DaveP SAS - 3 week Saga

[GeneratorX]

So I blame Ryan and Alex for what you are about to see. Thanks guys and I can't wait to get her on the trail.

With a LOT of help from John and a some killer help from Ryan we are looking to have this X ready for G.O.N.E. MOAB X.

The Parts list is crasy and here are a few things going under the X.
-New JK Rubicon D44 rear axle 4.10s w/ e-locker ( Craigslist find )
-JK Rubicon D44 front axle 4.10s w/ e-locker (35,000 miles wheeled 4 times)
-Reid High Steer Knuckles
-RCV axle shafts
-Synergy Inner Sleeves
-Synergy Outer Sleeve kit
-Synergy C Gussets
-Ruff Stuff Diff Covers
-Synergy Chromoly Tie Rod
-Bilstein 9100 Remote Res Front Coilovers
-Bilstein 7100 Remote Res Rears
-95 Pathy steering box
-Pitman Arm
-PSC Steering Cylinder ( 6.75" travel )
-Rock Assault reservoir filter kit
-Ruff Stuff SOA conversion
-Ballistic Fab Box-O-Goodies to connect everything together.
-37" Goodyear Wrangler MT/Rs
-Mickey Thompson Classic Lock ( craigslist find )
-JK ABS Wiring
-JK Locker Wiring
-Tom Wood's Drive shafts
-Hard lines for Brakes
-SS Braided Brake lines
-1 Ton Rod Ends for drag link

The Project started yesterday with me tearing apart everything Shrock built. Also got the drive shafts off, anything that was attached to the rear axle came off and the B/L tid bits.

Day 2
What is no longer needed
http://i192.photobucket.com/albums/z228/XterraVT/SAS%20Build%20Album/SAS0013.jpg
John taking out the stock rear cross member
http://i192.photobucket.com/albums/z228/XterraVT/SAS%20Build%20Album/SAS0001.jpg
And installing the stronger new cross member in it's place
http://i192.photobucket.com/albums/z228/XterraVT/SAS%20Build%20Album/SAS0003.jpg
http://i192.photobucket.com/albums/z228/XterraVT/SAS%20Build%20Album/SAS0004.jpg
Got my learn on with the Plasma Cutter
http://i192.photobucket.com/albums/z228/XterraVT/SAS%20Build%20Album/SAS0007.jpg
http://i192.photobucket.com/albums/z228/XterraVT/SAS%20Build%20Album/SAS0008.jpg
Kinda looks like the X is on fire
http://i192.photobucket.com/albums/z228/XterraVT/SAS%20Build%20Album/SAS0012.jpg
Drivers side all cleaned up.
http://i192.photobucket.com/albums/z228/XterraVT/SAS%20Build%20Album/SAS0005.jpg
John putting the new hoops on the T-Case cross member.
http://i192.photobucket.com/albums/z228/XterraVT/SAS%20Build%20Album/SAS0006.jpg
T-Case cross member all set and waiting for paint to dry.
http://i192.photobucket.com/albums/z228/XterraVT/SAS%20Build%20Album/SAS0011.jpg

We were able to install the Modified T-Case cross member this morning which needed a little tweak yesterday because of the differences in the 2 Xs.

I was also able to finish cleaning up the frame after taking the Plasma to the coil buckets. I then turned back to the plasma cutter and got after the cross member under the oil pan.
As I was doing this John was able to finish off the battery box for the rear of his RubiX.

Just after lunch we headed into town to pick up my braided brake lines and a few fittings for the Pathy steering box. Then headed to Ryan's so we could take a stroll at the U-Pull salvage yard in Colfax.

I was able to tear into the JK locker/ ABS wiring harness tonight.

Top right is the wiring I do NOT need
Bottom right is what I'm keeping ( ABS and Locker connections )
Oh, and those are my rear shock mounts on the left.
http://i192.photobucket.com/albums/z228/XterraVT/SAS%20Build%20Album/SAS0001_2.jpg

I'll grab pics of some of the stuff we did today in the Am.

Good night from Casa de Creek

( John's going to need to get T-Shirt made. " Just Creek It! " )

Day 4
So today I was on my own again with guidance from John as to what I could hammer out.

