I copied this thread from my post over HERE

I decide to make some lift shackles for 1984 Runner. These things are 8" between the holes (2.25" lift) and they are pretty freakin big, I think if they sit weird or anything, I will cut them down to 6" (1.75" of lift), which is the biggest size, I could find commercially available.
I started with some 1/4" X 1.5" Steel Flat Stock. I then measured for the holes, added about a 1/2" to each end for strength and cut them out on my angle grinder with a thin (.045) cutoff wheel. I then took them over to my drill press and drilled out the 1/2" holes for the bolts, I then took them back to the angle grinder and bench grinder (and wire wheel) to round off the edges, and soften up the look a bit, and then painted!
I'll let the pics explain better...
Let me know what you think.

Cutting them out of the stock... (NOTE: See the "Safety Goggles" - Proto Anti-Fog Competition Anti-Glare Paintball Mask. lol)




Drilling out the holes... (NOTE: David, you know you want the drill press)





Grinding them round...



Finished?...




Painted!



Now, I just had 6 more to do...




And all it took was these simple tools...

(Note the OME struts in the rear right, and the OEM 4Runner Coils in the rear left. Pack Rat!!)



Thanks for reading, let me know what you think.

Just for comparison sake, I am posting the measurement of the center of my fender wells, (from ground through hub, to fender) from before and will post the results once they are installed.

BEFORE:
Front Driver - 35.25"
Front Passenger - 35.25"
Rear Driver - 32"
Rear Passenger - 32.25"

 

Those shackles look great and you never know about those stray paintballs!

 

Okay guys.... what do we think about bracing these? They are pretty long... I have a couple of design ideas, but lets hear yours...

 

I would have used thicker metal.

X2 on bracing.

 

Yes, I generally use 3/8"x2" flat bar for my shackles. I recommend bracing them when 2" longer than stock, especiall up front, for stability:
- http://www.4crawler.com/4x4/ForSale/...es.shtml#FAQ11

 

You seem to have never drilled metal, reason I say this is b/c your smoking the bit and ruining the temper of the metal. Use lubricant, I like pb blaster or plain old motor oil. Not knocking ya, just some good FYI..

Also I woulda used thicker metal too and brace them.

 

why would you use a penetrator for drilling. and its supposed to smoke when using a lube. i've got some kind of wax the local machine shop guys gave me and it works pretty good.

 

Just cause its what I had laying around, penetrator oil seemed to work fine. I have had drills smoke, but not like that. I take my time, my grandfather taught me to take your time, if it begins to smoke you need to back off a bit and let it be otherwise you can ruin the metal or the bit easily.

I trust a guy who has been a machinist for most of his adult life.

 

I always heard if you take youre time you'll ruin the bit, so u have to put some pressure on it and "help" it cut. Dont just let it sit there and heat up. Seems to work good for me.

 

Nice Chris, now lets see the comparision pictures. I'm very interested to hear what you gained off-road.

 

Well not take your sweetass time, just dont make the thing violent smoke is what I was told.

 

Thats WD-40 smoking, not the metal, or the drill bit, I had a little tiny bit of 3 in 1 machine oil I started with, but WD40 is all I had to finish up. lol. Thats what is smoking.

 

Also running your drill press at a lower speed helps with cutting metal.

 

I've never seen a bit smoked without lube. Bits can only smoke with lube. This is because there is nothing to burn when you are drilling metal. You can smoke a bit drilling wood fairly easy, but not metal to metal.

 

Musta been the drill bits or something, cause they heated up without lube and smoked like nuts.

 

Yeah had it down to 620 RPM, thats the lowest spindle on the drill press.

 

HSS drill bits...I use them all the time dry and at the proper rpms no need for lube.

How much lift you trying to get out of those shackles? I got a set of 3" lift shackles sitting on a shelf somewhere collecting dust.

I would use 3/8" plate as well...as 1/4" is just too flimsy.