Rear Leaf Swap Begins

[Phalanx]

http://a32.ac-images.myspacecdn.com/images01/124/l_a43c6868ef35e6f21f1c3ae5ff07987f.jpg

http://a483.ac-images.myspacecdn.com/images01/73/l_8cdcec81930aa9d4d8632a7a1ff040da.jpg

http://a99.ac-images.myspacecdn.com/images01/66/l_5f2eafb8da7ea04f04472b5d03de0d82.jpg

http://a756.ac-images.myspacecdn.com/images01/92/l_647443b739cef897813901892d00c31b.jpg

[Marc P]

You have a LOT of cutting to do :thumbup:

Glad to see you got it started...

[Bob98SR5]

josh,

looking fwd to seeing your progress. PLEASE take alot of pics and submit a writeup!

Bob

[Good Times]

sweet :)

keep us all posted! we all love pix!

[Lee]

definitely keep the progress pics coming. ill likely be doing this when i sas.

[freejake3]

Looking good Josh. Now comes the fun part. Don't forget to
wear eye/ear protection at all times..........you decide on
those Marlin springs? Keep the cameras rolling.

[Phalanx]

Shaved one side of the housing today.
http://a943.ac-images.myspacecdn.com/images01/119/l_d0eb7ab70cf3a6016ffd8cad4f68329e.jpg

http://a296.ac-images.myspacecdn.com/images01/87/l_ae7da7a33a633968fc2057465495831f.jpg

Bob, you got it. I'll do a step by step writeup with pics.

Andy, I've always got the earplugs, goggles and face shield on with the grinder going. I went with the 5" Marlin rear lift kit. I was impressed with their front leaves that I have, their kit was the most complete and it was on sale :thumbup:

[ecchamberlin]

Very impressive Josh. Looking forward to seeing how is performs for you on the trails this fall! Should at least be more balanced feeling with leafs from and rear.

[freejake3]

Excellent job on cleaning the axle.....

[TMR]

Great job trimming down that axle! Looking forward to this thread!! :D

[Cheese]

Go slow, even with the grinder. Keeping the axle complete should stand in the way of warping.

Balance is key. I hope all the others who try to cheap out see this and how you are doing it up right.

Good work.

[Phalanx]

Watch the video!!! :D

http://www.youtube.com/watch?v=JjW8QMwLvYQ

The housing needs some finishing touches.
http://a221.ac-images.myspacecdn.com/images01/125/l_cfd33840925a82858938703caec53524.jpg

An old sub magnet is useful for cleanup :thumbup:
http://a661.ac-images.myspacecdn.com/images01/123/l_f45287935aa22c05a35478e0eaa398dc.jpg
http://a873.ac-images.myspacecdn.com/images01/112/l_24f1e07f1cb48bfcd2b1254f0057a8e8.jpg

On to the frame mounts...

[xonetruthcrewx]

Very nice. I may i say, awesome fu**ing choice of a song for the video. Haha. Seriously though, i like this writeup. I will be doing this myself someday.

[Robinhood4x4]

That magnet is pretty cool. I'd like to see what you eventually do with the parking brake routing.

[Marc P]

Funny vid Josh...I suprised you didn't use the Rocky theme song.

[Good Times]

damn i need a magnet too now! lookin good man

[freejake3]

Wow! That must have been quite the day. I like watching the shadow
of the sun on that video.

[wifesaysimadumbass]

dude sweet.... cant wait to see that thing all welded up guess your rear end wont be hopping all over anymore

[freejake3]

Where we at with this project Josh......your fans want to know.

[04 Rocko Taco]

Need more montage videos!! Thats good work!! Also more updates!!

[Phalanx]

Been grinding here and there over the last few days. Done most of the mandatory cutting and grinding. I still need a little trimming and sanding.

Heres what the truck looks like.

Rear Tie down Mounts: They were the first to go
http://a600.ac-images.myspacecdn.com/images01/104/l_96455a9a7db2ab07fd919497ca33b417.jpg

Passenger side: Still needs some trimming on the inside, probably play it safe with a dremmel.
http://a286.ac-images.myspacecdn.com/images01/88/l_cdda2e78fb208c38a7f39e7a9f6fe0cd.jpg

Driver side: Just needs to be sanded
http://a964.ac-images.myspacecdn.com/images01/68/l_d7d97bd151881838306b7f8a46192feb.jpg

Panhard Mount: Going to trim it and plate the bottom, Ill take care of that after everything else is done.
http://a828.ac-images.myspacecdn.com/images01/79/l_eab5d572f7c8b2e08250d5eb2584946b.jpg

Marlin's Hangers:
http://a594.ac-images.myspacecdn.com/images01/103/l_d34db4c5cad25484970993c2a992efd1.jpg

[wifesaysimadumbass]

i love the quality of the hangers i got from marlin good stuff!!!!

