Author Topic: Synwars' 1st Gen Build  (Read 75728 times)

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synwars

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haha about time somone closer to me...   maybe ill have to drive down this summer and we can go wheelin. i have a few friends near where u live. 

ps. i love the frame work.. its inspired me to try something like that.

Sure mang, bring it.
"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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Back to business... It's only been about 6 MONTHS since I've gotten to work on my truck. :( Oh well. I'm back at it. I've been hording parts for the past while, and have ordered some new parts...

So far I have:

36" TSL's.
NEW FJ80 Non-ABS Master Brake Cylinder.
Rebuilt Master Clutch Cylinder & Slave Cylinder.
New rear spring poly's.
New clutch & resurfaced flywheel.
Machined DOM for pivot perches.
IFS wheel hubs.
Black "rust-not" paint.

I'm waiting for:

4x US Wheel 15x8 rims.
4x Rockstomper DIY beadlock kits.
Wide track rear axle.
Sky IFS spacers.
Marlin HD Seals, Twin stick, spring perches, and knuckle ball gussets.
FROR Skid plate & ARP studs for the knuckles and hubs.

That's the list for now. I hope everything goes together okay... :willynilly: :turtle:


« Last Edit: Apr 10, 2007, 01:34:33 PM by synwars »
"Don't let common sense stop you..."

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

KEEP IT CLEAN PEOPLE!!! :bat:

MR_DIY

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nice! keep it coming.  she ain't going anywhere  8)  :smack:
I'm going yota JUST so I can buy from Marlin more.

*quote*-  goes to show that a ramp hero doesn't always have what it takes to be a trail hero as well.

fatt_matt

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awesome build!
Jeep

synwars [OP]

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Thanks guys.

So UPS brought me some goodies:

30 Spline Longs.
Sky spacers.
Marlin Twin-stick.
FROR skidplate + ARP kunckle bolts.
Rockstomper Beadlocks.
US Wheels.

Still waiting for:

Marlin knuckle ball kit and perches.
FROR ARP hub studs.
"Don't let common sense stop you..."

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

KEEP IT CLEAN PEOPLE!!! :bat:

MR_DIY

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 your parts pile is the heat :flamer:
I'm going yota JUST so I can buy from Marlin more.

*quote*-  goes to show that a ramp hero doesn't always have what it takes to be a trail hero as well.

synwars [OP]

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That's cuz its 6 months worth of saving up and hording parts... I actually remind myself a little of Gollum... "oohhaaa haaaaa twin stick Myyy PRECIOUS!!!"  :respekt:
"Don't let common sense stop you..."

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

KEEP IT CLEAN PEOPLE!!! :bat:

fatt_matt

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true that /\
Jeep

86bobbedtoy

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NICE LOOKIN PARTS COLLECTION AND BUILD

synwars [OP]

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This weekend I didn't do much. I got my buddy Maffy to come over with his Mig welder to attach my beadlocks to my new rims. To make it easy, I temporarily put the new hubs back on the IFS spindle, and clamped the knuckle in the vice. Then I put the rim on the hub so that we could spin it easily while welding. It was a sinch. Also, I bolted down the spacers onto the IFS wheel hubs... I'll paint them through the week and them mount them next weekend. I still need to locate some steel BB's...

It'll get there... :crossed:
"Don't let common sense stop you..."

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

KEEP IT CLEAN PEOPLE!!! :bat:

MR_DIY

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rock on!  I like the locks!
  :thumbs:
I'm going yota JUST so I can buy from Marlin more.

*quote*-  goes to show that a ramp hero doesn't always have what it takes to be a trail hero as well.

synwars [OP]

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I haven't been doing much lately because of sickness and vomiting. Got some rims and rings painted with some thick glossy rubberized epoxy paint used for frames. So far I've only mounted two, NO LEAKS! They take a long time to bolt up and torque 32 bolts in a criss-cross pattern to 15 ft/lbs! It seriously takes forever.

