How to make sweet Long Travel Suspension

[dirtydeeds]

I've broken my driver side lower arm twice, and passenger once, I'm building these to keep it from happening anymore, it's gotten pretty annoying:mad:

http://i213.photobucket.com/albums/cc109/keith-carty/LongTravel1.jpg
I built this jig off the stock arm, only it's extended 3.5"
http://i213.photobucket.com/albums/cc109/keith-carty/LongTravel2.jpg
Cut out some sleeves, just need a good clean up on the grinder.
http://i213.photobucket.com/albums/cc109/keith-carty/LongTravel4.jpg
2 1/4" .250wall chromoly outer sleeve
http://i213.photobucket.com/albums/cc109/keith-carty/LongTravel5.jpg
http://i213.photobucket.com/albums/cc109/keith-carty/LongTravel6.jpg
All parts needed for the pivot points at the frame minus the bushings.
http://i213.photobucket.com/albums/cc109/keith-carty/LongTravel7.jpg
Tapered ball joint reemer.
http://i213.photobucket.com/albums/cc109/keith-carty/LongTravel8.jpg
Just need to weld it up.
http://i213.photobucket.com/albums/cc109/keith-carty/LongTravel9.jpg
Viola.
http://i213.photobucket.com/albums/cc109/keith-carty/LongTravel10.jpg
Deep penetration.
http://i213.photobucket.com/albums/cc109/keith-carty/LongTravel11.jpg
All bolted in, just need to cut out the plate.
http://i213.photobucket.com/albums/cc109/keith-carty/LongTravel12.jpg
http://i213.photobucket.com/albums/cc109/keith-carty/LongTravel13.jpg
http://i213.photobucket.com/albums/cc109/keith-carty/LongTravel14.jpg
I'll cut out the plates tomorrow. After it's all tacked together I'll install it on my truck and make sure nothing hits. Everything looks good for now!

I'll post up more pics as I go. For now, have a good night everyone!:D

[dirtydeeds]

IMG]http://i213.photobucket.com/albums/cc109/keith-carty/LongTravel15.jpg[/IMG]
top and bottom plates
http://i213.photobucket.com/albums/cc109/keith-carty/LongTravel16.jpg
fits perfectly
http://i213.photobucket.com/albums/cc109/keith-carty/LongTravel17.jpg
http://i213.photobucket.com/albums/cc109/keith-carty/LongTravel18.jpg
http://i213.photobucket.com/albums/cc109/keith-carty/LongTravel19.jpg
just need to cut out 9 side plates
http://i213.photobucket.com/albums/cc109/keith-carty/LongTravel20.jpg
Everything is tight and perfect, no gaps!
http://i213.photobucket.com/albums/cc109/keith-carty/LongTravel21.jpg
http://i213.photobucket.com/albums/cc109/keith-carty/LongTravel22.jpg
http://i213.photobucket.com/albums/cc109/keith-carty/LongTravel23.jpg
http://i213.photobucket.com/albums/cc109/keith-carty/LongTravel23.jpg
Just need to cut a couple tack welds and I'll gusset insides.
http://i213.photobucket.com/albums/cc109/keith-carty/LongTravel25.jpg

[5.7yotafan]

Well that definately looks strong! Hope it works out for ya!

[dirtydeeds]

These DirtyDeedsIndustries.com extended arms (http://www.dirtydeedsindustries.com) are as strong as possible to be able to handle high speed travel across knee high whoops!
http://i213.photobucket.com/albums/cc109/keith-carty/LongTravel26.jpg
http://i213.photobucket.com/albums/cc109/keith-carty/LongTravel27.jpg
http://i213.photobucket.com/albums/cc109/keith-carty/LongTravel29.jpg
http://i213.photobucket.com/albums/cc109/keith-carty/LongTravel30.jpg
http://i213.photobucket.com/albums/cc109/keith-carty/LongTravel31.jpg
http://i213.photobucket.com/albums/cc109/keith-carty/LongTravel32.jpg
http://i213.photobucket.com/albums/cc109/keith-carty/LongTravel33.jpg
http://i213.photobucket.com/albums/cc109/keith-carty/LongTravel34.jpg
http://i213.photobucket.com/albums/cc109/keith-carty/LongTravel35.jpg
http://i213.photobucket.com/albums/cc109/keith-carty/LongTravel36.jpg
http://i213.photobucket.com/albums/cc109/keith-carty/LongTravel37.jpg
http://i213.photobucket.com/albums/cc109/keith-carty/LongTravel38.jpg
http://i213.photobucket.com/albums/cc109/keith-carty/LongTravel39.jpg

[dirtydeeds]

http://i213.photobucket.com/albums/cc109/keith-carty/LongTravel40.jpg
http://i213.photobucket.com/albums/cc109/keith-carty/LongTravel41.jpg
http://i213.photobucket.com/albums/cc109/keith-carty/LongTravel43.jpg
http://i213.photobucket.com/albums/cc109/keith-carty/LongTravel42.jpg
http://i213.photobucket.com/albums/cc109/keith-carty/LongTravel44.jpg
http://i213.photobucket.com/albums/cc109/keith-carty/LongTravel45.jpg
http://i213.photobucket.com/albums/cc109/keith-carty/LongTravel47.jpg
http://i213.photobucket.com/albums/cc109/keith-carty/LongTravel48.jpg
http://i213.photobucket.com/albums/cc109/keith-carty/LongTravel51.jpg
http://i213.photobucket.com/albums/cc109/keith-carty/LongTravel52.jpg
http://i213.photobucket.com/albums/cc109/keith-carty/LongTravel53.jpg

So I pretty much worked on my DirtyDeedsIndustries.com Long Travel Suspension (http://www.dirtydeedsindustries.com)all day today. Made huge progress. After cycling the suspension I've gained 2 inches of wheel travel over the Total Chaos Long Travel kit this is replacing. You can see in the pics above that the ball joint bolts hit the chaos arms (in grey) I built my slugs up a little so this problem is eliminated. I pushed my arm forward a little so that I can lean my coil over back a little more which gains almost an inch of up travel.

