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Well, I have long been wanting to SAS my truck. It is not my DD and probably never will be ever again. So...that being said it's time to start my swap thread. I have spent a lot of time reading through the SAS Forum and have seen lots of people who couldn't decide if they should SAS or not. Lots of folks say "if you have to ask yourself this question then you don't need to". Let me be up front about this, I DON'T need to SAS. I WANT to. That is all it boils down to and all the justification I need.
This is going to take me quite some time and you know what? I don't care. I have no fabrication skills whatsoever but I'm going to buy a MIG Welder and learn how to weld. At the end of the day that purchase, the knowledge and skill that will come from it, and the experience will be worth it. Looking at the Hobart Handler 140. You guys think that will be sufficient to tackle the swap?
I already have my complete front axle. I believe it's an 84' b/c of the short bottom gusset. It will get the full rebuild treatment.
I have plenty of time to figure this out but at the end of the day here are my long term goals:
-4" lift kit front and rear (haven't decided on which company yet)
-35" BFG KM2's or KO2's
-15x8 crawler steelies
-4:88 gears front and rear
-Aussie Locker for the rear
-Open diff front (for now)
-Winch bumper for front
-TG rear tube bumper
-12,000lb winch (don't know which company)
There are plenty of other non swap related things but I'll post all that in my regular build thread.
You guys crack me the hell up I tell ya! Thanks for the laugh though!
Hey...you did ask for it. Did you not?
If I was worried about getting flamed I wouldn't have posted to start with. I've had my truck for over 20 years and have gotten plenty out of the IFS...so you're "mall crawler" and "web wheeler" comments serve as nothing but motivation to do what I've been wanting to do since I got the truck.
Last edited by Back to the Future; 04-14-2016 at 10:00 AM.
You guys crack me the hell up I tell ya! Thanks for the laugh though!
Hey...you did ask for it. Did you not?
^^^Your post cracked me up, I had to double check the date, I thought I time warped back to pirate 4x4 in 2003...
Originally Posted by Back to the Future
If I was worried about getting flamed I wouldn't have posted to start with. I've had my truck for over 20 years and have gotten plenty out of the IFS...so you're "mall crawler" and "web wheeler" comments serve as nothing but motivation to do what I've been wanting to do since I got the truck.
I gotta commend you for keeping the same truck for 20yrs, that's something I've never been able to do, looking back there were alot of rigs I wished I'd kept! Sounds like you've done some research, one tip I'd pass along is tack weld your front spring hanger in place and don't fully weld it until you've got some weight on the front springs/axel and can double check your front shackle angle. I've seen alot of people burn in that front hanger, and then later realize the shackle angle is way off.
^^^Your post cracked me up, I had to double check the date, I thought I time warped back to pirate 4x4 in 2003...
I gotta commend you for keeping the same truck for 20yrs, that's something I've never been able to do, looking back there were alot of rigs I wished I'd kept! Sounds like you've done some research, one tip I'd pass along is tack weld your front spring hanger in place and don't fully weld it until you've got some weight on the front springs/axel and can double check your front shackle angle. I've seen alot of people burn in that front hanger, and then later realize the shackle angle is way off.
Look forward to the build!
Thanks rustED. I said 20yrs but I got the truck in 99' so I've actually had it for 17yrs. In the end it doesn't matter because I have no intentions of ever selling it. If anything I will give it to one of my sons. Yeah I traded my 03 Tacoma crew cab for a v6 mustang so I know how you feel. We all make mistakes though don't we...lol
I really appreciate the tip about tack welding the hanger. I have noticed that a few guys on here have fully burned in the hanger before they cut the IFS off so I wonder if it wound up being an issue for them.
Looking forward to the build. I am in the same boat with fab skills, I am not allowed to measure nothing at work, nothing. I am going to begin my sas by May. I just don't have the patience I have to get it done as this is something I have wanted for 20 yrs. lots of good info and people on here that seem to help a lot.
Scott Ross
Looking forward to the build. I am in the same boat with fab skills, I am not allowed to measure nothing at work, nothing. I am going to begin my sas by May. I just don't have the patience I have to get it done as this is something I have wanted for 20 yrs. lots of good info and people on here that seem to help a lot.