First thing on the agenda was a Sales guy from Work asking me tech Q's on my vacation.

Off to the SAS Build

1st real thing was extending and converting all the ABS wires on the X to JK ABS.
http://i192.photobucket.com/albums/z228/XterraVT/SAS%20Build%20Album/SAS0003_2.jpg

Next up was taking the Plasma ( Love this thing ) and cut out the brackets to support the link cross member.
http://i192.photobucket.com/albums/z228/XterraVT/SAS%20Build%20Album/SAS0006_2.jpg

Off to cut out the Shock strengthening brackets ( Love the Plasma Cutter )
http://i192.photobucket.com/albums/z228/XterraVT/SAS%20Build%20Album/SAS0007_2.jpg

Finished the last bit of grinding to the frame ( the last bit of the coil bucket )
http://i192.photobucket.com/albums/z228/XterraVT/SAS%20Build%20Album/SAS0002_2.jpg

What can Brown do for you?
http://i192.photobucket.com/albums/z228/XterraVT/SAS%20Build%20Album/SAS0009_2.jpg

John got to work on the cross member for the X.
http://i192.photobucket.com/albums/z228/XterraVT/SAS%20Build%20Album/SAS0008_2.jpg

Ryan showed up at the end to finish up the welding to the Path Steering Box.
http://i192.photobucket.com/albums/z228/XterraVT/SAS%20Build%20Album/SAS0011_2.jpg
http://i192.photobucket.com/albums/z228/XterraVT/SAS%20Build%20Album/SAS0010_2.jpg

Some parts

Bilstein 9100 Rock Crawl Coil Overs
http://i192.photobucket.com/albums/z228/XterraVT/SAS%20Build%20Album/SAS0005_2.jpg
Mock up of Mickey Thompsons and 37" Goodyear Wrangler Mt/Rs
http://i192.photobucket.com/albums/z228/XterraVT/SAS%20Build%20Album/SAS0004_2.jpg

[GeneratorX]

So, Today's projects were to clean the garage for the weekend. This is one heck of a project in of it's self.
Before
http://i192.photobucket.com/albums/z228/XterraVT/SAS%20Build%20Album/SAS0001-1.jpg
After
http://i192.photobucket.com/albums/z228/XterraVT/SAS%20Build%20Album/SAS0002-1.jpg
Yes I did organize the shelves as well.

Then I tackled the front Rad cross member. John was able to hit the welding up early and I just had to clean it up for fit and finish.
http://i192.photobucket.com/albums/z228/XterraVT/SAS%20Build%20Album/SAS0003-1.jpg

All was going very well till Ryan and Allen showed up in the Hard body. Come to find out that my JK axle was all set up with the 5.13s!!!
http://i192.photobucket.com/albums/z228/XterraVT/SAS%20Build%20Album/SAS0004-1.jpg
You kids will be seeing this under the X tomorrow as well as the steering box.

Great turn out for the Mod Day.
Jonathan, Nate, David, Jeremy, Remy and Allen all showed up to lend a hand.

So on to the pics

John finishing the welds on the New Radiator cross member.
http://i192.photobucket.com/albums/z228/XterraVT/SAS%20Build%20Album/SAS0001-2.jpg
John and David were able to cut the old cross member out of the way.
http://i192.photobucket.com/albums/z228/XterraVT/SAS%20Build%20Album/SAS0004-2.jpg
Nate left the spatulas at home and picked up the grinder to clean the frame.
http://i192.photobucket.com/albums/z228/XterraVT/SAS%20Build%20Album/SAS0005-1.jpg
New cross member with the mounting plates ready to be drilled for mounting holes.
http://i192.photobucket.com/albums/z228/XterraVT/SAS%20Build%20Album/SAS0002-2.jpg
John and Jonathan drilling the mounting holes for the cross member.
http://i192.photobucket.com/albums/z228/XterraVT/SAS%20Build%20Album/SAS0007-1.jpg
All hands on deck to get the cross member under the X.
http://i192.photobucket.com/albums/z228/XterraVT/SAS%20Build%20Album/SAS0009-1.jpg
Jeremy lending a hand mounting the New cross member.
http://i192.photobucket.com/albums/z228/XterraVT/SAS%20Build%20Album/SAS0008-1.jpg
John getting his Weld on
http://i192.photobucket.com/albums/z228/XterraVT/SAS%20Build%20Album/SAS0013-1.jpg
http://i192.photobucket.com/albums/z228/XterraVT/SAS%20Build%20Album/SAS0012-1.jpg
John let me have a turn with the welder.
http://i192.photobucket.com/albums/z228/XterraVT/SAS%20Build%20Album/SAS0016.jpg
Frame plated for the Pathy Steering Box
http://i192.photobucket.com/albums/z228/XterraVT/SAS%20Build%20Album/SAS0010-1.jpg

