DIY 1 Ton IFS Long Travel

AssBurns

will wheel for beer
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Got the seals in yesterday from Spidertrax. Good news is the seals are the same size OD as the seals that were in there. I guess I didn't need to order the kit with the seal cup, which is great because that $50 kit only came with one cup...
 

Hank

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Got the seals in yesterday from Spidertrax. Good news is the seals are the same size OD as the seals that were in there. I guess I didn't need to order the kit with the seal cup, which is great because that $50 kit only came with one cup...

these seals are awesome. I ran two of them on each axle shaft to double seal it.
 

AssBurns

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these seals are awesome. I ran two of them on each axle shaft to double seal it.
Yeah not sure if I'll have the space to run two of them. I'll have to machine off the current seal cup and weld the new one on. I'll try with one seal first and if that doesn't work I'll make adjustments for two seals.
 
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@AssBurns I don't know how it took me so long to find a build like yours using Fusion 360. I'm working on some a arms as well and have questions regarding how you actually modeled them- I've been having trouble for quite some time. Any chance I could pick you brain a little bit offline through email? By the way it sounds like a pretty rad build. I like the fabbed housing.
 

AssBurns

will wheel for beer
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@AssBurns I don't know how it took me so long to find a build like yours using Fusion 360. I'm working on some a arms as well and have questions regarding how you actually modeled them- I've been having trouble for quite some time. Any chance I could pick you brain a little bit offline through email? By the way it sounds like a pretty rad build. I like the fabbed housing.
Yeah man, I'll shoot you a DM with my email.
I'm still a novice at the CAD stuff, but I am learning as I go. I'm more than happy to go over any questions you have.
 
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Hi there, I came here to follow this posting. I have a 2004 Chevy Tahoe I want to make a mid to long travel suspension on, the problem i find is some of the part kits are for 2007n and above. I am wanting to do away with the torsion bars and go with coil overs for ride and travel. For lift I am only looking at 3 to 4 inches. any ideas are helpful. I am finishing my welding degree to assist my blacksmithing so I know my way around moving metal. just don't know all the details yet about the suspension changeover needed for this setup.
 

Itaro

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Hi there, I came here to follow this posting. I have a 2004 Chevy Tahoe I want to make a mid to long travel suspension on, the problem i find is some of the part kits are for 2007n and above. I am wanting to do away with the torsion bars and go with coil overs for ride and travel. For lift I am only looking at 3 to 4 inches. any ideas are helpful. I am finishing my welding degree to assist my blacksmithing so I know my way around moving metal. just don't know all the details yet about the suspension changeover needed for this setup.
Your wallet is going to hate me but
https://jdfabrication.com/products/chevy-1500-99-to-06-4x4-long-travel-kit-extreme
 

Rockdawg84

Confidence the feeling before fully understanding
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Any update on this part of the beerrunner build? Im so tired of breaking CV's and am debating SAS but would love to build a strong IFS I don't think that I need to go to this level but happen to have a 4th gen runner front diff sitting in my shed. and I think 30 spline rcv's would be more than strong enough to keep up with what I want to do. Mostly crawling over desert running. Scott at Front range off road seems to have a pretty strong setup with the front 8" and rcv's. He also built long travel that is similar to Marlin's RCLT.
 

Arcticelf

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Any update on this part of the beerrunner build? Im so tired of breaking CV's and am debating SAS but would love to build a strong IFS I don't think that I need to go to this level but happen to have a 4th gen runner front diff sitting in my shed. and I think 30 spline rcv's would be more than strong enough to keep up with what I want to do. Mostly crawling over desert running. Scott at Front range off road seems to have a pretty strong setup with the front 8" and rcv's. He also built long travel that is similar to Marlin's RCLT.

You can probably get the guys at JD Fab to make a 934 conversion for the 4 runner diff, they just have to machine down the oem inner CV. Then build an outer off the D60 hub.
 
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Any update on this part of the beerrunner build? Im so tired of breaking CV's and am debating SAS but would love to build a strong IFS I don't think that I need to go to this level but happen to have a 4th gen runner front diff sitting in my shed. and I think 30 spline rcv's would be more than strong enough to keep up with what I want to do. Mostly crawling over desert running. Scott at Front range off road seems to have a pretty strong setup with the front 8" and rcv's. He also built long travel that is similar to Marlin's RCLT.

I too was plagued with this issue.... Building an 8" Toyota front axle at the moment for a SAS. Are you wanting to build stock width IFS or LT IFS with the 8" center?
 

Rockdawg84

Confidence the feeling before fully understanding
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I too was plagued with this issue.... Building an 8" Toyota front axle at the moment for a SAS. Are you wanting to build stock width IFS or LT IFS with the 8" center?
Ultimately I would like to do a mid Long travel (2.5-3") with the 8" center. I ran a solid axle 84 Runner for years and once I had longfield axles even on 39.5 pittbull rockers I stoped carrying spare axles. never broke another. I have gone back and forth about doing a SAS but for the money I really think I can build a strong IFS but we will see.

You can probably get the guys at JD Fab to make a 934 conversion for the 4 runner diff, they just have to machine down the oem inner CV. Then build an outer off the D60 hub.
thats great news thanks.
 
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Ultimately I would like to do a mid Long travel (2.5-3") with the 8" center. I ran a solid axle 84 Runner for years and once I had longfield axles even on 39.5 pittbull rockers I stoped carrying spare axles. never broke another. I have gone back and forth about doing a SAS but for the money I really think I can build a strong IFS but we will see.


thats great news thanks.


That sounds right up my alley. At the moment I have a Toy front axle with the 8" center that I'll be swapping HP running gear into eventually, but for now it will be the LP. Axle housing was chopped at the outer's and widened with a sleeve.... still have yet to set caster and burn it all together. It will be about 61" in the front if I remember correctly (I think that's about .25" wider overall than the stock IFS width?) Longfield sounds like the way to go because I want to avoid having to take spares; with the tires at 35" MAX I doubt it will be an issue from what it sounds like you had.
 

AssBurns

will wheel for beer
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Any update on this part of the beerrunner build? Im so tired of breaking CV's and am debating SAS but would love to build a strong IFS I don't think that I need to go to this level but happen to have a 4th gen runner front diff sitting in my shed. and I think 30 spline rcv's would be more than strong enough to keep up with what I want to do. Mostly crawling over desert running. Scott at Front range off road seems to have a pretty strong setup with the front 8" and rcv's. He also built long travel that is similar to Marlin's RCLT.
No updates at the moment. I just don’t have the time to draw everything up right now. I know DIY Offroad on IG has a centermount 4wd bulkhead setup on their site. I kinda want to look more into that to save time on designing. The problem lately is I just don’t have the time to work on these projects like I would want.
 
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