Quick update then I've got to get back to enjoying my holiday!
Tools first.....................................
I've ended up with far too many socket sets as just before buying my big tool box at work, which came with a big socket set, I bought 2 of these sets really cheap at Aldi.
The sockets are good quality and single hex which is much less likely to slip and round bolts and nuts than multi hex. But as is often the case with cheaper sets the ratchets are of poor quality and fail.
So I decided to make some T bars instead.
I bought these galvanized ones about 10 years ago but after loosing the 10mm I only had an 8, 12 and 13mm left.
I selected an 8, 10, 12, 13 and 14mm 1/4" drive sockets from the set.
Cut some stainless steel rod.
Drilled out the sockets which was extremely difficult as there hardened steel, but my sharp Dormer drill bits soon got through them.
The stainless steel rod now fitted snugly into the sockets.
I could then TIG weld the rod to the sockets.
I then laid it on the bench and once the handle was in position and nice and square it could be welded to the other piece of stainless.
They worked out well and now have their own drawer in my big tool box.
I had to do a little job on the Suzuki I built which has now sold.
The buyer had asked if we could fill in the tube doors as he was worried about his small children falling out.
I cut and painted some alluminium checker plate and riveted it on.
Then parked it outside ready for the new owner to pick up.
And finally LJ.
The new suspension arrived a few days before my 4wd trip after my boss got me an amazing price on it.
I made a start fitting it.
Rear first.
I needed to remove the OME Defender shocks and Dobinsons 79 series front coils.
Shocks removed and comparing the length to the new Dobinsons ones.
A few inches shorter but then this lift kit will drop LJ by about 100mm and the Defender shocks were too short anyway but thats all I could get in Birdsville.
And comparing the coils.
Only about 40mm difference in height but the new springs are much softer.
I also needed to remove the hastily knocked up using bits of scrap metal and ply wood, spring adapters.
I discovered that the inner oil seal has been leaking on the driver side.
That means that both the pinion oil seal and half shaft oil seal have been leaking and I put this down to the bloody ARB air locker leaking inside the diff and filling the diff full of compressed air.
Did I mention I will NEVER fit ARB air lockers to any of my vehicles EVER again!
Too unreliable!
I'm going for Eaton electric lockers next time!
The other side looked OK thankfully.
Realising I was running out of time I put it all back together and did the trip.
This week I got a few hours after work and once again cracked on with replacing the suspension.
Removed all this from the rear.
And fitted the new coils.
I was very pleased with how much lower the car was now sitting!
A drop of over 100mm which will not only make LJ legal it will also make it look a lot more legal and mean I'm less likely to get stopped by the police and be hit with a defect notice.
It will also make it more practical getting in and out and putting stuff in the back. I'm also hoping it will make LJ a bit more stable.
Front next.
Wheels off.
I'm really pleased with my drop boxes which have pushed the front axle 50mm forwards.
But as I'm probably going to use the shocks that have come with the Dobinsons lift kit I wont need the shock absorber top mount relocation brackets.
Its worth noting that all these custom suspension components that I designed and made before the Simpson trip stood up to the extreme conditions faultlessly!
It was a combination of rear springs not being rated for the load I was carrying and no rear bump stops which led to the sagging of the springs and failure of the shocks.
Removed the OME 79 series front springs and EFS shocks.
New Dobinsons springs.
It got dark and I ran out of time to finish the front.
I found the original bottom spring perches that I cut off my axle when I moved it 50mm forwards.
Sadly these wont sit flat on the 6mm flat steel I welded to the axle, so I will need to make some new ones as the ones I made and fitted for the 79 series front springs wont fit the new springs.
I cut some tube, this is actually the tube I use for my TIG welding practice forTAFE.
Cut and marked some 3mm sheet.
I then drilled out each piece of 3mm with a 92mm hole saw so that the 90mm tube fits through.
The 3mm will have a cut made in it and will then be bent and welded around the tube in a sort of spiral so that the bottom of the spring fits perfectly in it.
Then it can be welded onto the axle and the new springs fitted.
I'm really excited about a little project I'm planning!
I've thought up a way of making and fitting a 70+ litre aux fuel tank and 30+ litre water tank to LJ as fuel range is a constant issue as 90 litres just isnt enough.
I've got to do some more designing and measuring then I will get the materials ordered.
I'm going to use stainless steel for the water tank and alluminiumised steel for the fuel tank. I will fully TIG weld it so as to avoid the porous welds that seem to be almost unavoidable with MIG.
I will have to pull the rear diff out and fix the air leak and replace the leaking oil seals. I'm also going to look more seriously at converting the rear brakes to discs while its all apart.
I've also got a reasonably big engine oil leak that I need to locate and fix. Its some where above the oil filter on the passenger side of the engine.
So lots to do but then I can get out on some more trips!
hahaha!