I really dig this shot
http://i192.photobucket.com/albums/z228/XterraVT/SAS%20Build%20Album/SAS0014.jpg

So as you can see the axle isn't under the X But we got a bunch done. I'm heading down to the garage in a few min to finish the Steering Box mock up for welding tonight.
I'll also get the inner frame ready for some paint today and get the signature OD Green on a lot of parts.



Here are the mounting sleeves for the Steering Box
http://i192.photobucket.com/albums/z228/XterraVT/SAS%20Build%20Album/SAS0002-3.jpg
Nate went and cleaned up my attempt at a steering res bracket
http://i192.photobucket.com/albums/z228/XterraVT/SAS%20Build%20Album/SAS0005-2.jpg
And got it installed
http://i192.photobucket.com/albums/z228/XterraVT/SAS%20Build%20Album/SAS0006-2.jpg
A few of the Rigs that were here
http://i192.photobucket.com/albums/z228/XterraVT/SAS%20Build%20Album/SAS0004-3.jpg
David grabbed a can of OD Green and went to town
http://i192.photobucket.com/albums/z228/XterraVT/SAS%20Build%20Album/SAS0003-3.jpg
http://i192.photobucket.com/albums/z228/XterraVT/SAS%20Build%20Album/SAS0001-3.jpg

Alex showed up later and tackled some of the welding that needed to be done and gave John a break.
Steering box sleeves welded into place
http://i192.photobucket.com/albums/z228/XterraVT/SAS%20Build%20Album/SAS0009-2.jpg
Steering box installed
http://i192.photobucket.com/albums/z228/XterraVT/SAS%20Build%20Album/SAS0007-2.jpg
Shock hoop reinforcement plates were next
http://i192.photobucket.com/albums/z228/XterraVT/SAS%20Build%20Album/SAS0010-2.jpg
Love this shot
http://i192.photobucket.com/albums/z228/XterraVT/SAS%20Build%20Album/SAS0011-2.jpg
Driver side all set
http://i192.photobucket.com/albums/z228/XterraVT/SAS%20Build%20Album/SAS0013-2.jpg
Passenger side all set
http://i192.photobucket.com/albums/z228/XterraVT/SAS%20Build%20Album/SAS0012-2.jpg
And again a Big thanks to Allen for getting the G2 5.13s installed.
http://i192.photobucket.com/albums/z228/XterraVT/SAS%20Build%20Album/SAS0008-2.jpg

[GeneratorX]

Ordered the Shorty's today and should be here on Wed.
I have to replace a drivers Cat so might as well do the Headers. Look at all the room I have to work with now.

I found this cool gearing calculator ( www.4lo.com ) a while back and crunched some numbers.
37s with 5.13s in 6th gear @ 70mph I'm at 2500rpms
37s with 5.13s in 1st and 4 low I'll have a 58.8:1 crawl

Got some of the small things done today

While John was at work I fab'd a mount for my steering cooler.
http://i192.photobucket.com/albums/z228/XterraVT/SAS%20Build%20Album/SAS0001-4.jpg
Also cut and made all the steering lines
http://i192.photobucket.com/albums/z228/XterraVT/SAS%20Build%20Album/SAS0002-4.jpg

Ryan stopped by late last night and dropped off the rear axle all set up with the 5.13s.
John and I got the axle shafts, brakes and calipers back on tonight so she'll be ready for install.
http://i192.photobucket.com/albums/z228/XterraVT/SAS%20Build%20Album/SAS0003-4.jpg

Doing a little shopping in the Am tomorrow.