I also worked on that project in the morning so I was a little worn out when I started on the Long Travel arms. I'll try to put a full 8 hrs in tomorrow, that should finish this side and I'll be able to test drive then focus on other side.

For now, have a good night everyone!

[dirtydeeds]

so I posted a link to this thread here:http://www.tundratalk.net/forums/new-member-introductions/89739-long-time-lurker-form-san-diego.html#post506163

[dirtydeeds]

I set bump with the rubber stop fully compressed
http://i213.photobucket.com/albums/cc109/keith-carty/LongTravel55.jpg
http://i213.photobucket.com/albums/cc109/keith-carty/LongTravel58.jpg
http://i213.photobucket.com/albums/cc109/keith-carty/LongTravel57.jpg
http://i213.photobucket.com/albums/cc109/keith-carty/LongTravel60.jpg
Used .250 wall tubing to replace old limit strap clevice mounts
http://i213.photobucket.com/albums/cc109/keith-carty/LongTravel62.jpg
put hard brake line on top of frame instead of on side, now there's room for limit strap mount. And I don't have to pull the bypass to adjust the limit strap.
http://i213.photobucket.com/albums/cc109/keith-carty/LongTravel64.jpg
Real Estate is tight under there!
http://i213.photobucket.com/albums/cc109/keith-carty/LongTravel69.jpg
http://i213.photobucket.com/albums/cc109/keith-carty/LongTravel67.jpg
http://i213.photobucket.com/albums/cc109/keith-carty/LongTravel74.jpg
http://i213.photobucket.com/albums/cc109/keith-carty/LongTravel78.jpg
http://i213.photobucket.com/albums/cc109/keith-carty/LongTravel76.jpg
http://i213.photobucket.com/albums/cc109/keith-carty/LongTravel77.jpg
All I gotta do is bleed the brakes and install wheel. Oh ya, and build uppers:D
So I got the jig for the other side done, pivot points and ball joint slug bolted in, and top/bottom plates cut out. Pretty good progress. Done by midnight, but I started at like nineB)

http://i213.photobucket.com/albums/cc109/keith-carty/LongTravel79.jpg
http://i213.photobucket.com/albums/cc109/keith-carty/LongTravel80.jpg

I should have it boxed in tonight:yes:

[dirtydeeds]

So I tacked together the top and bottom plates. I also cut out and tacked together the outer boxed plate. Tomorrow I'll cut tack welds holding bottom plate and cut out and fully weld internal gussets. Maybe solid weld everything. I WILL be done completely and installed before the end of the weekend. Here's the pics:

http://i213.photobucket.com/albums/cc109/keith-carty/LongTravel82.jpg
http://i213.photobucket.com/albums/cc109/keith-carty/LongTravel83.jpg
http://i213.photobucket.com/albums/cc109/keith-carty/LongTravel84.jpg
http://i213.photobucket.com/albums/cc109/keith-carty/LongTravel81.jpg

[dirtydeeds]

finally built the uppers:
This jig has a point to clear for the coil bucket and the hose on my coilover, I used 9/16" steel rod.
http://i213.photobucket.com/albums/cc109/keith-carty/Longtravelupperarms1.jpg
I tapered the edge of this washer then welded it to the plate. This centers the uniball cup.
http://i213.photobucket.com/albums/cc109/keith-carty/Longtravelupperarms11.jpg
http://i213.photobucket.com/albums/cc109/keith-carty/Longtravelupperarms10.jpg
cup bolted in and tubing notched. I tapered the top washer to center the cup as well
http://i213.photobucket.com/albums/cc109/keith-carty/Longtravelupperarms7.jpg
perfectly notched, no gaps
http://i213.photobucket.com/albums/cc109/keith-carty/Longtravelupperarms5.jpg
http://i213.photobucket.com/albums/cc109/keith-carty/Longtravelupperarms4.jpg
http://i213.photobucket.com/albums/cc109/keith-carty/Longtravelupperarms2.jpg
http://i213.photobucket.com/albums/cc109/keith-carty/Longtravelupperarms3.jpg
http://i213.photobucket.com/albums/cc109/keith-carty/Longtravelupperarms8.jpg
as you can see, but the heat the penetration is excellent
http://i213.photobucket.com/albums/cc109/keith-carty/Longtravelupperarms9.jpg
Done, which would you rather have? 1 1/4" or 1 1/2" sickass arms?
http://i213.photobucket.com/albums/cc109/keith-carty/Longtravelupperarms13.jpg
http://i213.photobucket.com/albums/cc109/keith-carty/Longtravelupperarms12.jpg
http://i213.photobucket.com/albums/cc109/keith-carty/Longtravelupperarms14.jpg
I'm all ready to make a couple more sets:yes:
http://i213.photobucket.com/albums/cc109/keith-carty/Longtravelupperarms6.jpg

[MD_Weems]

great post