Author Topic: Synwars' 1st Gen Build  (Read 67476 times)

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synwars

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Synwars' 1st Gen Build
« on: May 13, 2005, 04:44:26 PM »
My name is Sammy. This is my project truck. I build it more than I wheel it. I bought it back in May '04 and wheel it in the summer. It's an '82 hybrid single cab mini truck. When I bought it, it was basically stock other than a shackle lift and blocks in the back. I started upgrading by March '05.

Index:

Rear spring swap.
Front end assembled.
Shocks F&R.
Dual t-cases.
T-case crossmember.
Plans for narrowing frame.
Before pics.
Narrowing the frame pics.
Hydro assist set up.
Flatbed and LED's.
IFS hub conversion & beadlocks.
Pivot perches.
*Battle scars!



This is what I have done so far:

- rebuilt front axle w/ ball trusses and Aussie locker
- vented fj rotors
- stainless braided brake lines
- Sky's IFS widening kit
- u-bolt flip front, u-bolt eliminator rear
- swapped double stack of 1st/2nd gen rears up front
- new Warren built 3" drop front hanger & Sky's boomerang shackles
- swapped 3rd gen rears in back w/ 6" shackles on Sambuilt rear hangers
- Sky's t-case e-brake
- BCC high steer kit w/ IFS box
- finished welding up shock mounts/towers
- finished plating my steering box
- swap my 4.7 gears in donor case
- clearanced my 2x IFS drive shafts to 35*
- square tube front drive shaft
- lengthened & balanced rear d-shaft.
- mated up my dual adapter to stock box and installed duals.
- t-case cross member front range style, Maffy welded.
- rear welded carrier.
- inboarded rear frame from cab back.
- built flatbed w/ LED's.
- installed hydro assist steering components.
- nerf's/sliders
- relocated motor & t-case mounts
- twin sticks
- pivot perches

Building is a little bit slower this time because I'M MARRIED. My wife likes 4x4ing, but she just doesn't like the time I spend (away from her) working on my junk. I have to admit, it is a purely selfish endevour...  

On the go list:

- Aussie lock front
- 30 spline Longs
- IFS wheel hub conversion
- traction bar
- ARP studs - hub+knuckles
- Gotpropane.com propane kit

To do list:

- front bumper
- interior roll cage
- V6 4.56's

Much thanks go out to Maffy, Warren, Steve, Marlin Crawler & Co, Sky Manufacturing, Cascadia Metals, Custom Plate & Profiles and of course my beloved wife, Marisa, who still allows me to spend time and money on this seeming fruitless hobby.
 
It's slow, but it's fun...

:turtle:
« Last Edit: Jun 02, 2009, 12:49:50 PM by synwars »
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Build up thread:
http://board.marlincrawler.com/index.php?topic=11425.0

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synwars [OP]

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Re: Sammy Pee's Project: Bigwig Rig
« Reply #1 on: May 13, 2005, 04:50:56 PM »
I've got to resize my pics I'll post em in a bit. Nevermind that but I can't even upload them. BIG MIKE CLEAR THE OLD FILES PLEASE. MAKE ROOM FOR SOME NEW ONES!!! :tantrum:
« Last Edit: May 13, 2005, 05:02:53 PM by synwars »
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synwars [OP]

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Re: Synwars' Project Bigwig Rig
« Reply #2 on: May 18, 2005, 03:53:45 PM »
When I bought it pics.
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awhotrods

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Re: Synwars' Project Bigwig Rig
« Reply #3 on: May 18, 2005, 04:26:09 PM »
 more pics of progress!!! :worthless:

synwars [OP]

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Re: Synwars' Project Bigwig Rig
« Reply #4 on: May 18, 2005, 04:34:42 PM »
Thanks. I am getting there:

My truck so far. I started with the rear. I pulled out my stock 1st gens and cut my old hangers off and welded new ones in. Then I threw in my 3rd gen ones with some 3" blocks and a u-bolt flip thinger. It pushed my shackle angle back to about 40-45* soft like a cadillac.
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http://board.marlincrawler.com/index.php?topic=11425.0

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synwars [OP]

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Re: Synwars' Project Bigwig Rig
« Reply #5 on: May 18, 2005, 04:50:00 PM »
Then I got to work on the front. It took me a whole day and some to cut and grind the old botch job of a drop hanger that the guy before me built. Then my buddy and I fabbed up a new front hanger out of 3/16" 4x2 rectangle tubing. Then we drilled the bolt holes an inch or so lower than stock. 3-4 inches of drop??? Then I threw my mix-n-match 1st/2nd gen rears in the front. While the axle was out I rebuilt it and put in a welded carrier. I shaved all bracketry that I could right off. and I put in my new BCC histeer. After I got the hanger in I made plates and drilled holes for my steering box. Then I put the axle in with the u-bolt flip thinger and 4* shims the correct the caster angle.
"Don't let common sense stop you..."

