Infectious Off-Road.com

For the handful of you that have met me...I have an older little buggy.

[img]http://i878.photobucket.com/albums/ab341/xjcracker/BUGGY/177329_547889111903186_529889811_o.jpg[/img]

It was changed a ton before I got it and I had to get it wheelable.

So, I can't leave well enough alone....

My buggy was built using 3/4" rod ends (with 5/8" bore) for front and rear control arms. I addressed the rear end already and I want to address the front end. I have gathered tons of parts already and am about to tear into the front end and would like to eliminate the 3/4" rod ends on the lowers.

(pics sitting at full bump)

[img]http://i878.photobucket.com/albums/ab341/xjcracker/BUGGY/2012-10-08_18-18-01_184.jpg[/img]

[img]http://i878.photobucket.com/albums/ab341/xjcracker/BUGGY/2012-10-08_18-18-10_475.jpg[/img]

[img]http://i878.photobucket.com/albums/ab341/xjcracker/BUGGY/2012-10-08_18-18-19_323.jpg[/img]

So....I tore the front end a part to get things corrected...mostly fix the steering.

Ripped the front end a part and posted some of the parts for sale.....

[img]http://i878.photobucket.com/albums/ab341/xjcracker/BUGGY/e077e11ebb61fe0930971013006eeef4.jpg[/img]

Discovered the long side shaft is twisted.

[img]http://i878.photobucket.com/albums/ab341/xjcracker/BUGGY/d99ccacb38e93a6aeb6b9a57706b2d6e.jpg[/img]

Finally pulled this POS off

[img]http://i878.photobucket.com/albums/ab341/xjcracker/BUGGY/d319765dbf10703cafc0e38a6b00265b.jpg[/img]

And I got to see what my front diff actually was.....just what I suspected

[img]http://i878.photobucket.com/albums/ab341/xjcracker/BUGGY/f0da4d21529e4823d1dca4cc007fa653.jpg[/img]

Then I started cleaning the king pin bearings in the solvent tank to see how bad they were and one of them fell a part with a bearing split in half. I then started to inspect the races and discovered this:

[img]http://i878.photobucket.com/albums/ab341/xjcracker/BUGGY/5a30b53db5798823ac20b7cd71ee7537.jpg[/img]
[img]http://i878.photobucket.com/albums/ab341/xjcracker/BUGGY/aa5740c8f570eb75d3e7a693740a6ee2.jpg[/img]
[img]http://i878.photobucket.com/albums/ab341/xjcracker/BUGGY/41a0919461532e6f19d2a9f72f809225.jpg[/img]
[img]http://i878.photobucket.com/albums/ab341/xjcracker/BUGGY/56490b221e27ea04ed96d3a01fed0e13.jpg[/img]

The race hole is out of round 0.150. The inner C is fucked. Dunno what to do. Either knock this knuckle off and install a new one, find a new housing (stock dodge D60 housing I think) or try to reshape it with some heat and take it to a machinist to make round again.

New Years now is in question.....

The inner C kingpin bearing hole ovalized so it is now narrower in one spot and wider the other way.....I would have to heat up and reshape the whole slightly to even get the new race in.

At this point I think I will swap the inner C (unless I fall on a cheap new housing). An inner C swap for me would be the cheapest. I may change my castor a tad on both sides then put gussets on the inner Cs if I am doing all that work anyhow.

Went with the new 'c' idea...still looking for one but I removed the damaged one.

[img]http://i878.photobucket.com/albums/ab341/xjcracker/BUGGY/c21cabfb4d1f6a9459c98b8bc5d17eb4.jpg[/img]

[img]http://i878.photobucket.com/albums/ab341/xjcracker/BUGGY/9419289150dcfe9fc8821df425ba72ff.jpg[/img]

Got the new inner C in....cleaned it up then removed the tube. It is in great condition.

[img]http://i878.photobucket.com/albums/ab341/xjcracker/BUGGY/54aa93c1287d49d26662396bbbe104cc.jpg[/img]

[img]http://i878.photobucket.com/albums/ab341/xjcracker/BUGGY/5d13e02147e0241601aecb351b799f35.jpg[/img]

[img]http://i878.photobucket.com/albums/ab341/xjcracker/BUGGY/eea54b060531633898d7a13a794b8718.jpg[/img]

[img]http://i878.photobucket.com/albums/ab341/xjcracker/BUGGY/037edfa10af7946a139e8dcb0ba17e3d.jpg[/img]

got the inner C prepped and installed on the axle.

