Hey YTer's, just wanted to start a build thread for my SAS as I'm looking for insight and motivation.

I bought my 83' Axle for $225 from a guy who is running full-size axles and 44's. He was about 2 hours away, and so for that price he was willing to meet me about 30 mins away. I got the axle and it was a rusty POS, but it was complete. He didn't know the axle ratio, but oh well, I didn't care.
Sorry, no pic.

I got it ripped apart, and cut off most of the junk. Once I got it apart I found out it was a 4.38 ring gear, so the hunt was on for a 4.10, but yet another delay.


In my hunt for a cheap set of 4.10's, I found a FJ80, so I snagged the front and rear E-Lockers and switch, but no ECU. A local YT member had a rear 4 cyl axle that he was willing to give up, plus some cash in exchange for the rear E-Locker, as I had no use for it. So, for $75 invested I ended up with a front 4.10 E-locker, and a complete (rusty) 84' rear axle.

So Now I must mod a perfectly good 83' housing for this E-locker... Sweet. This isn't a tutorial as there are sweet ones already out there, that's how I did this.


95' FJ80 E-Locker (Hi-pinion 3rd)


Making the squared edge.


Not enough.


I figured some heat would spice some things up, so I got the housing red hot, and punched the back of the housing with a brass drift and hammer.


The studs were next, so I cut them flush, than welded the leftover part in the housing, than ground it all flush. I than placed the 3rd member in the housing, and used spray paint to mark the new stud locations.


Drilled and tapped the new stud locations


Success, it's in flush. Now I need to find M8x1.25 rod, or studs of the right length.



The next step for me is to build my own spring hangers, get some Chevy's, and another set of rears to build my RUF swap. I'm hoping to having this truck on the trail by Memorial Day, including the SBC swap.

 

That e-locker is not interfering with the spring or the u-bolt?

 

i plan on adding e lockers front and rear on my 82 in the near future, if i can ever stop spending money on my 88 runner instead lol

looks good so far, any reason for not doing rear e locker as well?

 

looks to me like he will have issues with the inner Ubolt...


Nice find on the HP.

 

I hear ya, I can never stop spending money. I do plan on a rear E-locker once I have the SAS and 350 swap done. My main concern was the front diff, and as a bonus, it's an E-locker. The rear FJ80 diff doesn't fit in the truck housing, so I need to source one, and just haven't gotten around to doing it yet.

Thanks for the concern. From my research, it would appear that the FJ80 hi-pinion 3rd requires no further modification to fit in the front housing other than what I've done. When it was pulled, it was sitting in a very similar SOA, with a U-bolt right next to the 3rd member. If you look at the E-locker side of the 3rd member, you'll see that the edge is flat, which is where the U-bolt was before, with no problems. Also, the spring perch is higher than where the E-locker would contact it, so that's not really an issue either.

This is not my setup, as it was yanked from Pirate. It's an FJ80 E-locker in a (I think) 82'-83' front housing, same exact setup as mine, and required no further grinding. I could be totally wrong, but with a die grinder, it wouldn't take much, if any to get it to fit fine.

 

Hy-steer & IFS box relocation kit.


I had to buy new cone washers because I have no idea what happened to them, there goes another $50.

 

Axle almost together... I re-threaded all studs, torqued them, and started assembly. So far, my axle is e-locked, armored, waiting for truss, and hysteered.


I need to transfer my IFS hubs over to the SA, and get 97' Tacoma rotors, I like the idea of a non-captured rotor. Rebuild my Aisin hubs, build my RUF leafs, and drill and tube the frame.

 

Cool build.

:wabbit2:

 

Thank you, I've definitely peeked at your threads a time or two.

Update. Friday, when I got off of work, another tech kept pushing me to pull my truck in and cut off the IFS. He wouldn't leave until I did, so I did.



Long travel IFS. I'm only saving the hubs and calipers.


Saw more people not running dust shields than people who were, so I made my own eliminator kit.


On it's own weight, I like the height but the rear shackle angle is super lazy and the leafs are touching the frame. I still need to make a hybrid set, these are just my old saggy rears.


My dad came to the shop and rocked out this flip plate out of scrap we had.


Ready for IFS hubs and install.


Hung, like a horse.


From the left.


From the right.


Had to get it out of the shop, and not having rotors caused a piston to come out of it's bore and spill brake fluid on my tire.


Hey Sweet Thang, saw you from across the way, and wanted to buy your sexy @$$ a drink.


And, like that she's SAS'd. Still to do..
- Brakes
- Hybrid leafs
- Move rear shackle mounts back 1-2"
- Rebuild my Aisin lockouts
- Shocks

 

That front hanger looks a little sketchy IMO.

That elocker HP front is pretty cool thought.

 

Thanks for checking out my build. Someone on Pirate mentioned the hanger in almost the same manner, what is sketchy, the shackle strength, welds, etc? I'd like input on how to improve it, gussets?

I saw the FJ80 in the yard w/ diffs and it was a no brainer. I'm building the locking switch/relay setup now.