Build up thread:
http://board.marlincrawler.com/index.php?topic=11425.0

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synwars [OP]

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Re: Synwars' Project Bigwig Rig
« Reply #6 on: May 18, 2005, 05:12:28 PM »
I cut quite a bit out to move my box forward and up as far as I could. Cut my rad support and fender and body mount and other crap that looked useless. The box was getting heavy so I just started cutting until my arm got tired. :hammer:

Next up is shocks and a rear trac bar. When I shaved my front axle I saved the stock track bar to install in the rear. I'll take pics when its done...
"Don't let common sense stop you..."

Build up thread:
http://board.marlincrawler.com/index.php?topic=11425.0

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synwars [OP]

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Re: Synwars' Project Bigwig Rig
« Reply #7 on: May 18, 2005, 05:25:21 PM »
Oh and I dropped in Sky's T-case E-brake too. Looks yummy. I should have waited for phase two though....
"Don't let common sense stop you..."

Build up thread:
http://board.marlincrawler.com/index.php?topic=11425.0

KEEP IT CLEAN PEOPLE!!! :bat:

synwars [OP]

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Re: Synwars' Project Bigwig Rig
« Reply #8 on: May 18, 2005, 05:26:37 PM »
And then phase two is MUHAHAHAHA:

Operation Just What The Doctor Ordered!!!

 :drooling:  :drooling:  :drooling:  :drooling:  :drooling:  :drooling:  :drooling:  :drooling:  :drooling:  :drooling:

My donor 85 top shift t-case.

The goods.

I got a front drive shaft out of an IFS 4 runner and will be clearancing and lengthening it to fit in for my rear drive shaft. The front I will make a hybrid IFS CV square tube drive shaft for the front. I'm gonna go to CV for the front (even tho I know I don't have to) so it will take a bit of the shakes out. It helps with the angle anyways.
"Don't let common sense stop you..."

Build up thread:
http://board.marlincrawler.com/index.php?topic=11425.0

KEEP IT CLEAN PEOPLE!!! :bat:

synwars [OP]

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Re: Synwars' Project Bigwig Rig
« Reply #9 on: May 18, 2005, 05:27:36 PM »
That's all for now. Ill post more pics as I go along...
"Don't let common sense stop you..."

Build up thread:
http://board.marlincrawler.com/index.php?topic=11425.0

KEEP IT CLEAN PEOPLE!!! :bat:

bigman

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Re: Synwars' Project Bigwig Rig
« Reply #10 on: May 18, 2005, 07:37:52 PM »
i like the truck wish my one looked like that one
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Re: Synwars' Project Bigwig Rig
« Reply #11 on: May 18, 2005, 08:51:28 PM »
Nice project.  Great job soo far.

synwars [OP]

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Re: Synwars' Project Bigwig Rig
« Reply #12 on: May 19, 2005, 07:38:39 AM »
Thanks! Ya it sucks I can really only work on it on the weekends so progress is slooooooow. :headshake: Oh well, I'm gonna keep pluging away at it, can't wait to try out the dual ultimate! :driving:
"Don't let common sense stop you..."

Build up thread:
http://board.marlincrawler.com/index.php?topic=11425.0

KEEP IT CLEAN PEOPLE!!! :bat:

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Re: Synwars' Project Bigwig Rig
« Reply #13 on: May 19, 2005, 07:40:55 PM »
I like the looks of the drop hanger
2008 Tacoma regular cab, 4.88s, ARBs, crawl box, manual shift FJ case

Salvo

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Re: Synwars' Project Bigwig Rig
« Reply #14 on: May 19, 2005, 11:44:55 PM »
trucks looking good... but do yourself a favour and get rid of those lift blocks in the rear... you are going to spit those out with those shims ... I noticed when i shimmed my front axle that the center pin heads were barley long enough to corectly fit into the center hole on axle pad. i had to shim my center pin about 1/4 to make it contact properly... Im sure those blocks to not have enough lenght to work properly with the lift blocks.. Blocks usually come tapered to correct driveline angle.... Don't want to see ya sput them small blocks out on the trail... or worse yet on the road and hurt someone...