[img]http://i878.photobucket.com/albums/ab341/xjcracker/BUGGY/5e824e4983b5c840719b272ea0b2f4a7.jpg[/img]

[img]http://i878.photobucket.com/albums/ab341/xjcracker/BUGGY/ca513ae1087e043719aaeeae8cb0eb3d.jpg[/img]

So....my pinion was leaking so I figured I would put a new seal in. Noticed that the PO had put a pretty nice yolk on there too (Strange) so I cleaned up the rock rash a tad. I grabbed the impact to pull the pinion nut and the nut was not even tight and there was no washer under the nut. I swapped the seal and put the nut back on and the pinion wouldn't turn and I didn't even crank it down. I loosened it and it started to turn but not as it should. It appears that the guy the PO paid to put the new yolk on but they just backed the nut off so it would turn and didn't address the shim issue. I have to pull the pinion and re-shim it....FML.

[img]http://i878.photobucket.com/albums/ab341/xjcracker/BUGGY/f4dbad7ca2bbdced90d2a80d82bdd3e0.jpg[/img]

Made some more progress....

inner C on and with a gusset on both sides now
[img]http://i878.photobucket.com/albums/ab341/xjcracker/BUGGY/902dfabf428486f943fbacf633273e08.jpg[/img]

reshaped the lower gusset after I installed them
[img]http://i878.photobucket.com/albums/ab341/xjcracker/BUGGY/af524100ffe7114b434a0fccc1c66aa4.jpg[/img]

Installed knuckles with all new parts, bolts, bearings and races
[img]http://i878.photobucket.com/albums/ab341/xjcracker/BUGGY/a470c28550bfe844f2cb72a3aa7fa19e.jpg[/img]

Positioned axle back in rig at full bump and positioned tie rod as high as I could and cut the sleves to length
[img]http://i878.photobucket.com/albums/ab341/xjcracker/BUGGY/6ddd68627482f60a1355e6182c961e19.jpg[/img]

Lost of room for a track bar now...
[img]http://i878.photobucket.com/albums/ab341/xjcracker/BUGGY/4365af481f0ac0208571ede618be795e.jpg[/img]

I'll be moving the front axle forward so I should have enough room to get the track bar in there.

Got the new reservoir in position and bracket all made. Removed the KRC alloy pump and modified the bracket to get it to fit a TC pump (spare) I had here at the house. Had to go out and get some metric bolts and a new belt to get it to fit. Made all new hoses with parker fittings (-10 feed, -8 return) and will do -6 to the ram when I can get the axle in. Everything in my steering will be new except for the orbital so lets hope my steering issues will subside.

[img]http://i878.photobucket.com/albums/ab341/xjcracker/BUGGY/3428284700fdba13e5e37db9989aedcc.jpg[/img]

[img]http://i878.photobucket.com/albums/ab341/xjcracker/BUGGY/59af2a2463f91185534e8e16ecf653e6.jpg[/img]

[img]http://i878.photobucket.com/albums/ab341/xjcracker/BUGGY/1e143b089660667caff248a46cba1488.jpg[/img]

[img]http://i878.photobucket.com/albums/ab341/xjcracker/BUGGY/bcef87f5c93743da68d2f557b9f2a76c.jpg[/img]

I got the 4130 in from Aircraft spruce. It is normalized and if I can finalize my measurements, I will drop them off to be swaged soon. I negotiated with them a lower price for the swaging CTM will bore and tap them afterwards. THese will be stupid expensive LCAs at maybe $800 for the pair

[img]http://i878.photobucket.com/albums/ab341/xjcracker/BUGGY/0464bad74be57651b65f4598f0690ade.jpg[/img]

Cut off and welded on a new UCA mount. It is an Artec bracket they send out with their rear trusses for UCA links that I trimmed 5/16 off the top of. It sits at the same location but is physically smaller yet provides me 3/8 more room of clearance for the bump stop and in vertical travel. I will need to have what it is welded to all rewelded to the casting with nickel rod before I can use the front end.

[img]http://i878.photobucket.com/albums/ab341/xjcracker/BUGGY/02971724c94c7d3f1a90438d1292f6fe.jpg[/img]

Made some progress on the ram mount. Made a simple bracket to hold the mount in place and got it mostly done. I need to add a support piece on the other side and drill some holes in the bottom of it for drainage.

