we tore out…so if you want to know how much grinding is required to do an SAS…a hell of a lot. needless to say I hope to never see a girder again though it is inevitable…my hands are still vibrating

Mark this is just for you…only enough to tease you of course

when I said we cut the frame this is what I mean


and finial crawler install


been going hardcore for almost 48 hours…I think I will go take a nap

 

Geez, give the guy a break Some people are too busy building to satisfy the craving of a bunch of web wheelers

 

Looking good Josh

 

I gotta get my phil somehow since I sold my sami project....