J Kimmel
Hard Core 4+
Looks great you going to make it to cm?
Gert's New Legs
- Thread starter Gerty
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J Kimmel
Hard Core 4+
Good luck!
No time for sickness. Let’s get that shit in and put together!!
Gerty
Rising Sun Member
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You know where I live 😉
Gerty
Rising Sun Member
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Got the front frame plates welded in this weekend (side and bottom) with the next major task being tacking on the link mounts on the front axle (frame-side mounts are installed, but not burned in) so that I can get my shock towers cut to length and start cycling the suspension for steering clearance (using good ol' PVC pipe for mock links). I didn't take any pics of those frame plates but can. I unloaded at least half of my brand new 10lb welding wire spool - so much welding, took forever.
I separately received my PSC full hydro kit. My remaining large purchases are the links and heims (although there's a small chance that I can use my friend's brand new aluminum links he'll sell me) as well as my front shafts. Branik told me that they're only running 1-2 weeks lead time on 4340 front shafts. Same with Currie. ECGS and someone else I can't remember told me 15 weeks!
I have additionally decided to not use my front hydro mount from TMR and instead bit the bullet and bought a mount from Hulse Engineering which is specifically made for my Trail Gear housing (pretty slick - check out his webaite). I also bought his "low profile" ram clamps which will keep the ram itself about an inch lower than PSC's clamps would. I just unfortunately don't have time to figure out custom fab'ing of components at this point if i wanna have a shot at making it to Moab, especially one as critical as a hydro ram mount. This one I have coming from Hulse will require little, if any, cutting.
I have 7 weekends left Until Cruise Moab but I'm gone for one of them, meaning I have 6 left. I'll take time off work if need be but it'll be extremely tight in any case. I HAVE GOT to get those front shafts on order ASAP but I obviously need to make 100% sure that the housing is precisely the length it needs to be. I already know that I need to modify one side of the pumpkin as well as one of the axle link mounts (I'll provide a pic of the problem next weekend).
@Notyourmomslx450 has been over a couple weekends in a row to help, which I very much appreciate! I've provided a pic of the PSC box from Santa. I will post some good updated pics after this weekend's garage sesh.
I separately received my PSC full hydro kit. My remaining large purchases are the links and heims (although there's a small chance that I can use my friend's brand new aluminum links he'll sell me) as well as my front shafts. Branik told me that they're only running 1-2 weeks lead time on 4340 front shafts. Same with Currie. ECGS and someone else I can't remember told me 15 weeks!
I have additionally decided to not use my front hydro mount from TMR and instead bit the bullet and bought a mount from Hulse Engineering which is specifically made for my Trail Gear housing (pretty slick - check out his webaite). I also bought his "low profile" ram clamps which will keep the ram itself about an inch lower than PSC's clamps would. I just unfortunately don't have time to figure out custom fab'ing of components at this point if i wanna have a shot at making it to Moab, especially one as critical as a hydro ram mount. This one I have coming from Hulse will require little, if any, cutting.
I have 7 weekends left Until Cruise Moab but I'm gone for one of them, meaning I have 6 left. I'll take time off work if need be but it'll be extremely tight in any case. I HAVE GOT to get those front shafts on order ASAP but I obviously need to make 100% sure that the housing is precisely the length it needs to be. I already know that I need to modify one side of the pumpkin as well as one of the axle link mounts (I'll provide a pic of the problem next weekend).
@Notyourmomslx450 has been over a couple weekends in a row to help, which I very much appreciate! I've provided a pic of the PSC box from Santa. I will post some good updated pics after this weekend's garage sesh.
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J Kimmel
Hard Core 4+
Should be able to get it lined up and cut and measured for shafts in a couple evenings max
Gerty
Rising Sun Member
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Yep agreed. That is THE next focus with the goal to get it done this coming weekend. My passenger axle link mount doesn't currently fit into the small amount of space/length that exists between the inner C and the housing pumpkin (TG's pumpkins are so damn wide). I'm looking at cutting both the link mount and the housing and integrating them. Lesson learned in getting too excited and prematurely cutting the axle tubes without the bracketry. But the catch-22 is that as currently cut, that pinion centerline is dead nuts and if i were to make that passenger side longer, I'm getting into a VERY wide front track width. If I can't get that to work, I've already settled on POTENTIALLY driving my butt up to SpiderTrax and getting another housing off the shelf same day. Is what it is, and not something I'm proud of (and frankly embarrassing). But I'll do it right no matter what, even if it means biting the bullet (yet again).
I went out just now and took some pics of not only this problem I'm describing, but also the frame plates (I'm no champion welder - keep the scrutiny to a minimum 😀). Note that those towers are just free standing in their location. Not burned in and not cut to length.
I went out just now and took some pics of not only this problem I'm describing, but also the frame plates (I'm no champion welder - keep the scrutiny to a minimum 😀). Note that those towers are just free standing in their location. Not burned in and not cut to length.
