Synwars' 1st Gen Build

[synwars]

why not just inboard the springs like a formula toy? It seems much simpler and stronger with less chances of messing up to me

Because everyone does that. I hate being a follower. I'm bored with the old. IN WITH THE NEW.

Besides, I don't let common sense stop me.

I see many advantages with inboarding the frame. More clearance, shocks on the outside of the frame, still better flex (same), and takes just as much work rerouting everything like exhaust and gas tank. Plus while I'm in the I get to beef up the common problem area on Toyotas as far as rust goes.

I have a vision, I'm flying with it.

[burnyota]

sounds good ...keep trucking

[burnyota]

any updates?

[synwars]

any updates?

You betcha. I bought a new "steering stabilizer", in the form of a new hydrolic ram. 6" stroke, 1 1/2" bore, 3/8" fitments.
They was on sale for $99 Cdn, or in American $$$ would be like $10 or something...

[synwars]

Okay, and here we go again.

More work done on the weekend. Welded the narrowed section of the rear frame back to the new crossmember, shaved down the rear axle, and replaced the rear crossmember with some 3x2 x 3/16" square tubing.

[synwars]

Chopped the center section out of the narrowed crossmember, and welded some plate on top of the frame rails.

[synwars]

Now it holds its own weight. I can lift up on the back end now and it doesn't flex. You can see the cab/frame move with it. THAT'S A GOOD SIGN.

[synwars]

On to the rear crossmember:

Chop, torch, sleeve, weld, torch. In the order.

[synwars]

then welded all around...

[burnyota]

sweet..

[synwars]

sweet..

Thanks! It's getting there. I wish I had more than just Friday to work on it though... :S

[seanc]

if i were you i would gusset the crap out of the union where your crossmember is. maybe a triangle on the inside and out side...

[synwars]

if i were you i would gusset the crap out of the union where your crossmember is. maybe a triangle on the inside and out side...

It's already in the plans... http://board.marlincrawler.com/index.php?topic=11425.msg223807#msg223807

It's gonna require triangles and plating top, bottom, and all sides. I've got 1/8" and 3/16" plate for those requirements. I believe that is the next step. I'll try to get all support and gusseting done and new perches by next Friday...

[MR_DIY]

nice work... what inspired you to do this?

[synwars]

nice work... what inspired you to do this?

Thanks!

As far as inspiration goes, I'm not 100% sure where the idea came from.

The majority of it came from the fact that my double rears up front flex waaaaay better than my single Taco rears in back, which is fine for climbing up, but brutal for decending. I started making plans for 3/4 elliptical, thinking that would solve my issues. And it very well may have worked. But it seemed too likely for something to go wrong, and too many loose ends to figure out. Inboarding the springs doesn't solve all my problems, so I'll just inboard everything.

I've seen lots of guys chop their frame and tube the rear so it's narrow, mostly because it's rusty and they're linking it... But I've never seen anyone else narrow an existing frame. So I thought I'd try it out. Something new, you know? Besides, it gives me the opportunity to reinforce my frame while I'm in there.  

[MR_DIY]

10-4  great explanation man... cool build and I am watching for those after pics 

[6.72:1]

Yes!

[whiteman]

This is a cool idea

Thanks!

As far as inspiration goes, I'm not 100% sure where the idea came from.

The majority of it came from the fact that my double rears up front flex waaaaay better than my single Taco rears in back, which is fine for climbing up, but brutal for decending. I started making plans for 3/4 elliptical, thinking that would solve my issues. And it very well may have worked. But it seemed too likely for something to go wrong, and too many loose ends to figure out. Inboarding the springs doesn't solve all my problems, so I'll just inboard everything.

I've seen lots of guys chop their frame and tube the rear so it's narrow, mostly because it's rusty and they're linking it... But I've never seen anyone else narrow an existing frame. So I thought I'd try it out. Something new, you know? Besides, it gives me the opportunity to reinforce my frame while I'm in there.

I like the way you think. 

[synwars]

This is a cool idea

I like the way you think.

Thanks! Me too!

[synwars]

I had some square tubing left from my front drive shaft creation, so I made some new spring perches out of the scrap. The new perches were cut with O/A torches and a zip disc. I didn't even feel like drilling new holes so I torched em out. They're snug, no slop.

They measure at:

6"L x 2.5"W x 2.5"H @ 1/4" thick. 2.5"D was used for the arc, but the arc only reaches 1" into the material from the bottom, leaving me 1.5" lift. Angles were cut to fit approx 1.5"L x 2.25"H.

I made them a bit taller to be able to spray out any mud that gets in there, plus then I won't have to have such a big block in the rear. I also need it an extra 1.5" higher for my future plans to make some "revolving perches", but thats for another day when I have an extra $80 laying around and nothing to do. They are not only taller but they are another inch longer for better spring support and again for future plans.

Me thinks they be perfect.

[burnyota]

making good headway, good job..

[synwars]

Thanks Burny! I appreciate everyones compliments!!! It really keeps me going ...

[6.72:1]

Those are some cool perches!

[synwars]

Update time!!! Ok so I worked on it last Friday and failed to post up pics for a few days, so what?

Ok here we go! Basically, all we got done was bracing...

I cut out a bunch of 3/16" plates to be welded to the stubs and union member. Plates for all four sides. While Maffy was welding them in, I was cutting out and notching the corners.

[synwars]

Welded in place. Lots of boring pics I know...

[synwars]

Triangles both sides.

[synwars]

Ummm. Wait wait wait. Is that some patch work?

[synwars]

The common "cancer" zone on Toyota frames was getting the best of my baby. The inside walls of the frame right in front of the spring hangers were rotting pretty bad. I mean paper thin walls. I decided that, because the 2x4 fit so nicely sleeved inside the frame, I could easily box in the rotted portions. So that's what I did. Easy fix.

[synwars]

That's all for now, be working on it again Friday. I have done more work but no pics yet. Well I took pics but I can't show you yet. Top Secret Mission.

[MR_DIY]

more work and update those pics... 

this build is really cool