91 xtra cab SAS build

[jarboarder1]

Well I figured it was about time to post up the build I have started.
the goal: A very functional wheeler while being a reliable daily driver.
the truck: 1991 extra cab 3.0 V-6
Build at this time
SAS the front
Chevy swap the rear
Lock the rear
Some armor

+Parts list
-Front spring hanger kit Trail-Gear
-High Steer Trail-Gear
-Steering Box mount Trail-Gear
-U-Bolt flip kit Trail-Gear
-Shock Hoops 12” Trail-Gear
-Break Lines Trail-Gear
- 78” Sliders Trail-Gear
-Chevy Spring kit Sky Man.
-Toyota Rear Shock Hoop Kit Sky Man.
-Toyota Axle widening kit Sky Man.
-FJ 40 rotors
-Front springs Datin Fab/ trail gear
-Chevy springs 63”
plus other stuf i didnt write down


In the near future
Duals
Re-gear
30 sline longs
Lock the front
Front and rear bumpers
Half doors


So here is what we have to start with

[jarboarder1]

This is the axle we built in between my house in Boulder and the shop I do work at on campus.
I am an Engineering student at the University of Colorado so working on the axle in one of the shops was a nice little project here at school.

The first axle i got was bent :hammerhead: ( A great way to start off my first build) but luckily was able to find someone who wanted it for close to what I bought it for
stuck birf on the old bent axle



So once I got rid of the bent axle I picked up this one and cleaned it up


the axle being worked on in the CU welding shop
Armored this thing up with Sky's truss and diff armor and used marlins gussets.




Here is my buddy Mat who is walking me through the build :beer:


a couple more pics of rebuilding the axle


Got my little bro doing some of the shity work :ha_ha: its ok this truck is going to end up being his


also decided to go with Sky's widening kit instead of wheel spacers. I like the piece of mind since its a daily driver.



so here is the axle waiting to be put in

[Avsfreak1234]

whats your major in the college of engineering. im going to be there next year for aerospace engineering and have that really nice machine shop at my disposal too.

[jarboarder1]

Originally Posted by Avsfreak1234

whats your major in the college of engineering. im going to be there next year for aerospace engineering and have that really nice machine shop at my disposal too.

Im in civil engineering right now but might try and switch into mechanical.
There are actually quite a few shops around campus that you can do work at you just need to get certified on the machines.
The one that I do work at is in the physics building because they are a little more lax and they have welders

[jarboarder1]

Since My garage isn't big enough to work on a truck I have to do this build at my parents house which is a real pain in the ass because I have classes 5 days a week and a lot of other stuff going on as well. My parents house is about 45 minutes away which is a ways to drive just to get to my truck. So Saturdays are the only days that I get any work done on this build. Cant wait for school to get out for the summer.

Anyways we started of with the rear suspension first. Went with some Chevy springs.


cut off the overloads i didn't like them there and Im not going to be carrying heavy loads so i didn't see a point in keeping them.

The bushings were shot. Had one hell of a time getting them out. Ended up drilling and burning them out
Even got the old man helping with them


Replaced the old ones with some energy suspension bushing



For the rear I went with Sky manufacturings Chevy swap kit.

Here is the rear after we pulled all the suspension out.


front hanger being welded on




Here Is the welder I'm using. Its a Hobart 187. I havn't had it for long but I love it :greengrin:


trying to test out the new rear suspension.





It seemed to work well but we didn't have anywhere to really test it out.

So we turned it around so we could start working on the front.

and here is how its sitting now.

[poorboyota26]

did you notice any difference in the way it articulated at all?

How much lift did you get out of them?

[jarboarder1]

They lift about three inches. They did flex better than stock even when I was just messing around in the drive way, but that wasn't a very good place to test it out

[00regcab]

lookin good so far man!

makes me miss my old truck

[jarboarder1]

Alright so over the weekend I got the front torched out.

This is the last weekend to work on it before finals. Now I have to wait until may 7th to work on it again. My brother should be working on grinding the frame smooth so that we can get straight to work after I’m done with the semester.

Any ways here are the picks

Last pic of the ifs



Starting to torch away, there is no turning back now



And it finally it hit the ground



The famous torched ifs. Every build needs this shot


The frame waiting to be ground down


And here is how it sits until I’m done with this semester



That was a lot of fun and I can’t wait to through the axle under it.

[Volcom]

Originally Posted by jarboarder1

That was a lot of fun and I can’t wait to through the axle under it.

Easy for you to say that since you don't have to grind all that crap off (getting your brother to do it, )

Should be a nice setup once you get it done!! Finish those finals and then &

[poorboyota26]

what are you doing with the IFS axle shafts? I need one for my 4Runner (Driver's).

[jarboarder1]

Originally Posted by Volcom

Easy for you to say that since you don't have to grind all that crap off (getting your brother to do it, )

Should be a nice setup once you get it done!! Finish those finals and then &

haha yea he should get a good amount done but i bet i still do plenty of grinding

[jarboarder1]

Originally Posted by poorboyota26

what are you doing with the IFS axle shafts? I need one for my 4Runner (Driver's).

Once im done with school Im going to tear the ifs apart and sell what I can. you have dibs if you want

[Mythica]

Sweet! It should be fun!!!

[fondigley]

Nice build so far. Can't wait to see it done.

[poorboyota26]

Dibs if the price is right.

hubs too?