Scott Ross
Flippz,
Welcome to YotaTech! I'm a relatively young member of YT but will tell you that there is more than enough experience on here to help you through it. That's why I have no worries about my lack of Fab skills. With a little research you can find just about anything you need to know and then if you still need help all you have to do is ask. My plan is to have mine done by next year. Gotta get home from this deployment, then I have to move, get resettled and start a new job so that we be my main priority over the next couple of months. Keep us posted with pics and updates. Good luck!
Well, made it home. Wife keeps asking what do I plan on doing with that "rusty old part" in the back of my truck...lol. I told her I'm going to rebuild my axle (rusty old part) then install it on my truck. I think no matter which way I explain it she won't understand. She keeps telling me I should just buy a new truck...psssht, ain't gonna happen. I told her I plan on buying a welder so I can do the job and she's said "You don't even know how to weld." It cracks me up. I love her to death.
Got some really minor work done on the axle. If you notice I managed to cut off the old leaf spring and grind a little of the old brackets down. Like I said not much but the first real update in months. Been collecting tools and trying to get finished with the move. Been at the new place for almost two full months now and we are still not done moving in. It has been house project after house project...but progress is progress. Got to get some PB blaster so I can finish up the disassembly. And crack the sucker open and get to the real fun stuff.
Last edited by Back to the Future; 08-14-2016 at 03:42 PM.
I was in the same boat on this , Having owned my 90 4R since 04 . it was a great dd for years , then tires then gears ,lockers , bigger tires , crawl box ,etc. stone stock suspension it has never broke anything and went everywhere mostly on 3 wheels ,but every single panel has a dent or scrape of some kind except the hood.... flopped a bunch. the cost of a sas build and time had me thinking just look for a running rig . I found an 86 4r and made the deal .It needs some work like the timing chain was clacking , but it appears to be a well done truck with all the parts I would have chose like gears lockers chromoly blah blahs etc crawl box hi steering trimmed tubbed body on 37" it even has a few dents so im not afraid to hurt it . the only con is that I didn't build it ,and the understanding , knowledge that comes with that like how to fix it or improve it i missed .pro is that I still have my 90 4runner too since it has only value to me being so beat up.. anyway i'll be following the build
I was in the same boat on this , Having owned my 90 4R since 04 . it was a great dd for years , then tires then gears ,lockers , bigger tires , crawl box ,etc. stone stock suspension it has never broke anything and went everywhere mostly on 3 wheels ,but every single panel has a dent or scrape of some kind except the hood.... flopped a bunch. the cost of a sas build and time had me thinking just look for a running rig . I found an 86 4r and made the deal .It needs some work like the timing chain was clacking , but it appears to be a well done truck with all the parts I would have chose like gears lockers chromoly blah blahs etc crawl box hi steering trimmed tubbed body on 37" it even has a few dents so im not afraid to hurt it . the only con is that I didn't build it ,and the understanding , knowledge that comes with that like how to fix it or improve it i missed .pro is that I still have my 90 4runner too since it has only value to me being so beat up.. anyway i'll be following the build
Yeah, this truck and I have been through a lot over the years. I'm so glad I opted to do the SAS instead of the bracket lift. Cost a lot more $$$$ in the long run but still cheaper than buying a new truck and that is why I'm happy to take my time. It's not a DD anymore so no need to rush. Thanks for the reply BTW.
Hi Back to the future,
Gonna follow your build thread....a truck you've had for 17 years and now getting around to SAS.....I imagine the IFS stuff was getting worn out and I bet it was either put money into making the IFS work correctly or just SAS it. That was part of the thought process for my 01 Taco SAS build.
rustED has a thoughtful suggestion there....to only tack the axle housing in place til you're 100% sure everything clears perfect. There is a great temptation to weld it up thinking if it's not quite perfect that you can somehow "work around it" and that ends up sucking in the end. Many of the SAS build you might notice are sold within a year after they are completed. I think it's because they realized they fubar'd it up and didn't set things just right. Even I have prematurely welded things on 100% to later discover that this or that needs to be moved 1" to make it work perfect.....and that meant a lot of weld grinding to break it free. I am excellent at weld grinding....and it's a damn good thing, too.
May I recommend leaving the factory axle perches alone and use a piece of 3/8" thick flat stock 2.5"wide x 9" long with a hole in the middle to use as a custom shim of sorts? Then weld it once it's angled properly.