[img]http://i878.photobucket.com/albums/ab341/xjcracker/BUGGY/2fb7ea70f56211ff9a6273906ff34225.jpg[/img]

Got the ram in place and established that I needed ram travel of no more than 7 21/64". I have an alloy sleeve that I will machine down and then put it in the ram to limit the travel.

[img]http://i878.photobucket.com/albums/ab341/xjcracker/BUGGY/c08ed485443882894b5b2898fe96a8e1.jpg[/img]

[img]http://i878.photobucket.com/albums/ab341/xjcracker/BUGGY/2f36c9c871d8e0babfa516fe56a7ad27.jpg[/img]

I finished the axle ram mount. Used a die grinder and ground all the cracking weld of where the UCA mounts to the casting....took forever. Plasma cut off and ground off the old LCA mounts and that fucked up bump stop. Welded up the pass LCA mount and built a new bump stop tower then tack welded the drivers LCA mount.

[img]http://i878.photobucket.com/albums/ab341/xjcracker/BUGGY/99c369973183593d2f05342cf5b629ea.jpg[/img]

Then I needed to position the axle in the rig so I made a temporary radius mount

[img]http://i878.photobucket.com/albums/ab341/xjcracker/BUGGY/077faf409f92676914d3df553f9dd421.jpg[/img]

Not much done tonight but I did limit the ram travel. Had to take a 1" spacer down to 0.675 so I went to a bussies house and we did it on the lathe. We were able to use the lathe clamps to hold the ram cap to open it as well. Ram travel is now 7.325".

[img]http://i878.photobucket.com/albums/ab341/xjcracker/BUGGY/813fc99101814ec97bc2b6c0d0741d48.jpg[/img]

[img]http://i878.photobucket.com/albums/ab341/xjcracker/BUGGY/e08681121e8b9365c1479c259ba9e385.jpg[/img]

[img]http://i878.photobucket.com/albums/ab341/xjcracker/BUGGY/87caf5a912b7a4638eac13d1664a984c.jpg[/img]

[img]http://i878.photobucket.com/albums/ab341/xjcracker/BUGGY/825a6d7900a622c72c78fb908de88083.jpg[/img]

[img]http://i878.photobucket.com/albums/ab341/xjcracker/BUGGY/fa41add7787f8442cc1eebd618e5e96e.jpg[/img]

[img]http://i878.photobucket.com/albums/ab341/xjcracker/BUGGY/ff0cc102ff76104f35f4c8f6c46804e9.jpg[/img]

This is all I think I can do before I leave for town for Christmas....won't be back working on it 'till the 27th.

looking good

Are you going to completely dump the radius arm set-up and go triangulated 4-link?

Awesome build man! I just bought a beater buggy and am going through the same chit.

I've wheeled with this fag...... his junk is legit and while CRACKER is a condescending piece of shit, I really like him. Probably will have to introduce him to the rape shack next time out.

[quote="Desert Dog"]Are you going to completely dump the radius arm set-up and go triangulated 4-link?

Awesome build man! I just bought a beater buggy and am going through the same chit.[/quote]

Thanks

I am keeping the identical suspension design as it works so damn well....

Here it is (without the suck down winch sucked down) 'crawling' backdoor.....

http://www.youtube.com/watch?v=LOfmb7jZSQE

[quote="abendx"]I've wheeled with this fag...... his junk is legit and while CRACKER is a condescending piece of shit, I really like him. Probably will have to introduce him to the rape shack next time out. [/quote]

Hedley Lamarr: Qualifications?
Applicant: Rape, murder, arson, and rape.
Hedley Lamarr: You said rape twice.
Applicant: I like rape.

[quote="cracker"][quote="abendx"]I've wheeled with this fag...... his junk is legit and while CRACKER is a condescending piece of shit, I really like him. Probably will have to introduce him to the rape shack next time out. [/quote]

Hedley Lamarr: Qualifications?
Applicant: Rape, murder, arson, and rape.
Hedley Lamarr: You said rape twice.
Applicant: I like rape.[/quote]


Bart.... I told you to wash your hands after a cross burning.... see, it's coming off already!

My fave movie!!

Got a spool coming today that will replace the welded front carrier.

[img]http://i878.photobucket.com/albums/ab341/xjcracker/BUGGY/spool.jpg[/img]

I actually got some time last night to work that I didn't expect to have. I welded on the other LCA bracket, set the axle in line with the rear axle (within 1/16th of an inch). The LCA arm lengths are both about 36" eye to eye so now I can get my LCAs swaged tot he right length. I also removed the old chassis side track bar bracket and took some measurements to design my new one.

