Shane

I'll eventually do a proper writeup on this but for now I'm gonna use this thread to take notes on my swap so you guys can watch the progress. I'm hoping to setup a webcam like Rob's except live motion instead of stills, if I can get it sorted out in time I'll edit this post and link to it at the very top.

The webcam will be up when we start work on Friday the 28th at ~9-10 AM Pacific time, you can view it at webcam.4-low.com Windows Media Player is required and a broadband connection is highly recommended.


So usually a SAS involves buying/building a spring hanger and welding it to the bottom of the frame. I've decided to take a different approach to this after doing some measuring and realizing that it won't be too terribly difficult to modify my ARB bumper to include the mounts and beef it up at the same time. If things don't work out I'll fall back to the traditional methods and worry about the bumper later.

Here's what the ARB bumper brackets look like on my bumper
http://4-low.com/tech/SAS/IMG_1116.jpg
http://4-low.com/tech/SAS/IMG_1119.jpg

Or should I say that's what they used to look like before the plasma cutter gained a mind of it's own
http://4-low.com/tech/SAS/IMG_1131.jpg
http://4-low.com/tech/SAS/IMG_1137.jpg
http://4-low.com/tech/SAS/IMG_1142.jpg

How I setup the vertical pieces in order to get their shape to match. The 1/4" offset is because two of them ride on top of the main horizontal plate while two are butted up against the ends. In hindsight it would have been easier to make them all the same length and make the horizontal plate wider to suit. Not sure why I did them the way I did to be honest...
http://4-low.com/tech/sas/IMG_1061.jpg
http://4-low.com/tech/sas/IMG_1072.jpg

Two were left "proud" on the leading corner as they will be blended into the vertical panels of the bumper.

The main parts layed out
http://4-low.com/tech/sas/IMG_1077.jpg

The makeshift alignment jig for the new hanger, just getting things tacked in place
http://4-low.com/tech/SAS/IMG_1149.jpg

And welded up
http://4-low.com/tech/SAS/IMG_1168.jpg
http://4-low.com/tech/SAS/IMG_1171.jpg

That's 1/4" plate and the tube is 1.5x4x.120

Added a 3/16" spacer to take up the extra room under the crossmember
http://4-low.com/tech/SAS/IMG_1180.jpg
http://4-low.com/tech/SAS/IMG_1183.jpg
http://4-low.com/tech/SAS/IMG_1213.jpg

You don't think I went a little overboard with the welding, do you?

So, I was just about done drilling out the mounting holes when this happened
http://4-low.com/tech/SAS/IMG_1189.jpg
http://4-low.com/tech/SAS/IMG_1200.jpg
http://4-low.com/tech/SAS/IMG_1208.jpg

The frickin' bit SEIZED in the hole My 1/2" drill stalled dead and nearly spun me AND the hanger around! Thankfully that was the last hole and I'd already gotten all the way through, it seized as it broke through. I let it cool for a few minutes and then was able to smack it out with a #4 minor adjustment tool. You can see where it galled right above the 9/16 marking on the bit, and the chunk(s) missing out of the tip after beating the crap out of it by drilling tons of holes with a handheld drill. Considering the hell I put it through, this is one of the best drill bits I've had in a long time.
http://4-low.com/tech/SAS/IMG_1264.jpg

And here's the hanger so far bolted up to test for fit. I got the 6 middle holes almost exactly centered, the other 6 we're not gonna discuss...
http://4-low.com/tech/SAS/IMG_1221.jpg
http://4-low.com/tech/SAS/IMG_1224.jpg
http://4-low.com/tech/SAS/IMG_1230.jpg
http://4-low.com/tech/SAS/IMG_1236.jpg
http://4-low.com/tech/SAS/IMG_1244.jpg
http://4-low.com/tech/SAS/IMG_1252.jpg

And yes I have already hit my head on one of those pointy bits ("pulled a Tony" for those of you who made it to the non-yotajam) but thankfully not hard enough to need stitches. Yes, it hurt.

Oh ya, and I plan to finally take care of this little nagging issue. ARB made this bumper for '89-'95 but it just so happens to bolt right up (almost, gotta remove a couple brackets first...) to the older trucks. The only con is the sides are the wrong length to match up with the fender opening.