UPS brought me some more goodies: :willynilly:

Marlin HD Seals
Turtle knob SAE tapped for twin stick
MC Knuckle ball gusset tabs
MC axle perches

I may be buying a '90 Auto V6 rear axle with 4.56 gears. :think: I also sourced out a 4.56 3rd from another feller. So soon, I may have a wide track axle with stock V6 4.56 gears front and rear! Althought price-wise I'll be near to $450 by the time it's all said and done... :ack:
"Don't let common sense stop you..."

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

KEEP IT CLEAN PEOPLE!!! :bat:

MiniSimp

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I think you need a bigger bolt for your pivot perches!!!! :gap:

What dia is that? looks like 1.75"

Keep posting the pics! Work looks good.

synwars [OP]

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I think you need a bigger bolt for your pivot perches!!!! :gap:

What dia is that? looks like 1.75"

Keep posting the pics! Work looks good.

Thanks.

After seeing BigMike's failure on his PP's, I decided because of all the stress place on the single pivot point as opposed to dual Johnny Joints, the material I use has to be BEEF. I'll also be running a trac bar to reduce my axle wrap which is a instant breaker of leafs nevermind PP's.

That's a good question though, I'm not sure how big that bolt is. I designed it to be able to replace my 2" lift block's and high perches without sacrificing COG. The wall thickness of the DOM is 3/8", plates are 3/8", and MC perches 1/4". To sandwich the leafs I've got 1/2" Grade 8 bolts w/ nylocs. I'll measure the bolt. I'm thinking 1.5" but...
"Don't let common sense stop you..."

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

KEEP IT CLEAN PEOPLE!!! :bat:

MiniSimp

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You can also lower the height of the perch to adjust your height.
I was thinking about doing that, but the springs have settled now.

synwars [OP]

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True that. Mind you, the MC perches are pretty low already, I think they only have about 3/8" on the inside of useable space anyway.

I measured up that bolt at 1.479" D x 7.5" L. The DOM is 3/8" thick x 5 3/4" L x 1.485" ID. Pretty tight tollerance, enough for grease. I didn't want too much slop in there, but not too tight either.

I'll be welding that up in the next while, I'll post up pics as I do...
« Last Edit: Apr 26, 2007, 12:22:19 PM by synwars »
"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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I got another present from UPS today! :beerchug:

FROR ARP hub studs yipee!!!

Alls I need now is my rear axle!!! :eyebrow:
"Don't let common sense stop you..."

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

KEEP IT CLEAN PEOPLE!!! :bat:

gonepostal

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good work man, keep the updates coming.  1st gens rock :beer:

synwars [OP]

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Thanks man!

I really appreciate everyone's encouragement! It really keeps me hyped to finish my junk and hit the trails. :bud:

I spoke to my potential seller today, and I should be picking up my auto V6 rear axle next Weds! I'll try and grab another V6 4.56 3rd for the front as well. I'll weld one and Aussie the other! If I can't get another 4.56 3rd for a decent price, I'll stick with 4.11's for now...
"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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I had an hour to work on my junk last night so I quickly threw on another coat of paint on my last two beadlock rings, and in between coats I worked on installing the ARP hub studs in my IFS hubs.

I double nutted the stock studs to get them out, and man that was work on its own. I had to get 50 lbs of torque on the double nuts before it would lock enough to turn the old ones out. :o Then I took my handy dandy 8mm x 1.25 tap and ran them through all 12 threaded holes. I gave it a shot of brake clean, dried out all the holes. Then I used blue locktite to secure each ARP stud into place. I threaded each stud in all the way by hand, then torqued it down using the double nut method again to the recommended 28-30 ft/lbs on each stud. Took about 45 mins in total. No bad. :cheese:

After that I put another coat of paint on the rings and went home to my beloved wife. I have to thank her a lot for letting me keep my truck, most of my buddies had to sell their junk after they got married. I love my Marisa. :love:
"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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Got some work done on my truck after my meeting at the KH and afternoon ministry.

Started at about 3:30pm, worked until 7:15pm. In that time I pulled out my engine, transmission/t-case stack, and front & rear drive shafts.

Once I got the engine out I pulled the clutch off and found out why it was slipping. The pilot bearing went poof and the shields got stuck behind the clutch and the fly wheel. :_oops: It's such a new clutch (less than a year old) with NO wear that I'll re-used everything, just bolt it onto my resurfaced flywheel.

