As I posted a couple days ago in the “SAS bout to go down” thread, I just bought some toy axles for my eventual SAS. I wanted to get some advice from you guys out there who have prepped a front axle and subsequently swapped it out for your IFS. I have read SAS build threads and seen what different people have done. I just wanted to get a current consensus about what people think.
So, my question(s) is this; did you guys opt to prime it and paint it? If so, how’d you do it? Rattle can? Brush? Flat black? Gloss? Color? Powder coat? Did you wire brush it down before priming/painting it? Did you sand blast it? I always thought wire brushing it would be the safest and cheapest way to get rid of some or all of the surface rust. Is there a better way? Should I not even worry about minor surface rust?
I already plan on rebuilding the thing from ground up… So as you would guess I’ve got the knuckle rebuild kit, new seals, etc. I’m on the fence about upgrading the inner axles and birfields at this point…
I’m also thinking about grinding off and replacing the shock mounts because they are not in the greatest shape, and it looks as though someone has tried to re-weld them… When it comes down to it, I’ll see how strong they are, and decide then.
Is there anything else I should look into before I paint this front axle? Anyone used Marlin’s axle ball gusset kit? http://marlincrawler.com/axle/front-axle-parts/axle-ball-gusset-kit I’m thinking about it because it would not only add strength, but solve my suspected shock mount issue.
I don’t have the axles with me so I can’t get a detailed pic, but here’s a shot of them when I picked them up the other day.

 

No picture here.

For my axle i completely tore it down to the bare housing and cleaned out all the nasty gear oil from the inside. THen i cut off all the uncessary brackets and ground it smooth.

I used a wire wheel that attached to the end of my cordless drill, to clean the paint and dirt off. Then once i had the axle armour welded on. (diff armour, upper truss, marlin knuckle ball kit) i went ahead and put a couple layers of primer on and then a few layers of flat spray paint. (i wish i used a different brand for mine is chipping off some the dupi-color sucked IMO)
Just rattle can'd it.

Then i cleaned and painted the knuckles.

THen once the paint dried i started assembling everything.

 

 

I'd recommend a 4 1/2 inch angle grinder with a wire wheel. It'll strip rust and paint down to shiny metal in a big hurry with minimal mess.

As for paint, if you're going to be doing a lot of painting, a paint gun is a good investment. Doesn't have to be a good one if you're just using flat black. But I've seen some surprisingly nice rattle can jobs.

 

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I have a few pictures of preparing my axle.

https://www.yotatech.com/forums/f152...ck-sas-164531/

 

toyospearo; yeah, I saw your thread. its got good pitctures. it's guys like you who take the time to post pics and descriptions that make it easier for guys like me. THANKS! I noticed you took the axle to your local guru to have the knuckles scaled properly... Do you recommend that? Did you try to do it yourself first? I didn't think it could be that difficult, but maybe I over looked some stuff...

P.S. I'm trying to get that picture up there, but I must be dumber than I think I am...
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WTF! I must be doing something wrong...

 

Thanks for the compliment!
I took the axle to my friend mainly because he wanted to see and work on it. He never worked on a modified SA. He only worked on the complete stock ones. The FSM is pretty straightforward when it comes to the knuckles. I don't think you would have any problem doing it.

 

Seriously do yourself a favor. I used 4crawler's writeup for tear down and assembly of my axle.

 

The FSM seems good. I agree, I think I can follow it. I also looked in Haynes. It might come in handy but i didn't see anything about using a pull scale on the knuckles. 904 runner. 4crawler you say... I'll have to read that one. thanks!

 

Clean it up after you finish welding on it...otherwise it'll just sit there and rust. Complete tear down and rebuild is the way to go.

 

Not a problem

heres two links:
http://www.4crawler.com/4x4/CheapTri...ch/index.shtml
http://www.4crawler.com/4x4/CheapTri...eRebuild.shtml


When i put the knuckles back together, i used one thick and one thin shim from the marlin kit, on both knuckles upper and lower. Then i used the pull scale and it was in spec.