IFS to 1 ton Truggy

So... Umm, had too much fun wheeling this summer, but really hate IFS. Here's some shots from this summer into winter.




So it's Dana 60 one ton time! I suppose I'll pick up this thread again, since I'm doing more than wheeling every weekend now.

 

Good luck with the SAC.

 

I have no legs...

 

-Yoinked all the front IFS bullshit out.
-Cut the rear so it's easier to walk around in my tiny garage, left enough to put axle on (frame = redneck workbench)
-Got a killer deal on 1.25 Heims for links (3 link front, 4 link rear)
-Got gears delivered for the dana60/sterling 10.25 (5.38 Yukons)
-Cut out the inner fenders, removed the radiator, going to use electric fan for cooling and find a shorter radiator (2wd Auto is 18.5" tall)
-Repurposed my old winch mount from TrailGear for front crossmember, burned in (lots of gap fill welding)
-Bent up tubing for radiator core mount
-Pulled apart the D60 for regear and truss weld
-Got the steering shaft yanked out
-Waiting for rear sump oil pan
-Found set of 16" beadlock steel wheels with roller 40s (bald) for $150
-Grabbed metal to fab up sliders (2" x 0.25" wall square tube)
-Picked up 16" 2.0 FOA dual rate coilovers and 16" Racerunner Nitro shocks


Need to:
Strip the Sterling, regear both axles weld spiders and plate, manual hubs on d60, fab up axle trusses + link brackets, come up with a solution for rear linkmount/crossmember/transmission mount all-in-one, motor tube with fender mounts, shock towers for both, tube rear, mount fuel cell and wire up external pump, wire up battery relocation (next to fuel cell) and cover with plastic boat battery box, change oil pickup and dipstick to rear sump, re-run brakelines (maybe change out master), sort out IFS steering box mount and tack the wheel side steering shaft (spline shaft size is wrong), remove my air bag before I get a black eye, and buy 2" x 0.25" wall DOM for suspension links, get 150/200 springs for front FOAs, fill 200psi on the RR Nitros. Rewire lights (since I'll no longer have headlights I'll be using the 4" LED pods).

Lastly, I'll need to get an effin trailer.

 

Cool build.... subbed

 

Hard to get things done with a 3, 5 and 11 year old constantly getting into stuff. Going with 2x4" 3/16" wall for the base of my sliders, welded to 90° plates so I don't peel back the thin ass frame.

Got the sliders mocked up, but I didn't like the fit, so I'll flush mount across the bottom and build the engine and bed cages off that.

There angle on the plate was kind of off, so there's some undercut, but nothing some clean up work can't solve. Gears go into axles tomorrow. 5.38 of deliciousness.

 

Got the 5.38s installed in the D60, now I need to drain the 10.25 and install gears back there. Backlash was a bitch. Welded the 4 corners of each side of the spider, gonna throw in some plate and finish the carrier.

Got some more work done on the sliders. Prepped to paint and weld on to the frame plates.

 

So sweet! Great pics!

 

Actual builds are refreshing these days. Nice work

 

Yup!! Subbed!

 

Got front and rear end caps half-welded up. Ran out of daylight... and apparently children require food?

 

My wonderful mother picked up my wheels/tires (39.5/13.5/16x10) for me locally down in CA Central Valley. Not too shabby for $150. They will require some cleanup, but not too bad to roll around on until proper meats have been purchased.

 

Finished up the passenger side sliders. I think I was welding too much in one spot and warped the rear mount because it kicked in a hair on the front, either that or I was trying to go too fast and mis-measured. It's off by about 1/4 in at the front... bummer. I'll go back and fix soon.

Then I bought some 1.5" DOM from a dude on FB market. 3 lengths at 18' a piece. Now just how the fuck am I gonna get this home?!?

So I took a piece of angle iron, some track lighting nuts, and a piece of tube kinked by me playing around with the tube bender. Sho nuff, made a little bracket/rack that hangs over the side of the bed. I then hung the tube on that and my front passenger mirror (stuffed some rags to make sure I didn't destroy my truck), and headed home.

Gonna try to regear the Sterling to 5.38 this weekend and get the steering box mounted. Reusing the TG crossmember worked out, but it would appear I need to hack it up a bit to push the steering box as far forward as I can. I'm hoping to bend it down using leverage and hulk strength and build a skid for the box at the same time. Once that's mounted, I can get my axle location set, then calculate my link lengths...

Additionally, there is an awesome axle mover thing some dude on YouTube built which I'm gonna replicate. Should make it easier to move the axle around with minimal effort.

 

That axle jack adapter is sweet! I almost lost my fingers and hand a few times and fucked up the spindle threads on my fj 80 axle with it falling off the jack stands evreytime I went near it trying to locate it under the truck. Post some pics when you are done so I can copy it LOL!!

 

man this is getting better & better. i was staring at the tundra pic trying to figure what you did... perfect description!

 

Haha, kept staring at the Tundra as well... me gusta

 

Hah, I sold my 17 Infiniti Q50 Redsport making around 500whp 550trq AWD for the Tundra. I thought I would miss it more. XD

 

Dang coming along great! Are you doing leaf spring suspension?

 

Hah, thanks! I was going to do leafs but I figure, "why not just do everything without redoing anything." From what I've seen, links end up being the end goal. So, I'm gonna do 4-link rear, 3-link front.

Also, I got started on the axle attachment for the jack. Need to find some tube that fits tighter in the jack hole. (Giggity)

 

Trusses came in for the 60 and 10.25. Heims fit perfectly.

However, I was tasked by my wife to do yard work this weekend. Sacrifices...