While I got the T-cases out, I'll pull the rear one off so I can set up the twin stick. I'll also bolt on the new FROR skid plate. I'll be refabbing the driver side of the t-case mount to clear the body and exhaust when I do my drivetrain lift.

IT'S GETTING THERE!!! :woohoo:
"Don't let common sense stop you..."

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

KEEP IT CLEAN PEOPLE!!! :bat:

DTB

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I had an hour to work on my junk last night so I quickly threw on another coat of paint on my last two beadlock rings, and in between coats I worked on installing the ARP hub studs in my IFS hubs.

haha that sounds like me...im lucky if i can get more than an hour at a time to work on my junk......looking sharp :thumbsup:
RIP KYOTA
Quote
toyminator2000 There has to be dumb people in order for there to be smart people
Low down & durrrrrrty Rock Stacking Web Wheeler :driving: Too many Yuppies..:shake:...Not enough Hippies :flamer:  Hobbies: stealing cookies, slangin' tacos, owning tequila bars, wheeling with paco

synwars [OP]

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haha that sounds like me...im lucky if i can get more than an hour at a time to work on my junk......looking sharp :thumbsup:

Ya that sounds like about every day of my life. I'm either slowly accumulating parts or money, or wittling away at my truck. Speaking of which...

After work I had about 1/2 hour before my Marisa came to pick me up, so I bolted the clutch back up. I inspected the rear main seal (still good from the rebuild 20,000 kms ago), globbed some grease on the new pilot bearing, cleaned the newly machined surface with carb cleaner, torqued the flywheel to the crank 85 ft/lbs with green locktite (all I had available), and torqued the new 13mm grade 8 bolts to the flywheel surface 15 ft/lbs of torque with lock washers and green locktite. My handy dandy centering tool helped greatly. All ready to go...

I didn't notice this before, but the new flywheel has far more surface area than the old flywheel. I measured the flywheel dimensions and it has approximately 3/8" greater diameter than the old one. 3/8" doesn't sound like much, but when it means 15% more clutch gripping power, it adds up to a lot.
"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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Ok, so lately I've been working on my pivot perches. I'm not going to post pics yet until I have it all welded up and grease zerks installed and what not. I've also got to get my rear axle while I'm at it.

Instead I'll post pics of my twin stick. On Saturday afternoon, I took split my t-cases (what a mess) and took out the pin between the shift forks. After I installed the twins and put the t-case back together.

Sorry I had no patience for my "progressive pics". I figure there are already pic by pic installation instructions on this website anyways, no need for me to post another... right?
"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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Also, when I put the t-cases back I bolted up my new FROR skid plate and some low profile plugs too. I never realized how close of clearance there is from the plate to the front output flange. I wonder if my CV will hit it... There is MAYBE 1/8" between them. :hammer: And I already bumped it over as much as I could. Oh well, I guess I could always pull out the torches... :flamer:

That's it for now, once I have the rear axle and PP all welded up I'll post "progressive" pics for y'all. :eyebrow: Beefy indeedy.
"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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Last, I also had a casualty while working on Saturday. Pure alcohol abuse if you ask me... :spankbutt:
"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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ill forgive you
MONTANA BOYS KICK A$$
IF U CANT DUCK IT F IT

Wermz84

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Been a while since Ive seen ya around, but then again i been busy as well.

just cruzing though here.  looking good..   :thumbs:
I like to Drive!

synwars [OP]

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:smack: I forgot, I got all the tires mounted up and seated. NO LEAKS c/o Maffy's professional welding abilities. 4 brand new rims, 8 rings, 128 bolts and nylocks @ 15 ft/lbs, 1200 balls of 1/4" steel shot, and about 10 hrs total labour later... :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:

Wermz84

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:smack: I forgot, I got all the tires mounted up and seated. NO LEAKS c/o Maffy's professional welding abilities. 4 brand new rims, 8 rings, 128 bolts and nylocks @ 15 ft/lbs, 1200 balls of 1/4" steel shot, and about 10 hrs total labour later... :burnout:
 
Damn, those are sick...    :drool:


hopefully you wont blow a bead.  :hammer:
I like to Drive!

 
 
 
 
 

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