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Project Shamu
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2,792 Posts
Discussion Starter #1,542 (Edited)
Lots of progress yesterday. I finished welding all the brackets, drilled the rest of the holes in the frame, and bolted all the brackets on. 32!! 1/2"-20 bolts were used!

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Then I assembled the axle and slid it under the truck and started assembly. We had a problem with the Reman caliper, it had a deep gouge right through the matting surface of the banjo fitting, making it leak profusely. After some sanding, filling, and double up on copper washers, it stopped leaking and we were able to bleed it.
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Now the truck is on the ground, im waiting for hardware for shocks, and to lower the rear end with shorter blocks and put the sway bar on. After that, we are ready to drive it!!!
 

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PSN intsigator
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6,706 Posts
I love your tiny shopping cart!

Is that the only size your wife will let you have.... when its full your done shopping
 

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Project Shamu
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2,792 Posts
Discussion Starter #1,545
I love your tiny shopping cart!

Is that the only size your wife will let you have.... when its full your done shopping
Haha. She said I could only get what I could carry in it. Just wait till I try and carry some new 35s in there! Lol
What are you using on the top of the coil spring brackets to keep the spring centered?
I'm going to water jet out a 1.25" thick aluminum Puck that will fit the inside diameter of the spring (which is 2.75") and bolt it into the top of the coil bucket. I havent done it yet, but I just drove it about 25 miles and I had no issues, the bucket is a pretty tight fit as is.

I am a little unhappy with fitment of the coilbuckets, and the front end of the truck is 1" too high to be level, so I might be remaking them here soon, we'll see.

I'm also planning on getting limit straps, and making a rubber bump stop mount to utilize the bump stop pad that is built into the axle. After that, custom radius arms with caster adjustments and then an adjustable track bar... We'll see what I come up with.
 

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PSN intsigator
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Haha. She said I could only get what I could carry in it. Just wait till I try and carry some new 35s in there! Lol
Is that what your old axle is going in
 

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don't play well w others
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4,066 Posts
No doc. You cant have it. It's already spoken for......

Sent from my SM-N960U using Tapatalk
 

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Project Shamu
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2,792 Posts
Discussion Starter #1,549
Shamu made it about 30 feet before it got hooked to a trailer and put to work 🤣
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I'm pretty happy with the way it turned out altogether. It rides way way better, handles nicely and drives straight down the road. The rear is a little stiff just from the stock springs, so I'll probably do the 10'+ rear springs in the future.
 

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That is really cool! Great Job!
 

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Project Shamu
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2,792 Posts
Discussion Starter #1,551
A little follow up, everything has been great other than the track bar. It keeps shifting inside the mount because the hole in the track bar is larger than the bolt, I have it torqued to 300 ft/lbs and I still hear it pop/move every once in a while. I think I'm gonna pull it out and see if a 3/4" bolt will fit (currently it's an 18mm), then I just have to drill out the mount a little bit.

Also, now that I have a new blue top steering box, and a nice tight heim steering, I can tell how much play is in the steering shaft, its unreal watching it while someone turns the wheel... maybe a borgeson shaft is in my future now. Sigh.... it never ends...

Also, I just sent out the files to have intake plenums machined. They will just be flat like IDP plenums, except mine will retain the 2" inlet, and I am having them machine an o-ring groove for a Viton o-ring. No more RTV (which is the reason why mine is leaking in the first place).
 

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You should have sent them my way.... I could have made a "test" set to verify the programming...

Cj
 

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Also, I just sent out the files to have intake plenums machined. They will just be flat like IDP plenums, except mine will retain the 2" inlet, and I am having them machine an o-ring groove for a Viton o-ring. No more RTV (which is the reason why mine is leaking in the first place).
That sounds awesome!
 

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Project Shamu
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2,792 Posts
Discussion Starter #1,554
Few small things taken care of... fixed an oil leak at the hpop gear inspection plate, replaced with dieselsite plate and o-ring, leak fixed.

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Got the first test plate for the intake plenum and mocked it up on my spare engine on the stand. Looks like it should work perfect with the stock OBS/E99 turbo (which Is a damn tight fit!!!), stay tuned for how we finish it off.

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I got the revised front coil buckets installed so the truck sits level with just a 2" block. Roughly 3-4" of bump travel still.

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Also made my flatbed extension again, this one geared towards being lighter, stronger, easier to install by myself, and look better. Nailed it across the board I think. Its 3 seperate pieces, 2 sides and 1 tube in the middle. The 1700lbs 4 Seat RZR fits like a glove, doesnt bow, bend, or anything while it's up there, and with 60psi in the bags, the truck sits level. I'm leaving for a day trip tomorrow, so wish me luck!
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Project Shamu
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2,792 Posts
Discussion Starter #1,555
Fixed 99% of my boost leaks, have no exhaust leaks (that I can find), but yet struggling to make 24psi of boost and have more smoke than ever right now. Going to check fuel pressure next I think...
 

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Project Shamu
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2,792 Posts
Discussion Starter #1,558
Another little project I've had waiting for quite some time now. Dual Pump mount and filter mounts that bolts to the inside of the frame rail. I'm only running the bottom pump though, the top is just a place holder for now.

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don't play well w others
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Beautiful work as always

I love how you cali guys never have to paint anything.
Try that here in the east, the surface rust gets a good hold in 1 day......
 
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