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J Kimmel
Hard Core 4+
Put the axle underneath, line it up and trim the brackets to fit. Even on a tube chassis my front lines up tight on the short side. I’m reasonably sure my third has to come out to get the lower link bolt out. Don’t overthink it and spend where you don’t need to just modify your brackets and add bracing if necessary
justin4045
Rising Sun Member
I agree with @J Kimmel. I had to modify two of my front link brackets so much it was crazy. Almost would have been easier to make my own. Just one of the many compromise that have to be made. Forgive me if i don't fully understand, but in my opinion modifications to the brackets and keeping the width you planned is way better than going wider to fit a bracket. It's a slick looking bracket and too bad it doesn't fit as planned, but it's not wrong or improper to modify stuff to make it work. Each setup is crazy unique even though many people have done 3 link front suspensions.
Gerty
Rising Sun Member
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Certainly appreciate both of your suggestions as well as confidence builders 
I agree with both of you - I'm simply going to start by cutting off about half of the width of that bracket and not touch the housing until it's absolutely necessary. I need probably three inches of additional space and cutting half that bracket (the part that I'm cutting off is only for the bump stop which the ORIs are taking care of) will give me more than 2", probably 2.5". I just didn't want to cut up the 4WU artwork! And yeah, I'm not jumping to conclusions or in panic mode at all when I reference the potential for another housing - that's just me thinking of the "what next" factor. And yeah Justin, definitely not going wider (and won't). More to come - just goes back to me thinking too hard about things! Thank you both again. Significant updates coming after this weekend.
I agree with both of you - I'm simply going to start by cutting off about half of the width of that bracket and not touch the housing until it's absolutely necessary. I need probably three inches of additional space and cutting half that bracket (the part that I'm cutting off is only for the bump stop which the ORIs are taking care of) will give me more than 2", probably 2.5". I just didn't want to cut up the 4WU artwork! And yeah, I'm not jumping to conclusions or in panic mode at all when I reference the potential for another housing - that's just me thinking of the "what next" factor. And yeah Justin, definitely not going wider (and won't). More to come - just goes back to me thinking too hard about things! Thank you both again. Significant updates coming after this weekend.
Gerty
Rising Sun Member
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Had a super productive weekend this weekend. Got my panhard bracket cut and now fits into my tight axle space and I didn't have to touch the housing. Also got everything (mostly) located and tacked in place and some PVC mock up lower links installed, towers cut, ORIs sitting in there, all at full bump. Realized that the 8" ram from PSC will be too short so I sent it back and got a 9" ram instead. Waiting on that. Also still waiting on my ram mount from Halse Engineering to arrive. When those come in, game on for the steering system and hopefully by that time I'll have the front fully adjusted and ready to fully weld (lots of finicky refinement on the front to be had). Then I'll cycle the suspension and only then, fully burn in and gusset and whatever. LOTS going on right now, certainly in the thick of it. Also can order front inner axle shafts after I confirm my measurements once more tomorrow night.
Just ordered all my links, heims, and a BUNCH of miscellaneous stuff from Barnes tonight. I also inquired with Tom Woods for driveshafts. Got the rear driveshaft measured but need to get the front axle perfectly located (probably going to bring the axle back a little bit from what's shown in the pic otherwise I am in for an absolute shit load of clearancing and trimming work where it sits now). I won't like my wheelbase being shorter than I was hiping when i move the front back, but I can make up for wheelbase when I 4-link the rear at some point.
So the major to-do's (work, not purchases) are plenty and include:
-Front axle cycling and refinement
-Front axle links
-Steering
-Rear shock mounts (and a couple smaller things to finish the rear)
-Skid plate/tcase mount
-Front tire trimming/clearancing
-Paint everything
-Then a whole slew of miscellaneous stuff (probably have 40 "smaller" items written down
Far too early for me to have comfort that I'll make it to Moab but this weekend unlocked a bunch of stuff (in a good way) and if they continue to go like this, there's still a shot.
Indeed there's some weird strut positions and tower positions in the pics, but all that will be corrected, trued up, aligned side to side, etc. Again, lots of adjustments to be made on the front. Just wanted to get everything rough mocked and components in their approximate positions. Also, that third link mount on the axle pumpkin IS NOT where it's going to be installed. My friend and I were just playing around. It'll be moved up/back on the pumpkin where it should be.
Back to steering real quick, with my 9" ram, I can get about 45 degrees steering. For a slew of reasons, I decided to not max out to the 50 degrees I could theoretically have with my knuckles and C's. 45 degrees is still WAY more than a stock 99-04 super duty axle by like 10 degrees (I think those are like 32 to 34 degrees).
Just ordered all my links, heims, and a BUNCH of miscellaneous stuff from Barnes tonight. I also inquired with Tom Woods for driveshafts. Got the rear driveshaft measured but need to get the front axle perfectly located (probably going to bring the axle back a little bit from what's shown in the pic otherwise I am in for an absolute shit load of clearancing and trimming work where it sits now). I won't like my wheelbase being shorter than I was hiping when i move the front back, but I can make up for wheelbase when I 4-link the rear at some point.