ChrisCo

Looks pretty good. What kind of welder are you running? Those are some clean lookin' beads.

hehe #4 minor adjustment tool... I like that

Shane

Thanks! I'm running a Miller 251 now. I used to have a little Century 110v unit that just plain sucked, I either couldn't get enough penetration or I'd overheat it. I decided to bite the bullet and get a unit big enough that I won't outgrow it anytime soon and I have no regrets. Welding is a lot more fun when you can put some real heat into it. Overkill is good.



So I guess I should give an update on the progress I made tonight....

Zero. Zip. Zilch. Nada. Nothing. In fact I think I've taken a few steps backwards.

Murphy - 1
Me - 0



I'm so, so, sososososoooooo frustrated with the damned bolt holes right now. Once I had the hanger lined up on the frame where I wanted it more than half of them were way too far off. I've decided to scrap the first attempt because I'm just not happy with how it's coming out. I got all the holes opened up enough to get bolts in them but too many of them are way too big now. I'm just not comfortable continuing with it.

But, as I was staring at it and muttering explicit words I had an epiphany. It's kind of hard to explain so you'll have to wait for pictures but basically I'm going to make a template from some scrap to get the true location of the holes off the frame. Then I'll drill out the holes in the main 1/4" plate FIRST and make sure it bolts up before going any further.

I need to buy more steel before I can attempt this so it's going to be a few days before I make any more progress.

ChrisCo

mmmm.....Miller 251... :drool: haha I've been a bit shocked at how well this little 110 Lincoln I've got has done this week. With Rob at the helm, it was laying beads that, had I not known better, I would have said were laid by a 220 stick. If I had the funds, and a perminant place to put it (we're just renting this place), I'd get me a 220 mig, too... 'course, then I'd have to have a nice tubing bender, a dedicated notcher, and all the goodies... Those are all required parts of the 220v Mig setup, aren't they?

Do you have a drill press? It sure makes it nice when you can setup a jig for repeating holes...

Murphy must die. haha

Shane

I'm still working on the bender, hope to get one in the next six months or so after my credit cards recover from my axle swap .
Yes, but with the hanger at the point that I had it it's a little too akward to use. The problem is measuring the location of the holes in the frame, they're not all bang on from Toyota to start with. I'll be using the press on the second attempt though definitely as I plan to drill the plate first before welding anything to it.
I've always said that if I meet someone named Murphy I'm gonna beat the crap out of him just because.

Shane

We did the tools/parts move tonight to my friend's house, the work resumes tomorrow evening.

Mad Chemist

Keep your chin up little camper! Good work Shane, can't wait to go wheeling with you once its done!

Shane

Thanks David, we're finally making some progress. Yesterday was pretty much a waste spent finding stuff. You know, the same thing that happens every time you move...

The webcam is in limbo, couldn't get it running this morning after an hour or so of screwing around with it so we abandoned it for the meantime. It might be up later if we find time to futz with it.

We've got the 1/4" plate cut out, drilled, and bolted up. Yes, this time it actually bolts up to the frame. We're breaking for lunch now, but we should have the hanger/bumper done today and might have time to start removing the IFS.

Mad Chemist

I'm guessing you'll be locked in the front and rear- ARB lockers? And you've already got a crawler in there, right?

Shane

e-lockers front and rear, and 4.7s in the rear t-case.

Shane

Here is today's progress report. We are still working on the bumper but I think we've got all the issues worked out. *knock-on-wood*

The template for drilling the frame holes into the new bracket, just a scrap of 18guage sheet and some 3/16" "washers" tacked in place. I used the bunk hanger to mark the approximate location of the holes and then zapped them out with the plasma cutter way oversized. Then we bolted it up to the frame using the "washers" and once I had the sheet in the position I wanted it I tacked the "washers" to it. The pieces of 3/16" on the other side are just spacers to keep the sheet flat against the uneven bottom of the frame.
http://4-low.com/tech/sas/IMG_1280.jpg
http://4-low.com/tech/sas/IMG_1284.jpg

And here's version 2 of the bumper mods. We extended the inner vertical plates up the sides of the bumper to both tie it further into the bumper's structure as well as reinforce the recovery points to keep them from bending on side pulls. Thanks go to HiLux_1990 for the idea.
http://4-low.com/tech/sas/IMG_1308.jpg
http://4-low.com/tech/sas/IMG_1319.jpg

ChrisCo

Very nice! Seriously clean lookin'! If that bracket were painted to match the bumper, I'd never be able to tell it wasn't stock!