[img]http://i878.photobucket.com/albums/ab341/xjcracker/BUGGY/7738f0e10743a4480dab88aee0819f64.jpg[/img]

[img]http://i878.photobucket.com/albums/ab341/xjcracker/BUGGY/f7faa3c3efce72c02ee2c5a4ec45a9c7.jpg[/img]

[img]http://i878.photobucket.com/albums/ab341/xjcracker/BUGGY/55fc36377534d5226f4f811feb71205e.jpg[/img]

[img]http://i878.photobucket.com/albums/ab341/xjcracker/BUGGY/21b40f716819b5c354b5c7b22d83ce74.jpg[/img]

The 'hard to find' LH 7/8 x 14T tap came in as well

[img]http://i878.photobucket.com/albums/ab341/xjcracker/BUGGY/bd24ce1aeae2c2715597af1fa72578ba.jpg[/img]

After 9 days of travel and being sick, I am back in the garage....although I wish I was wheeling in JV

Got my CTMs back from Jack. He did a rebuild. Found out these are actual 300m joints from an early production.

[img]http://i878.photobucket.com/albums/ab341/xjcracker/BUGGY/db028128b7570fc02473fab3aa257a0f.jpg[/img]

Made the chassis side track bar bracket

[img]http://i878.photobucket.com/albums/ab341/xjcracker/BUGGY/78a3270ecf0c939f31c938d5a5ed1d35.jpg[/img]

[img]http://i878.photobucket.com/albums/ab341/xjcracker/BUGGY/10fd3cbe522e1c4fd1fc28118b754bb8.jpg[/img]

Mocked up some of the parts....

[img]http://i878.photobucket.com/albums/ab341/xjcracker/BUGGY/cd03c84645974158569e87a258af5e9b.jpg[/img]

Then tack welded the bracket in place

[img]http://i878.photobucket.com/albums/ab341/xjcracker/BUGGY/0f4a3d2287f14089ee3ae405547657b5.jpg[/img]

[img]http://i878.photobucket.com/albums/ab341/xjcracker/BUGGY/526899e35339ef68ff02afe161a4bb70.jpg[/img]

[img]http://i878.photobucket.com/albums/ab341/xjcracker/BUGGY/40c37e8238f63b881c0474c5b94e96ea.jpg[/img]

Bent the track bar to work....just two clicks on the bender

[img]http://i878.photobucket.com/albums/ab341/xjcracker/BUGGY/0b6ded28362913eb3b495a1e471dfee9.jpg[/img]

Track bar bracket is tight....tie rod is at full right lock in this pic

[img]http://i878.photobucket.com/albums/ab341/xjcracker/BUGGY/566cb2175b8f4e818106a85ddec202ee.jpg[/img]

As you can see there is very little room at extreme bump and full right steering lock

[img]http://i878.photobucket.com/albums/ab341/xjcracker/BUGGY/cb51b68da4ab0d032dc1c5e8e99738f0.jpg[/img]

The UCA, bump stop, track bar and tie rod is a very tight package :/

[img]http://i878.photobucket.com/albums/ab341/xjcracker/BUGGY/69b09d9e17b3bb20fe9dc32a9ed65aa0.jpg[/img]

And the last thing I did today was cleaned up all the axle shafts and ready for u-joints.

[img]http://i878.photobucket.com/albums/ab341/xjcracker/BUGGY/5828d459d4c0868dfe122a591159852e.jpg[/img]

Tomorrow I should have the axle side track bar bracket all made and the track bar cut to length..... :fingerscrossed:

Nice work cleaning up that front end. It was in bad shape for sure! Glad you replaced the C instead of welding on the race area.

maybe i missed it, on the first post (and i'm to lazy to scroll back) but
what is your wheel base?

Nice!

How was the trip.... everything as fun and enjoyable as you were hoping for??

[quote="Uncle Cracker"]maybe i missed it, on the first post (and i'm to lazy to scroll back) but
what is your wheel base? [/quote]

Dunno if I said it or not but it is about 109 now.

[quote="abendx"]Nice!

How was the trip.... everything as fun and enjoyable as you were hoping for?? [/quote]


Spent a couple of days at the Air and Space Museum(s) and hung out with the family.



It was ok....glad to be home though....plus I have lots to do in the garage

Fuck yeah you got a lot to do..... how's she coming?

And thanks again for yesterday.