Replacing lower control arm brackets

Once again Bruce steps up to the plate graciously for me to cut off my old brackets and replace them with something more indestructable. Bruce..you are awesome man!

So here we go.

Here's the rear trailing arm hangars about four years ago

[img width=800 height=600]http://i3.photobucket.com/albums/y93/expatozzie/Carnage/Carnagephotos003.jpg[/img]

[img width=800 height=600]http://i3.photobucket.com/albums/y93/expatozzie/Carnage/Carnagephotos002.jpg[/img]

I have straighten them out several times but the metal was getting weak and it was over time to replace the.

So I bought some generic hangars from RuffStuff Specialties which are twice as thick. The stock hangars are pretty unique because they follow the contour of the frame and are also offset, so you may notice in pictures below that the new hangar does not look square but in fact it is.

http://i919.photobucket.com/albums/a...hangars011.jpg

Now I hadnt really looked at them since I bought them nearly two years ago but as soon as pulled them out of the box before heading off to Bruce's, I noticed one had bolt holes that didnt line up

http://i919.photobucket.com/albums/a...hangars010.jpg

Bruce said no problems, he would weld up one of the holes and redrill.

Onto the project

1. Place blocks under front wheels
2. Loosen wheel nuts
3. Jack vehicle and secure on stands and remove wheels
4. Use straps to secure axle

http://i919.photobucket.com/albums/a...hangars001.jpg

http://i919.photobucket.com/albums/a...hangars002.jpg

5. Take numerous measurements to locate cntre of retaining bolt then remove trailing arm from hangar.

http://i919.photobucket.com/albums/a...hangars003.jpg

http://i919.photobucket.com/albums/a...hangars004.jpg

6. Like Bruce says - measure a million times, cut once.

http://i919.photobucket.com/albums/a...hangars006.jpg

7. Let the cutting begin...plasma cutter makes things easy

http://i919.photobucket.com/albums/a...hangars009.jpg

8. The old and the new

http://i919.photobucket.com/albums/a...hangars016.jpg

http://i919.photobucket.com/albums/a...hangars017.jpg

http://i919.photobucket.com/albums/a...hangars018.jpg

9. Lining up to see where to cut the frame. (note the frame is curved so just welding it flat would have not been a good option so Bruce decided to cut into the frame which effectively allowed the hangar to sit inside the frame and make it a lot stronger)

http://i919.photobucket.com/albums/a...hangars019.jpg

10. Grind off the old welds

http://i919.photobucket.com/albums/a...hangars020.jpg

11. The frame cut

http://i919.photobucket.com/albums/a...hangars058.jpg

http://i919.photobucket.com/albums/a...hangars059.jpg

12. When it came to welding the wind was challenge so Bruce had to wrap a tarp around himself

http://i919.photobucket.com/albums/a...hangars021.jpg

http://i919.photobucket.com/albums/a...hangars023.jpg

http://i919.photobucket.com/albums/a...hangars024.jpg

13. Welded in

http://i919.photobucket.com/albums/a...hangars035.jpg

Bruce spent a lot of time building up the area at the leading edge of the hangar so that nothing would catch when sliding across rocks.

http://i919.photobucket.com/albums/a...hangars036.jpg

14. Next was the other side which required taking the gas tank out (I removed the skid at home prior)

It was hard work getting ot the plumbing - good luck anyone without a BL

Unclip the carbon canaster near the spare wheel

http://i919.photobucket.com/albums/a...hangars037.jpg

There are two clips on pins that need to be removed before lowering the tank

http://i919.photobucket.com/albums/a...hangars039.jpg

Some pipes to be disconnected - beware of gas loss

http://i919.photobucket.com/albums/a...hangars042.jpg

http://i919.photobucket.com/albums/a...hangars047.jpg

Fuel inlet

http://i919.photobucket.com/albums/a...hangars050.jpg

http://i919.photobucket.com/albums/a...hangars056.jpg

Loosening the fuel tank straps

http://i919.photobucket.com/albums/a...hangars044.jpg

Freedom

http://i919.photobucket.com/albums/a...hangars055.jpg

Welding work - not easy upside down and under a vehicle

http://i919.photobucket.com/albums/a...hangars033.jpg

http://i919.photobucket.com/albums/a...hangars032.jpg

http://i919.photobucket.com/albums/a...hangars034.jpg

More to come when painted and polished LOL

Poor soldier. He battled bravely!

http://i919.photobucket.com/albums/a...hangars060.jpg

Final pix

http://i919.photobucket.com/albums/a...hangars062.jpg

http://i919.photobucket.com/albums/a...hangars063.jpg

http://i919.photobucket.com/albums/a...hangars065.jpg

Thanks again Bruce!

looks great, good work guys

Nice work both of you. Looks pretty stout.

yeah those came out great! looks like what should have come from the factory

Nice Mark.