You know we're (at least, I am ) wishin' ya' the best of luck with the swap.

btw, where you getting your 1/4" plate from?

Shane

Metal Supermarket up in Woodinville. He's small quantity friendly and open on Saturday, and has always had what I've needed. If you go there tell him the guy from the UW with the black truck sent you.

Skydigger

Nice work there Shane. I just finished retrofitting my '89 - 95 IFS ARB to my SASsed '86 4Runner.

I ended up "building-out" my front body-mounts to match the '89 + ones so I could have the extra mounting support on the sides. Drilled and tapped them and it's pretty strong. I also extended my vertical sliding portions of the ARB and used the front spring hanger pin as the mounting point for them.

I had read somewhere that this is how the solid axle ARB mounts.

It has worked out pretty well so far. I haven't yet winched with it but I've taken a good few yanks out of some stuck situations and the bumper didn't move.

I'll post up pics if you'd like. Mine's definitely not as pretty as yours but it is functional.

The first cut's the toughest eh? lol.

Regards,

Warren

Shane

Thanks Warren.

Yesterday we started on strengthening and cleaning up the frame crossmember. 1/4" plate on front and top, 3/16 on the backside, and .120 wall 3/4" tube sleeves for 6 of the bolts that will hold the bumper on.
http://4-low.com/tech/sas/IMG_1330.jpg
http://4-low.com/tech/sas/IMG_1336.jpg
http://4-low.com/tech/sas/IMG_1349.jpg

Today was pretty much grind grind grind weld weld weld drill drill drill. Finished plating the crossmember and got the bracket aligned and tacked to the bumper.
http://4-low.com/tech/sas/IMG_1354.jpg
http://4-low.com/tech/sas/IMG_1366.jpg
http://4-low.com/tech/sas/IMG_1372.jpg
http://4-low.com/tech/sas/IMG_1380.jpg

Tomorrow I'll be finish welding the bumper and then it's time to start removing the old suspension. We've technically already started the removal though, the steering linkage gave it's life in order to make room for my 1/2" drill so I could finish a couple holes. Anyone need any tie rod adjusting sleeves? I've got a couple that I'll let go for next to nothing, some reassembly may be required...

BTW, thanks Rob and Chris for the cherry picker to help position the bumper idea.

Shane

No pics today, was too busy finishing the bumper. That nearly full 10lb spool of wire is starting to look a little thin, and that's the first time I've ever heard the cooling fan run in my 251...

I've got two braces, two spacers, and one plate left to add to the bumper, then it gets painted and bolted on. Should have that done by early afternoon tomorrow.

Mad Chemist

Lookin' good Shane. So when you going to start cutting! Thats when things start getting real exciting...

Shane

Today hopefully!

We got the webcam figured out, I'll be posting a link to it later this afternoon so you guys can watch the IFS fall to the ground.

Shane

Damnit, I gotta stop saying things like that. The bumper is done, cleaned up, and painted. We called it a day at that, and are taking tomorrow off. The work resumes Friday morning with bolting on the bumper and putting the truck up on stands, then it's off with the IFS!

The webcam will be up when we start work on Friday at ~9-10 AM Pacific time, you can view it at webcam.4-low.com Windows Media Player is required and a broadband connection is highly recommended.

Here's some more pics of the bumper...
http://4-low.com/tech/sas/IMG_1392.jpg
http://4-low.com/tech/sas/IMG_1398.jpg
http://4-low.com/tech/sas/IMG_1406.jpg
http://4-low.com/tech/sas/IMG_1411.jpg
http://4-low.com/tech/sas/IMG_1426.jpg
http://4-low.com/tech/sas/IMG_1431.jpg
http://4-low.com/tech/sas/IMG_1436.jpg
http://4-low.com/tech/sas/IMG_1439.jpg
http://4-low.com/tech/sas/IMG_1442.jpg
http://4-low.com/tech/sas/IMG_1448.jpg

ChrisCo

Nice work there, Shane!

Love the warining message on the webcam :