[jarboarder1]

Originally Posted by poorboyota26

Dibs if the price is right.

hubs too?

hubs are already taken. but i will let you know when i get the parts ready to go

[ducaria]

Can't wait to see more...keep us updated.

[jarboarder1]

Originally Posted by ducaria

Can't wait to see more...keep us updated.

Neither can I. I have 2 more finals then on Thursday I plan to have it rolling again.

[jarboarder1]

Alright so school is finally done for the summer!
The plan of getting a lot of work done last Thursday didn't quite work.
but I got some work done the last couple of days

So once i got home I went straight to work, but its been slow since Im doing most of this by myself.
Anyways here are some pics

Here is the front hanger with a 3/16 spacer welded to it.


Hanging the springs


Here is the shackle. It is sitting right around 12-13 degrees back. that should work just about perfect.


Here It is with the axle strapped on. Just starting to mess around with the steering.


Hopefully tomorrow I get all the steering stuf figured out and I can go test it out a little.

[Quick Draw]

Looks great! Just out of curiousity, what are you doing with the transfer case. Yours is driver drop, and the axle is pass drop, correct? Or is that just the Tacos? In all of the SAS build threads I've seen I haven't been able to figure out what they do with the transfer case, to go pass drop.

[Smitty4thgen]

I am so jeulous right now... I have a 90 PU and needless to say I want to SAS... Keep the pics coming... So i can dream a little more!


Jared (My name too)

[jarboarder1]

I dont know exactly what year they switched over to the driverside drop, but on the pre-taco's it was still a passenger side drop. So, I didn,t have to mess with any of that.

[Quick Draw]

Hmm...probably switched to Driver drop when the new Tacomas rolled out. That's lucky. I just did some research. Looks like SAS for my truck would be much more of an ordeal, than it is for your truck. Looks like there's an t-case adapter....or a new t-case....or "flip" the axle, which is basically fabricating the whole axle. Then the most popular choice seems to be a "waggy" axle. I've seen it mentioned before....but what exactly is that? My best guess is the front axle out of a Jeep Wagoneer, but I think that's probably going to be wrong.

Also, it's even easier yet, because you already have a steering box in the proper location.

[00regcab]

Originally Posted by Quick Draw

Hmm...probably switched to Driver drop when the new Tacomas rolled out. That's lucky. I just did some research. Looks like SAS for my truck would be much more of an ordeal, than it is for your truck. Looks like there's an t-case adapter....or a new t-case....or "flip" the axle, which is basically fabricating the whole axle. Then the most popular choice seems to be a "waggy" axle. I've seen it mentioned before....but what exactly is that? My best guess is the front axle out of a Jeep Wagoneer, but I think that's probably going to be wrong.

Also, it's even easier yet, because you already have a steering box in the proper location.

1st-3rd gen trucks/4runners are all pass drop t-cases.

95.5+ tacomas are driver i believe.

Youre right, a waggy axle is an axle out of a jeep wagoneer, its a dana 44 and its a little bit more narrow than a toyota axle, and 95% of the people that run the d44 out of the wagoneer end up using wheel spacers in the front if i remember correctly. A tacoma SAS is a much bigger deal, since you have to get a different t-case, find the IFS steering box, so on and so forth. In comparison i guess its not really THAT much more work/labor, but a lot more money.

Jared, the build looks great!

The only thing i would of personally done different, a little less money on beefing up the axle, and a little more money on gearing/lockers. But im sure that'll come, truck looks amazing!

I'll give you $5500 cash for it? makes me miss my old truck so bad

[Volcom]

Originally Posted by 92regcab

Youre right, a waggy axle is an axle out of a jeep wagoneer, its a dana 44 and its a little bit more narrow than a toyota axle, and 95% of the people that run the d44 out of the wagoneer end up using wheel spacers in the front if i remember correctly. A tacoma SAS is a much bigger deal, since you have to get a different t-case, find the IFS steering box, so on and so forth. In comparison i guess its not really THAT much more work/labor, but a lot more money.(

Waggy D44 isn't narrower than a Toyota axle. The Toyota axle is 55" WMS to WMS. The Waggy is closer to 59" WMS to WMS.

Here's a picture comparing the two. Were both running 1.5" spacers on the front (but I'm running 2.5" backspaced wheels and he's got 3.75" backspaced wheels)




The swap looks good Jared!! I wish my front shackle angle looked that good. Nice work!

[jarboarder1]

Thanks guys.

looks like the axle question was answered for you.

Yea I wish I had more money cause then I could regear it now, but all of it will come with time. I just need to get a job soon.

[00regcab]

Originally Posted by Volcom

Waggy D44 isn't narrower than a Toyota axle. The Toyota axle is 55" WMS to WMS. The Waggy is closer to 59" WMS to WMS.

Here's a picture comparing the two. Were both running 1.5" spacers on the front (but I'm running 2.5" backspaced wheels and he's got 3.75" backspaced wheels)

I knew it was one or the other, as i was typing that it seemed that i had it backwards, and alot of the guys were running spacers on their rear toy axle, with the d44 front?

i dunno, either way, questions still answered. Thanks for clearing it up!

Looking forward to getting out with you again jared, jenny creek again eh? Was a pretty fun trail last time!

[jarboarder1]

yea jenny creek was a lot of fun. I should be wheeling here soon. I just need to get a job and have this truck rolling, then i should be good for the summer.

[Avsfreak1234]

dude, looks good! I like the TOYOTA cutout on the axle gussets