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Discussion Starter #1
Finally getting around to starting a new thread. :nerd Some of you may have seen my other build threads, but if not click on the links below and have a ball reading for the next couple of hours...

Phase 1 - The original SAS build thread... that covers the initial build up, some additional post build changes, offroad expo coverage and a bunch of the wheeling trips.

Phase 2 - The post SAS thread that includes everything from the DIY beadlocks, reaer tire carrier, tube doors, shock tuning, lots of wheeling pictures and a bunch of helpful posts on the electronics and how to disable them.

In this installment :wink I'll cover the rebuild of the front end and the rear 3-link with 14" Fox 2.5" coilovers plus a bunch of other things as we go...

First... the original solid axle swap was completed almost 7 years ago and my FJC has performed amazing over the years. Over the last few years I've seen a number of successful rear 3-link setups on late model Toyota's and that made me believe it was time to do the rear 3-link on my FJC.

The parts list goes like this...

- 14" Fox 2.5" body coil overs with remote reservoirs
- Eibach coilover springs 300/350 spring rate as a starting point
- RuffStuff antiways (this thing is crazy stiff - same diameter as a Dana 60 axle shaft)
- Branik 2.25" solid aluminum links (all the way around)
- Currie's new chromoly narrow johnny joints (all the way around)
- FK heims on the panhards
- Fox air bumps (reusing the ones I had in there, but relocating)
- Polyperformance limit straps
- FJ-80 High pinion third member with an ARB for the front (moving away from the elocker third)
- and a bunch of pretty welds from the fabricator...

So enough with the words and on to the pictures.

Here is what I started with...



A few pics of the parts... new johnny joints



Fox coilovers



Started off by putting the FJC on the scales... let's just say it needs to go on a diet. PIGLET!





The first thing we started with was swapping out the front diff. When I originally built the front axle I chose to use an FJ80 high pinion third with an elocker. This go around I'm switching to the same FJ80, but with an ARB locker instead. This involved adding some steel to the face of the housing in order to make the ARB third fit. With elockers there is a large chunk of steel missing where the elocker shift fork passes through the diff and connects to the locking shift fork. We welded in a piece of 1/2" plate, drilled and tapped it and then installed the new diff.

Sorry for the crappy pic... this is post adding the steel to the face.



Post diff install...



At this point... things change direction and I decide to rebuild both the front and rear. After 7 years of hard wheeling the link mounts at the frame had taken a beating as had the front axle mounts. So...

Off came everything... :surprise and we started completely over. We kept the shock towers, steering and frame side panhard mount, but stripped the front axle and belly bare and started over.





The plan going forward it to rebuild the front axle mounts, new front and rear cross members with integrated link mounts, fully belly pan, 3-link in the rear with coilovers up into the rear cargo area, sway bar and a bunch of other cool things.

I will post more as we make progress...
 

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those johnny joints are huge ... looking forward to following your progress ... :cheers:
 

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This will be the "get up on a Saturday-Sunday morning, fill coffee cup, open this thread and review the progress . Important note would be the drool towel next to the computer.

After the seven years of using this, you will get the opportunity to rethink, not just the large hard parts, but the geometry . Plus remove some of the quirks, you probably have unearth, in the last phase.

Thanks for starting this update on the forum. :cheers:
 

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Subscribed for updates. Really appreciate you sharing the details with us! :bigthumb:
 

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Just, Wow! I've been reading through your other thread and all I have to say is I'm jealous. Did you ever say your overall height?

-Harrison
 

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Discussion Starter #8
Just, Wow! I've been reading through your other thread and all I have to say is I'm jealous. Did you ever say your overall height?

-Harrison
IIRC it was 84" to the top of the rack. But honestly, I can't remember.
 

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Discussion Starter #9
This will be the "get up on a Saturday-Sunday morning, fill coffee cup, open this thread and review the progress . Important note would be the drool towel next to the computer.

After the seven years of using this, you will get the opportunity to rethink, not just the large hard parts, but the geometry . Plus remove some of the quirks, you probably have unearth, in the last phase.

Thanks for starting this update on the forum. :cheers:
Just keep me honest and I build your future FJC. Don't want to skimp anywhere and disappoint you... :grin
 

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Just keep me honest and I build your future FJC. Don't want to skimp anywhere and disappoint you... :grin
Finally starting to see my point . I'm liking that :lol:
 

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Discussion Starter #11
Some progress... sorry about the cell phone pics. I will get better pics with my camera later. There were a few things I wanted to address during this build. The first was to address some very minor brake drive under very hard braking. most folks would be fine with the way it was, but... why not try and perfect the suspension? Increasing the separation between the lower link mounts and the top link mount will help. We added about 2" of separation.

The new top link bracket. This is about 2" taller than the original bracket.


Nothing but super stout brackets...


The bracket is wrapped 360 degrees around the axle housing. This bracket isn't going anywhere.


Next will come the panhard bracket and the rest of the front axle link mounts... more later. :smile
 

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Discussion Starter #15
Panhard bracket complete... nice wrap around the axle housing.



Panhard & Top link brackets...



The Branik Aluminum links are on order... should be arriving soon. Again, I'll get some better pics with my camera.
 

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Discussion Starter #16
Another view of the panhard bracket.





Nice and parallel panhard and drag link...



Lower link mounts and air bump strike plates...



Lower link mounts and new coilover mounts...



Bare belly... getting ready for some incredibly cool link mounts, cross member and belly pan! Super jazzed about this part...



Updates might slow down a little (sorry Don) as I'm a little distracted with a new project I just started. :grin
 

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Discussion Starter #18
Great update! Beautiful welds, no doubt. Looks like your DO sliders need a little touch up though.
They've definitely been used and abused and have held up incredibly well. They are on the list of things to be cleaned up... They'll look like new until the first Rubicon trip. ;)
 

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Curious about you wrap around comments- Did the previous mounts shift or flex too much, prompting the wrap around design or is this to make it sell higher to Don ? :lol:
 

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Discussion Starter #20
Curious about you wrap around comments- Did the previous mounts shift or flex too much, prompting the wrap around design or is this to make it sell higher to Don ? :lol:
No flex in the original mounts... purely focused on increasing the bling factor that Don appreciates.
 
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