synwars [OP]

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Re: Synwars' Project Bigwig Rig
« Reply #15 on: May 20, 2005, 08:10:38 AM »
Ya i was thinking of that already. Actually they came with the truck. They are home made it looks like but its cool cuz it has a big long 8" center pin going through everything, as in the block is bolted to the leaf pack. It's got a spacer too so the pin end is actually about 1/2 of an inch lots to go into the perch. It ain't goin' no where. And with the traction bar in there it should keep the pinion from slopping around (refering to the fact that blocks actually create leverage making it easier for my pinion to be bobbing up and down).
"Don't let common sense stop you..."

Build up thread:
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KEEP IT CLEAN PEOPLE!!! :bat:

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Re: Synwars' Project Bigwig Rig
« Reply #16 on: May 20, 2005, 10:48:27 AM »
I have never seen a block get spit out.  I have been running my 4 inch blocks for almost 2 years without any problems.  all you got to do is check the nuts to make sure they are tight.  I just replaced them with 2 inch blocks because i was getting bad axle wrap.  But the traction bar should help with that.

synwars [OP]

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Re: Synwars' Project Bigwig Rig
« Reply #17 on: May 20, 2005, 11:29:40 AM »
^^^ That's what I'm talkin' aboot! :eyebrow:
"Don't let common sense stop you..."

Build up thread:
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synwars [OP]

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Re: Synwars' Project Bigwig Rig
« Reply #18 on: Jun 02, 2005, 08:07:50 AM »
I hated the unsightly shock tower that the previous owner had installed, so I decided to pull out the zip discs once again and an hour later my truck was 40 lbs lighter. I couldn't believe that the guy had used 3/8" and 1/2" inch steel to construct these POS towers, and the worst part was that they were at stock height. I cut them out, and I got new plans for taller ones. I wanna cut a section out of the inner wheel well fender, and stuff them directly vertical about 14' or so...
"Don't let common sense stop you..."

Build up thread:
http://board.marlincrawler.com/index.php?topic=11425.0

KEEP IT CLEAN PEOPLE!!! :bat:

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Re: Synwars' Project Bigwig Rig
« Reply #19 on: Jun 02, 2005, 08:10:21 AM »
Trucks looking great, but that giraffe is hilarious!   :laugh:
IFS is best kept at ambient temperature in a pile of scrap in the backyard.  When kept under a functioning vehicle, it tends to greatly diminish said vehicle's offroad ability.     -reklund5

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synwars [OP]

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Re: Synwars' Project Bigwig Rig
« Reply #20 on: Jun 02, 2005, 08:15:50 AM »
After I cut the front towers off I started on the rear top mount for longer shocks. I cut up a 6" x 2" piece of 3/16" plate and welded it to the shock cross member, and gusseted in the back of it. And I made up some tabs for the bottom but ran out of time to weld em in place... If any one thinks strength is an issue, consider this: I ALWAYS test my welds, I took a 3lb sledge and hammered on it pretty good. It only started to bend the corners in so I hammered it the other way to straighten em out. It's plenty strong.
"Don't let common sense stop you..."

Build up thread:
http://board.marlincrawler.com/index.php?topic=11425.0

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synwars [OP]

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Re: Synwars' Project Bigwig Rig
« Reply #21 on: Jul 04, 2005, 06:58:58 PM »
I got to work on my rig some more. I fabbed up some shock towers, out of 3/16's plate steel. I cut out a template with a zip disc and then three more according to that, by tracing out the outlines with the zip disc as well. Then I drilled 1/2" holes in two spots (I like selection) and bent the tabs on the top and bottom of the plate with a vise, a dead blow mallet, an angle finder, and some patience. 12 and a half degree's later I welded up the backing plates by putting a 1 3/8"s spacer between the top tabs and clamped it together, and measured it for squareness. 1/2 a day later an voila. Then next day I spent grinding down the frame, welding in the towers, reinforcing the front of my frame, welding in my steering mounting plates, and painting everything.
"Don't let common sense stop you..."