You should still break the knuckle welds loose and re-angle the pumpkin to point straight at the transfer-case output. That means the flatstock will get welded on with about an 8 degree angle.
-4" lift kit front and rear (haven't decided on which company yet)....................... NICE
-35" BFG KM2's or KO2's.................. EXCELLENT SIZE......ko2 rule.
-15x8 crawler steelies.......................... Good width...10" is too wide these days.
-4:88 gears front and rear.........good choice(use Nitro Gear or G2 Gear)
-Aussie Locker for the rear.........Good....nice cheap locker....would be my choice if I was on a budget...other choice would be Spartan Locker.
-Open diff front (for now) That's what I said on my build......finally putting in a SELECTABLE locker in a couple weeks...Harrop elocker
-Winch bumper for front................hmmmm
-TG rear tube bumper.....sure why not
-12,000lb winch (don't know which company).....hmmmm.....Harborfreight is a "low cost" possibility......
Looking above at some of your build criteria I like it....commented after it....
Hi Back to the future,
Gonna follow your build thread....a truck you've had for 17 years and now getting around to SAS.....I imagine the IFS stuff was getting worn out and I bet it was either put money into making the IFS work correctly or just SAS it. That was part of the thought process for my 01 Taco SAS build.
rustED has a thoughtful suggestion there....to only tack the axle housing in place til you're 100% sure everything clears perfect. There is a great temptation to weld it up thinking if it's not quite perfect that you can somehow "work around it" and that ends up sucking in the end. Many of the SAS build you might notice are sold shortly after they are completed. I think it's because they realized the fubared it up and didn't set things just right. Even I have prematurely welded things on 100% to later discover that this or that needs to be moved 1" to make it work.....and that meant alot of weld grinding to break it free. I am excellent at weld grinding....and it's a damn good thing too.
May I recommend leaving the factory perches alone and use a piece of 3/8" thick flat stock 2.5"wide x 9" long with a hole in the middle to use a a custom shim of sorts? Then weld it once it's angled properly.
You should still break the knuckle welds loose and re-angle the pumpkin to point straight at the transfercase output.
-4" lift kit front and rear (haven't decided on which company yet)....................... NICE
-35" BFG KM2's or KO2's.................. EXCELLENT SIZE......ko2 rule.
-15x8 crawler steelies.......................... Good width...10" is too wide these days.
-4:88 gears front and rear.........good choice(use Nitro Gear or G2 Gear)
-Aussie Locker for the rear.........Good....nice cheap locker....would be my choice if I was on a budget...other choice would be Spartan Locker.
-Open diff front (for now) That's what I said on my build......finally putting in a SELECTABLE locker in a couple weeks...Harrop elocker
-Winch bumper for front................hmmmm
-TG rear tube bumper.....sure why not
-12,000lb winch (don't know which company).....hmmmm.....Harborfreight is a "low cost" possibility......
Looking above at some of your build criteria I like it....commented after it....
Zuk, first may I say that I am humbled to know you are following my build and second I sincerely appreciate the recommendations. You are indeed correct regarding my IFS. It is dead. I actually think the shocks are the OEM factory ones. I haven't changed them since I bought the truck back in 99'. As you probably read up above I was originally just going to install a bracket lift and now I'm so glad I didn't as that would've ended up costing more money in the long run maintaining the IFS.
As a matter of fact your thread and several other articles have really pushed me in the KO2 direction since I wouldn't initially be doing any super serious technical wheeling and durability/tread life is a requirement.
I definitely agree that a selectable front locker is the way to go but that will only become an option as the funds become available.
For now I think I will just rebuild the axle with the Marlin rebuild kit and as I progress I will figure out the rest.
The welding piece is what I'm missing right now. I don't have a welder and I would like to at least learn the basics before I tackle this job or spend a lot on a quality machine.
Found its rightful place in the garage. Only took a hurricane to gey me to bring it inside...lol. at least now when I work on it everything will be right there instead of me having to go get it from the garage to bring it to the back yard.
X3 on tacking your brackets in to make sure your shackle angle is correct!
Might i make a suggestion of slamming the axle as far forward as possible to avoid rubbing the firewall when the wheel is fully cut or when the axle up travels.
That was my mistake when i solid axle'd my t100. Ended up grinding every weld down to move the axle forward as far as i can.
04-14-2016, 01:00 AM