[freejake3]

Looking good. You just can't go wring with Marlin's products.

[Seanz0rz]

arent you done yet? i already have sliders and you dont even have a rear suspension...

[SD4runner]

Next you need to come over here and do mine! ;D

[Phalanx]

The grinding, sanding, and most of the measuring is done. Still need to weld (waiting for Josh), rebuild the driveshaft and mount the shocks. After I get my truck rolling, I'll figure out the plumbing for a manual brake proportioning valve. I'll get pics up tomorrow and a writeup as soon as its complete.

[Phalanx]

Here are the brake lines. I used 10mm male to 3AN Male adapters at each end. http://a917.ac-images.myspacecdn.com/images01/42/l_6748224218cabfdab7d9307710fac6e4.jpg
http://a722.ac-images.myspacecdn.com/images01/13/l_01bc2e35dfd52838cd4b587826bf4e51.jpg
http://a131.ac-images.myspacecdn.com/images01/127/l_ba2cb9e02737723c2e06afe05db01b4a.jpg

[freejake3]

Looking good. Gonna make some axle brackets to secure those lines
on the axle?

Can't wait to see those F250 lift blocks so the axle/springs can
seat together. Don't forget the flame shackles.

[wifesaysimadumbass]

where did you get the brake lines that you replaced the hard line with

[Phalanx]

The brake lines are Earl's Speed-flex 3AN threads at both ends, one end with 90 degree bend.
I ordered the brake lines from Summit Racing. I used 3AN with adapters at the center junction and at the calipers. I converted to 3AN because I couldn't find any 10mm male to 10mm male adapters anywhere. The lines aren't street legal, but neither was the line that Protrux installed three years ago (as I found out checking out my brake system). I also need to install a manual proportioning valve which also needs those bloody adapters. I need to get my truck rolling first...

3AN to 10mm Adapter
http://static.summitracing.com/global/images/prod/large/ear-592032erl_w.jpg

3AN SS Line
http://static.summitracing.com/global/images/prod/large/ear-63011714erl_w.jpg

WHATS UP NOW!!
http://a153.ac-images.myspacecdn.com/images01/2/m_ac14634a55065e3afdd56c6b40ff09a8.jpg

[Phalanx]

http://a981.ac-images.myspacecdn.com/images01/24/l_eb51deb7226dd51203ad5b5195153d1c.jpg
http://a784.ac-images.myspacecdn.com/images01/98/l_ed8003928e416f3c738af140188dccff.jpg
http://a556.ac-images.myspacecdn.com/images01/102/l_069e91110c41b9f68d9ec84487308ddb.jpg
http://a598.ac-images.myspacecdn.com/images01/120/l_3dfce26055d2fb73f729b302e0700ded.jpg

[Robinhood4x4]

Did you keep the same wheelbase? What length shocks did you use? Are you going to extend your bumpstops...because it looks like the shocks are going to bottom out before the bumpstops.

[Marc P]

Looks good Josh.....the shocks are way too long (do you still have the 10" 5150's?), and I am not sure about the placement. For the LPSV rod, you should cut it down and use a small turnbuckle from Home Depot.

You can see mine in this pic....you can adjust it as needed
http://www.imagestation.com/picture/sraid223/pd0ec6361d6aa3f2f240673a4e1f6d7b3/eace6b20.jpg

[Phalanx]

I set the axle back about a couple inches. I might move it up a notch, or trim the rear fender a little. For now I have 10" 5100 series that came with the marlin kit. The shocks work well but its temporary, Ill have Josh (Tubingworks) weld up a tube cross-member and install some 7100's for stability. I ordered some longer shackles for the front as well as the extended bump stop kit from TrailGear. As for the brakes. I'll be replacing the LPSV with a manual proportioning valve, I just have to figure out the plumbing, SAE adapters etc. E-brake wise... if i cant extend the lines (taking it to Protrux) I'll install a line lock so I'll be able to run in Superstition 10.

[Robinhood4x4]

I'm just running my stock parking brake lines.

[wifesaysimadumbass]

i think you can adjust your e brake to work ...mine had a hanger that made the main line really tight once i chopped the hanger the line gave me plenty of length.... as far as lspv i know frontrange has a kit to get rid of that thing