Build up thread:
http://board.marlincrawler.com/index.php?topic=11425.0

KEEP IT CLEAN PEOPLE!!! :bat:

synwars [OP]

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Re: Synwars' Project Bigwig Rig
« Reply #22 on: Jul 04, 2005, 07:08:11 PM »
As I cut out my inside fenders to fit them in, I realized that I completely forgot to take into account my steering shaft. :hammerhead: So I cut and notched out room in the drivers side tower to fit it in. Oh well, makes it light weight, right? :yupyup:

Still to do:
- Build longer front square tube drive shaft
- Install shocks
- Drop the box back on, wire it up
- Install dual t-case adapter
- Lengthen rear drive shaft
- Fab up my new t-case cross member (FROR style)
- Sliders's, front/rear bumpers
- Weld the rear

I need all that done by the end of July. I better get crackin'! :burnout:
"Don't let common sense stop you..."

Build up thread:
http://board.marlincrawler.com/index.php?topic=11425.0

KEEP IT CLEAN PEOPLE!!! :bat:

synwars [OP]

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Re: Synwars' Project Bigwig Rig
« Reply #23 on: Jul 04, 2005, 08:39:52 PM »
Ya ya, jacking my own thread, but here is my 4x4 bud's rig. His name is Warren. Say "Hi" to Warren everyone! "HI WARREN." He built my drop hanger for me. He's the one that introduced me to rock crawling and I have been building my rig ever since!

This is his rig. It's obvious to see he's running a Sami. He's got the important stuff in there: Toy axles filled with 5.29's and detroits, trussed and armored. 4:1 t-case behind stock tranny and 1.3L engine. Stock springs with Breeze drop links, and High steer. Sweet setup I'd say. Can't wait to hit the can opener!!! :driving:

Nice pics! What a poser! :shake:
« Last Edit: Jun 06, 2007, 03:49:58 PM by synwars »
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Northern Runner

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Re: Synwars' Project Bigwig Rig
« Reply #24 on: Jul 05, 2005, 10:24:25 AM »
Squatting underneath a truck while flexed by a forklift!!!!!!!
Hope he has life insurance....
LOL

 :hammerhead:

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Re: Synwars' Project Bigwig Rig
« Reply #25 on: Jul 05, 2005, 10:57:15 AM »
Sweet fab work synwars.  :thumbs:

shad

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Re: Synwars' Project Bigwig Rig
« Reply #26 on: Jul 05, 2005, 11:38:13 AM »
Nice truck. It reminds me alot of mine.
It's cool to see another 82 SWB truck being built.
Definately get some 5.29's and lockers for it.
I built mine a little different order.
I rebuilt the front axle, geared to 5.29's locked then did the flatbed and shock tower mounts then hysteer and now finally doing the suspension.

 :beerchug:
« Last Edit: Jul 05, 2005, 11:43:43 AM by shad »
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Re: Synwars' Project Bigwig Rig
« Reply #27 on: Jul 05, 2005, 12:23:33 PM »
Hey synwars what is the hieght of the shock tower?  Frame to top of tower. Thanks  :thumbs:

synwars [OP]

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Re: Synwars' Project Bigwig Rig
« Reply #28 on: Jul 05, 2005, 02:21:37 PM »
Hey synwars what is the hieght of the shock tower? Frame to top of tower. Thanks :thumbs:

It's 12" from the top of the frame to the center of the top shock holes. I know it's up high, and I took into account the leverage that would be created from it. Thats why I triangulated it front and rear, and of course side to side. Base is 6" @ 12.5* -/+ to 1 3/4" top.
"Don't let common sense stop you..."

Build up thread:
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KEEP IT CLEAN PEOPLE!!! :bat:

synwars [OP]

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Re: Synwars' Project Bigwig Rig
« Reply #29 on: Jul 05, 2005, 02:26:22 PM »
Nice truck. It reminds me alot of mine.
It's cool to see another 82 SWB truck being built.
Definately get some 5.29's and lockers for it.
I built mine a little different order.
I rebuilt the front axle, geared to 5.29's locked then did the flatbed and shock tower mounts then hysteer and now finally doing the suspension.

 :beerchug:

I'm going welded front and rear for now. I'll eventually go for an Aussie locker in the rear. As far as gears, I won't do that until I get 36" rubber and Smirfields. With the dual adapter and 4.7 in the rear with 4.11 diffs, I'll be at a crawl ratio at about 178:1. Not bad for now, it'll do me until I get more $$$.
"Don't let common sense stop you..."

Build up thread:
http://board.marlincrawler.com/index.php?topic=11425.0

KEEP IT CLEAN PEOPLE!!! :bat:

 
 
 
 
 

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