- Picking up the MT/Rs all mounted
- grabbing some brake fittings that AAI didn't have last week
- Finding some bump stops
- More welding wire, ball joint press
- Food

So, It's snowed like a Muther today. We got 7+" of the East Coast wet heavy snow all day long. Flipping crazy as it's MAY!!!

So what was able to get done today.

Got the front axle mocked up for the PSC steering ram mount install.
http://i192.photobucket.com/albums/z228/XterraVT/SAS%20Build%20Album/SAS0001-5.jpg
My new springs came in for the 9100s but needed a splash of OD Green.
http://i192.photobucket.com/albums/z228/XterraVT/SAS%20Build%20Album/SAS0002-5.jpg
Building the Bilstein 9100s
http://i192.photobucket.com/albums/z228/XterraVT/SAS%20Build%20Album/SAS0003-5.jpg
http://i192.photobucket.com/albums/z228/XterraVT/SAS%20Build%20Album/SAS0004-4.jpg
John got home after work and started cutting the steering ram bracket
http://i192.photobucket.com/albums/z228/XterraVT/SAS%20Build%20Album/SAS0005-3.jpg
I got to cutting the drag link to size
http://i192.photobucket.com/albums/z228/XterraVT/SAS%20Build%20Album/SAS0006-3.jpg
Welding the steering bracket onto the axle
http://i192.photobucket.com/albums/z228/XterraVT/SAS%20Build%20Album/SAS0007-3.jpg
http://i192.photobucket.com/albums/z228/XterraVT/SAS%20Build%20Album/SAS0008-3.jpg
http://i192.photobucket.com/albums/z228/XterraVT/SAS%20Build%20Album/SAS0009-3.jpg
Love me some welding shots
http://i192.photobucket.com/albums/z228/XterraVT/SAS%20Build%20Album/SAS0010-3.jpg
Heineken? **** that ****! Pabst Blue Ribbon
http://i192.photobucket.com/albums/z228/XterraVT/SAS%20Build%20Album/SAS0011-3.jpg
I got to grinding some tabs for the steering bracket
http://i192.photobucket.com/albums/z228/XterraVT/SAS%20Build%20Album/SAS0012-3.jpg
http://i192.photobucket.com/albums/z228/XterraVT/SAS%20Build%20Album/SAS0013-3.jpg
almost the finished product
http://i192.photobucket.com/albums/z228/XterraVT/SAS%20Build%20Album/SAS0014-1.jpg

So today was about finishing up the front axle and a few other odds and ends

First off was giving John's new springs a make over. OD Green Style
http://i192.photobucket.com/albums/z228/XterraVT/SAS%20Build%20Album/SAS0001-6.jpg
Didn't get a pic but I finished welding the Drag link and PSC ram bracket. Looks pretty good.
2 Santa's showed up for lunch. Ryan brought Pizza and John brought this stuff
Bilstein 7100s for the rear
http://i192.photobucket.com/albums/z228/XterraVT/SAS%20Build%20Album/SAS0003-6.jpg
Since Everyone here and 8th Man said it was a perfect time to get new headers. Here they are
http://i192.photobucket.com/albums/z228/XterraVT/SAS%20Build%20Album/SAS0002-6.jpg
Get all that IFS stuff out of the way and this is easy! LOL
http://i192.photobucket.com/albums/z228/XterraVT/SAS%20Build%20Album/SAS0004-5.jpg
C'mon! That looks SICK!!!
http://i192.photobucket.com/albums/z228/XterraVT/SAS%20Build%20Album/SAS0005-4.jpg
John finishing off the PSC ram mount on the chromo tie rod.
http://i192.photobucket.com/albums/z228/XterraVT/SAS%20Build%20Album/SAS0006-4.jpg
Here she is ready for install
http://i192.photobucket.com/albums/z228/XterraVT/SAS%20Build%20Album/SAS0007-4.jpg
http://i192.photobucket.com/albums/z228/XterraVT/SAS%20Build%20Album/SAS0008-4.jpg