So the major to-do's (work, not purchases) are plenty and include:
-Front axle cycling and refinement
-Front axle links
-Steering
-Rear shock mounts (and a couple smaller things to finish the rear)
-Skid plate/tcase mount
-Front tire trimming/clearancing
-Paint everything
-Then a whole slew of miscellaneous stuff (probably have 40 "smaller" items written down
Far too early for me to have comfort that I'll make it to Moab but this weekend unlocked a bunch of stuff (in a good way) and if they continue to go like this, there's still a shot.
Indeed there's some weird strut positions and tower positions in the pics, but all that will be corrected, trued up, aligned side to side, etc. Again, lots of adjustments to be made on the front. Just wanted to get everything rough mocked and components in their approximate positions. Also, that third link mount on the axle pumpkin IS NOT where it's going to be installed. My friend and I were just playing around. It'll be moved up/back on the pumpkin where it should be.
Back to steering real quick, with my 9" ram, I can get about 45 degrees steering. For a slew of reasons, I decided to not max out to the 50 degrees I could theoretically have with my knuckles and C's. 45 degrees is still WAY more than a stock 99-04 super duty axle by like 10 degrees (I think those are like 32 to 34 degrees).
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J Kimmel
Hard Core 4+
Did you order shafts
It's going to be neat when it's done!
Gerty
Rising Sun Member
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- Oct 5, 2022
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Not yet (drive shafts or axle shafts). Both Branik and Currie told me that they're running 1-2 weeks on 4340 inner front shafts and I'll get thse on order either tonight or tomorrow.
Gerty
Rising Sun Member
- Joined
- Oct 5, 2022
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Lots of movement since the weekend. Got my front shafts finally ordered from Currie and they're still saying 1-2 weeks (Branik is frustrating me). Got my front steering ram from Halse delivered, got my replacement PSC ram delivered (also had them throw in a set of trail spare hydraulic hoses). Got the orbital valve mounted, got the driver side coilover tower final adjusted. Need to get my very large order from Barnes (with the links and heims, most importantly). Also got the driver side link mount on the axle correctly located.
Next major thing is getting that steering ram mounted, truss installed, components plumbed, etc.
Just two pics for this post (I was in the zone and didn't take many pics). Had to french in a half sleeve on the driver coilover tower to clear the steering wheel shaft. I'll post pics of the towers final positioned when I get the passenger side done.
Next major thing is getting that steering ram mounted, truss installed, components plumbed, etc.
Just two pics for this post (I was in the zone and didn't take many pics). Had to french in a half sleeve on the driver coilover tower to clear the steering wheel shaft. I'll post pics of the towers final positioned when I get the passenger side done.
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justin4045
Rising Sun Member
Slick! Im sure that added some regigity and definitely some cool points!
Last edited:
truckin along!
Gerty
Rising Sun Member
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- Oct 5, 2022
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Took Friday off from work (mostly) and had nearly 3 days of good work put in. Significant things that got completed were the steering ram truss and the trans mount/skid plate. Just need to take it out and fully weld it. The friggin front axle is ungodly heavy, and that's without the third member or shafts in.
Also got my Barnes order (links, heims, misc.) in, so that opened up a good but of work so that I can cycle this front axle and fully burn everything. Shock towers are also done, as is the steering cooler, reservoir, and fluid overflow cylinder.
Next major things are links and plumb the steering. Then after that, weld a lot, paint a lot, thread lock a lot, finish brakes, and then cross my fingers.
I can also get rear driveshaft ordered but can't order or measure for the front until the links are done. So I'm going to be cutting it close on driveshafts. But I have two weekends left since I'll be in Austin for the solar eclipse the weekend of April 6th (exciting, but wildly interfering with my timeline). My third theoretical weekend is the weekend before Cruise Moab but I wanna use that weekend for tying stuff up and fixing any problems. I'll be taking off days from work if needed.
Got a lot done in the last few days, but still SOOOO much to do. Still hard for me to be confident to make it to Cruise Moab!
Also got my Barnes order (links, heims, misc.) in, so that opened up a good but of work so that I can cycle this front axle and fully burn everything. Shock towers are also done, as is the steering cooler, reservoir, and fluid overflow cylinder.
Next major things are links and plumb the steering. Then after that, weld a lot, paint a lot, thread lock a lot, finish brakes, and then cross my fingers.
I can also get rear driveshaft ordered but can't order or measure for the front until the links are done. So I'm going to be cutting it close on driveshafts. But I have two weekends left since I'll be in Austin for the solar eclipse the weekend of April 6th (exciting, but wildly interfering with my timeline). My third theoretical weekend is the weekend before Cruise Moab but I wanna use that weekend for tying stuff up and fixing any problems. I'll be taking off days from work if needed.
Got a lot done in the last few days, but still SOOOO much to do. Still hard for me to be confident to make it to Cruise Moab!
