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Track bar mount is made, mix of 1/4" and 3/8" Steel, kept it pretty simple looking, but fits perfect.
Installed for mock up. This is at full bump.
Clearanced the crossmember a little bit with the grinder. Might go a little more to get some more clearance, but I really want to make bump stops to prevent contact.
Clearance between track bar mount and diff cover. I have seen other manufactures make contact with the diff cover and/or the cover bolts.
Full bump with 35" tire installed.
Full bump, full lock, no rubbing in both directions.
So I pulled everything back off and welded most of it up. (In 107* heat I might add) So this weekend I'm pretty sure this truck will be on the road for test drives.
Well Lt.Dan1, I just want to say THANKS! I just "wasted" more than an hour drooling over these fantastic fab pics. I'm just gonna go throw my mig welder in the trash now.....
Very nice work, have really enjoyed following along with your build. Thanks for sharing and yes I am sure most on here follow along as I am when they are at work...so many things to do when I am at home.
Thanks for all the kind words guys! I really appreciate it! I finished welding all the brackets, drilled the rest of the holes in the frame, and bolted all the brackets on. 32!! 1/2"-20 bolts were used!
Then I assembled the axle and slid it under the truck and started assembly. We had a problem with the Reman caliper, it had a deep gouge right through the matting surface of the banjo fitting, making it leak profusely. After some sanding, filling, and double up on copper washers, it stopped leaking and we were able to bleed it.
I made it about 30 feet before it got hooked to a trailer and put to work haha.
I'm pretty happy with the way it turned out altogether. It rides way way better, handles nicely and drives straight down the road. The rear is a little stiff just from the stock springs, so I'll probably do the 10'+ rear springs in the future.
That looks great man, and I bet the ride is so much better. Any plans to paint or powder coat the parts?
Yes, I have a trip planned in 2 weeks, so when I return from the trip, I'll tear it all apart and take it to powdercoat. This way I can drive it for a little while, including towing my toy hauler, before I finalize it all.
A little follow up, everything has been great other than the track bar. It keeps shifting inside the mount because the hole in the track bar is larger than the bolt, I have it torqued to 300 ft/lbs and I still hear it pop/move every once in a while. I think I'm gonna pull it out and see if a 3/4" bolt will fit (currently it's an 18mm), then I just have to drill out the mount a little bit.
Also, now that I have a new blue top steering box, and a nice tight heim steering, I can tell how much play is in the steering shaft, its unreal watching it while someone turns the wheel... maybe a borgeson shaft is in my future now. Sigh.... it never ends...
Also, I just sent out the files to have intake plenums machined. They will just be flat like IDP plenums, except mine will retain the 2" inlet, and I am having them machine an o-ring groove for a Viton o-ring. No more RTV (which is the reason why mine is leaking in the first place).
Few small things taken care of... fixed an oil leak at the hpop gear inspection plate, replaced with dieselsite plate and o-ring, leak fixed.
Got the first test plate for the intake plenum and mocked it up on my spare engine on the stand. Looks like it should work perfect with the stock OBS/E99 turbo (which Is a damn tight fit!!!), stay tuned for how we finish it off.
I got the revised front coil buckets installed so the truck sits level with just a 2" block. Roughly 3-4" of bump travel still.
Also made my flatbed extension again, this one geared towards being lighter, stronger, easier to install by myself, and look better. Nailed it across the board I think. Its 3 seperate pieces, 2 sides and 1 tube in the middle. The 1700lbs 4 Seat RZR fits like a glove, doesnt bow, bend, or anything while it's up there, and with 60psi in the bags, the truck sits level. I'm leaving for a day trip tomorrow, so wish me luck!