Um, 9 days till Moab at this point

So today i got my bumpers back on the X ( you don't need to see pics of Shrock stuff on an X ).
I also got the wire wheel out and cleaned up the axles and gave them a splash of color. Ya, it's only a pic of the rear axle. I got too excited after the front was dry and forgot to take a pic before I got it under the X. LOL
http://i192.photobucket.com/albums/z228/XterraVT/SAS%20Build%20Album/SAS0002-7.jpg
Front axle all put back together and under the X!!!
http://i192.photobucket.com/albums/z228/XterraVT/SAS%20Build%20Album/SAS0001_2-1.jpg
John came home around 8 and we got the axle aligned and ready for tomorrow's project.
http://i192.photobucket.com/albums/z228/XterraVT/SAS%20Build%20Album/SAS0003-7.jpg

- Shock hoops go on tomorrow
- Drag Link and track bar are installed
- Front of the X sits at it's ride height tomorrow.

[GeneratorX]

It is officially the 2 week mark for my build and the X is on the home stretch. A couple things got in our way during the 2 weeks.
- Mother Nature playing games and dumping 7+" of snow on us.
- Mother Nature giving us another 3" dusting a few days later
- Because of Mother Nature playing weather games I got sick for the past 2 days.
- It may not be all her fault as my eating, Drinking and sleeping habits have been all screwed up as well.
- 13hr days for 2 weeks is a bit much for the body to take if you're not taking care of yourself.

Enough of that and onto some pics
John welding the shock hoop mounts on
http://i192.photobucket.com/albums/z228/XterraVT/SAS%20Build%20Album/SAS0001_2-2.jpg
http://i192.photobucket.com/albums/z228/XterraVT/SAS%20Build%20Album/SAS0002_2-1.jpg
Where coil buckets used to be is now a coil over shock hoop
http://i192.photobucket.com/albums/z228/XterraVT/SAS%20Build%20Album/SAS0003_2-1.jpg
Tacking the Drag Link to see how she looks under the X
http://i192.photobucket.com/albums/z228/XterraVT/SAS%20Build%20Album/SAS0004_2-1.jpg
She's on 37s this morning!!!
http://i192.photobucket.com/albums/z228/XterraVT/SAS%20Build%20Album/SAS0003-8.jpg
http://i192.photobucket.com/albums/z228/XterraVT/SAS%20Build%20Album/SAS0004-6.jpg
http://i192.photobucket.com/albums/z228/XterraVT/SAS%20Build%20Album/SAS0002-8.jpg

Today's projects
- Make the rear brake hard lines
- Call Nick @ PreRunner about the B Pipes
- Cut the pieces to box in the Track Bar mount
- Clean garage and try and find the front ABS mounting brackets
- Fab up the Shrock Rad Skid to fit on the X.
- I know I'm forgetting something here

Long day indeed but we were able to get the rear axle under the X and she is sitting crazy tall. I may need to take Natalie's advice and get and fire ladder to get in and out of this thing now. LOL

Here she is
http://i192.photobucket.com/albums/z228/XterraVT/SAS%20Build%20Album/SAS0002-9.jpg

So SICK!!!
http://i192.photobucket.com/albums/z228/XterraVT/SAS%20Build%20Album/SAS0001-9.jpg

Still have some work ahead of us but all the hard work is behind at this point.

So Mother Nature tossed another wrench into the works.
Rain, Hail, Fog, Rain, Heavy Rain, Hail, Snow, Hail and now Sticking Snow!
I think she needs to lay off the Sauce so we can have our good weather back.

Sooo I was able to get a few things done today.
- Adjust Tie Rod
- Adjust Drag Link
- Adjust Track Bar
- Connected all steering lines
- Make new Manual trans hard line
- Lower shackles a notch to loose some of the rack.

