I've only got another month or so until I'll have most all of my parts in/ on the way. Figured I'd start this thread now.
This thread will include parts lists, plans, pictures, beer, and I hope constructive criticism from everyone.
This will be my first time with such an epic fab project on my own vehicle although I have helped out with a couple solid axle swaps.

Cutting will not start until I have every part I will need to drive the truck safely. I will most likely be borrowing another TTORA member's garage, another members 220 welder, and hopefully a plasma.

Goals for this SAS: get rid of the death trap IFS. Make a more reliable front end. Allow me to wheel more than I wrench.
I want to push the front axle forward as far as possible. I want a better approach angle, I want the tires out of the firewall, and I want to stretch my short wheelbase a little bit.
I am going leaf springs. I don't need a crap ton of flex. I want the strength of a high pinion 8" diff with chromoly everything.

Parts list:

Front: Diamond Axle, 8" High pinion (Marlin built, 5.29's, Yukon grizzly locker). 67" WMS w/ IFS hubs. FROR Tacoma brake mount. RCV inner shafts. TG "longfield" birfs.

Marlin 25MM steering arms. FROR DOM Tie rod/ drag link. All-Pro FJ80 TRE's. Ford bronco forward swing steering box. Parts mike flat pitman arm. PSC 2.7L tacoma pump kit (I have found redline steering fluid that satisfies the needs of both the stock pump and the gear box. The PSC pump kit won't be needed). TG Steering shaft kit.

FROR SAS kit, All-pro 4" springs. Bilstein 12" 5125's. All-Pro frame plates.

T100 oil pan, pickup, and all that jazz.


Rear: T100/ Tyndra axle. Will transplant my 8.4 welded 5.29 diff into it.
All-pro 5" rear suspension kit. 12" bilsteins.

The truck will probably be on 38's-40's next if I can grow some balls.


That's the basic parts list, I'm sure I am missing some small things. Here are some pictures so far.

Obligatory broken IFS pictures.





















Remaining parts (steering shaft has been ordered):



The IFS has taken me almost EVERYWHERE I've wanted. From Moab, to AZ, the Hammers, to the Rubicon, Windrock ORV, Hidden Falls, etc.. IFS has its purpose. It served me well for the past 5 years. However, it is time to take the truck to the next level.

Stay tuned.

 

Heck yeah!! My favorite taco is about to get better!!

Best of luck to you!

 

Nice Scuba...I couldn't remember if you were going to use Leafs or Coils..

 

Nice! Stoked to see the progress!

 

Did some prep work today..
Got the studs in the housing, replaced the stock knuckle bearing races with the Marlin 25MM ones, polished the knuckles.. etc.
Biggest issue of the day.. when I tried to dry fit the Marlin diff inside the housing, it wouldn't fit. The adjusters are so far out... brought it home (I have to keep my parts at the storage unit a few miles away) and started grinding. Nicked a diff stud but got it out. Got the diff to fit. Took lots of persuasion.
I also pulled the old rotors off of the IFS hubs. I might try machine those down with my grinder here at home.

Pics..







Polished my balls. Will probably JB weld "polish" them becayse they are pretty pitted.


Brake mounts came in.





BTW: Whoever came up with this style wheel hub/ brake mounting system should be tarred, feathered, and then hung. I'd venture to say it's the same guy that came up with the 05+ Tacoma hub bearing.


Not a whole lot of "progress" but its just some prep work that I won't have to do when it's time to cut.

I should have my marlin rebuild kit tomorrow.
I also got confirmation that my knuckles, spindles, and steering arms were shipped from my dad's place out in CA.

 

Keep the pics coming! Cant wait to see this happen.

 

Sweeeeet

 

I just ordered 4" allpros last night myself. Looks like you have some nice parts to work with,ill be following your progress.

 

Got my Marlin service kit today. Missing the spindle nut kits that were supposed to be in the box. Will call them monday.

Prepped the IFS hubs today. Got them cleaned, stripped of the old bearings/ races, turned down, and cleaned again. Ended up taking them to Autozone to check the fit in a Tacoma rotor. 1 fits, 1 is slightly too big. Will fix that sooner or later.

Might be picking up a tundra rear axle this weekend.

Pics.









Yours truly!

 

Subscribed!! Hope the build goes smoothly.

 

so if you run the ifs hubs you dont have to run the spacers correct??

 

Well, I don't need to run spacers anyway. My front axle is completely custom. I could have gone 101" wide or 35" wide. Stock Tacoma width is 61". Stock 85 Toyota front width is 55". I ordered my axle 67" with IFS hubs so that A. I can run a production tundra rear axle and B. I can run my stock brakes with the Front Range Off-Road Tacoma Brake mount kit click (or tundra brakes in the future).

All that aside, with an 86-95, if you put the IFS hubs on a SFA you swap in, you are correct. You will not have to run spacers.

 

A good friend of mine just picked up my rear axle from up in Dallas. He was headed up there for the ufc fight anyway so it made sense.
Its from a 2002 Tundra, unknown mileage. These are 67" wide so it will match my front perfectly. Was only replaced because of a leaky pinion and axle tube seal.
I will end up putting my 8.4 3rd in this. I'll also use my brake backing plates with the tundra shafts so I can keep the e-brake cable up above the leaf springs.

It's a little dirty but that's not a big deal.

Edit: picked it up for $120 and I owe my friend $45 for gas. Not bad in my opinion.

 

sounds like a hell of a deal!

 

Nice!



Also, my official Longs showed up today

 

Your official longs? You mean RCV longs?

 

This makes my pants tight . Your truck will be even more bad ass. You did some great stuff with the IFS

 

Sure....

 

Talked to the guys at Marlin Crawler, they're shipping my missing spindle nut kits out today. No biggie.

Today I ordered the forward swing bronco steering box and a u-joint to connect to it (the one on the TG kit probably won't work).


Also finally ordered the FROR hanger kit.


Should have more parts in the mail after next Monday.

 

Who you order it through by chance??