- Install Tom Wood's Drive Shaft?
So this last step decided it wanted to beat me up a little.
1st attempt - Yoke slides in the new F1 flange TW made is huge and hits the bottom of the X. What the Heck!
2nd attempt - Yoke slides in and flange sneaks by floor and DING! What the heck is hitting now?
3rd attempt - Same as 2nd attempt. Ding!!!
I look inside the yoke and the case and there is nothing preventing this from going in. .
Now if you've never taken the drive shafts out of the X before Let me tell you that they are not light. Now add the weather report I gave you a few minutes ago and you'll see how things were going on this install.
So I decide to clean the garage

Creek gets home and says there are notches that I need to line up in order to get the yoke in.
Look around and there are no notches to speak of. So we try it again and Ding! F This
Come to find out the F1 flange TW made is getting caught up on the floor again.
Order up 1 BFH and 5 min later Yoke slides in No ProblemO!!!

Now I go to the other end and get ready to strap the u-joints in the axle and...

Creek - " Make sure the u-joints slide in between the 2 tabs on the axle before you tighten them down."
Dave - " These are not going to fit in between these 2 tabs"
Creek - " They have to or you will be breaking ****"
Dave - " There is now way these are fitting in between Dude"
Creek - "Let me see this. Yup, No way those are fitting in between the notches... Where your paperwork?
Dave - " Some where over there."

Turns out TW made the my DS with 1330 u-joints instead of 1310s. Hell!
We'll come to find out that TW has pulled these kinds of shenanigans before on a few other people. I'll find out what their plan is being that I'm 3 days from leaving to Gone.

Not all is lost as Napa Know How to the rescue!
They make a 1330 / 1310 u-joint that I can run. But of course we want to see what TW has to offer in the AM.

So Mother Nature is really starting to piss me off! Again today She thought it would be funny to dump another 3+" of Snow. Really Lady?

So what was able to get accomplished today.
- Tightened all Steering and front Brake lines and are ready for fluids
- Installed both Front and rear ( 1330/1310 U for the rear ) Tom Wood's DS's
- Cut and weld the Shorck rad skid
Cut It!
http://i192.photobucket.com/albums/z228/XterraVT/SAS%20Build%20Album/SAS0001-10.jpg
I love the Plasma cutter
http://i192.photobucket.com/albums/z228/XterraVT/SAS%20Build%20Album/SAS0003-9.jpg
- Rework the T-Case skid to fit under the X
http://i192.photobucket.com/albums/z228/XterraVT/SAS%20Build%20Album/SAS0002-10.jpg
What can Doug Thorley do for you? How about a set of B-Pipes!
http://i192.photobucket.com/albums/z228/XterraVT/SAS%20Build%20Album/SAS0004-7.jpg
Creek got home and went to work on the tire carrier
Say Good Bye to 6 on 4.5 ( Check out Creek's new Weldering helmet )
http://i192.photobucket.com/albums/z228/XterraVT/SAS%20Build%20Album/SAS0005-5.jpg
Say Hello to 5 on 5
http://i192.photobucket.com/albums/z228/XterraVT/SAS%20Build%20Album/SAS0006-5.jpg

I have a ton of **** still to do to get her on the road and hope to cut into that list better tomorrow.

[GeneratorX]

save post 4

[5280HIGH]

Sick!!! I one day want to have a garage like that. That's one bad ass rig.

[tmorgan4]

Wow...impressive parts list and write up! No way I would ever want to start an axle swap 2 weeks before a big 4 wheeling trip. Looks like you guys got it as long as the driveshaft issues (and whatever else you haven't figured out yet) works out.

You don't live out here, right? Did you just leave for GONE a few weeks early? Looks like you got an awesome crew helping. If you weren't so far away I'd love to stop by and lend a hand!

[Houdini]

Sweet! Nice detailed write up!

Looks like you guys are doing a lot of good work. Subscribed.

[the josher]

You guy's should open a SAS shop! I'd place an order!

[Sully4x4]

That is an amazing write up. And yea...it looks sick!

[Creek]

almost done...

[GeneratorX]

And she is done. Well she was done a while ago but didn't have the time to post pics as she was too much fun to drive.
Here are a couple shots from Moab that Natalie took of me on Behind The Rocks
http://i192.photobucket.com/albums/z228/XterraVT/Gone%20Moab%20X/p5258505.jpg
http://i192.photobucket.com/albums/z228/XterraVT/Gone%20Moab%20X/p5248330.jpg

[5280HIGH]

Sick!!! That thing is tits to the max lol