Formula Toyota #38

[arizonaxj]

I'm tearing down my old trail rig and building a Formula Toyota. For those that are interested, here is the official F-toy site. http://www.pirate4x4.com/formula_toy/
This is the doner trail rig. It's already got almost all the parts I need for the F-toy.
http://img.photobucket.com/albums/v16/arizonaxj/Las%20Cruces%2006/pat_5.jpg
This is the doner truck I'm going to strip for the frame.
http://img.photobucket.com/albums/v16/arizonaxj/F-Toy/83_doner.jpg
Pulling the motor and gutting the trail rig.
http://img.photobucket.com/albums/v16/arizonaxj/F-Toy/motor_out.jpg
Gutting the doner truck.
http://img.photobucket.com/albums/v16/arizonaxj/F-Toy/cab_off.jpg
The basic F-toy in kit form.
http://img.photobucket.com/albums/v16/arizonaxj/F-Toy/F-toy_kit.jpg
Cleaned up frame.
http://img.photobucket.com/albums/v16/arizonaxj/F-Toy/frame_1.jpg
I'll post up some more info as the build progresses.

[Jeepin Jason]

NICE. :thumbsup: I think the Formula Toy program is really cool.

[HotSEXJ]

HELL YEAH! I'll be following this very closely - I think my next rig is going to be an FToy.

[arizonaxj]

It should be a pretty fun build. I'm planning to be done in 3-4 months. I could build it faster, but when it's 110, it's hard to get motivated to get out in the shop.

Here are a few of the specs, first the things I already have,

Dual T-cases.
4.7 gear in in rear case.
5.29 axle gears. Total reduction is 221:1. May change to 4.10's.
Spool in the rear.
Detroit up front.
Longfield super axles up front.
I have 37" MT/r's, but keep tearing sidewalls. I will probably change them. To what, I don't know yet.
Warn XD9000I winch.
I have a lot of springs, but I will have to mix and match to suit the weight. I'm shooting for sub 3000lbs. Hopefully 2700-2800lbs.

A few things to add,

PRP seats.
Synth winch line.
Flat belly.
Engine re-build. This one has 212,000 on it and SMOKES!
Engine will be relocated appoximatly 7" back. I want to have the T-case sitting dead center, with equal length drive shafts.
110" wheelbase, roughly.
Late model, 3" wider rear axle assy.
Bead lock wheels.
Inboard rear springs to 29" on center.

And, a lot of work. I would like to make the ProROCK in Cougar Buttes near the end of Sept. We'll see!!!

[nblehm]

maybe I am missing something but why didnt your old trail rig work for the series?

[Hoofmann]

Formula Toys are chassis specific, you have to run their chassis to compete.

[arizonaxj]

maybe I am missing something but why didnt your old trail rig work for the series?


It's a spec class. You have to run a chassis from an approved vendor. They call it a chassis, but is actually the cage.
Besides my old cage is too tall, wide and heavy. The new cage is a foot more narrow.
It was a major sticking point for me. I wanted to build my own cage to meet specs, but the rules won't allow it. Kind of a bummer, but it's still the cheapest class out there.

[nblehm]

It's a spec class. You have to run a chassis from an approved vendor. They call it a chassis, but is actually the cage.
Besides my old cage is too tall, wide and heavy. The new cage is a foot more narrow.
It was a major sticking point for me. I wanted to build my own cage to meet specs, but the rules won't allow it. Kind of a bummer, but it's still the cheapest class out there.

gotcha I didnt read the rules. I was figuring you just wanted something alittle less bulky or something. Kind of stupid you have to run a vendor shell though

[arizonaxj]

New Formula Toy website for the east coast people... http://www.formulatoyeast.com/php/

[arizonaxj]

Just about all the grinding is done on the frame. I really need a plasma cutter. That was starting to really suck. Some parts from Trail Gear showed up a couple days ago. Here is the front spring hanger, frenched rear spring hangers, rear shackle hangers and three position rear spring perches.
With any luck, by the end of next weekend I'll have a roller....
http://img.photobucket.com/albums/v16/arizonaxj/F-Toy/trailgearparts.jpg

[arizonaxj]

I'm starting to look into the front springs. I have All-Pro 4-1/2" lift springs front and rear. After I french the rear hangers, it should have about 1-1/2" less lift, making the rear about a 3" lift. To drop the front to match the rear, I'm thinking about using a pair of stock Yota rears with the overload leaf removed, and then add leafs off the All-Pro packs till I get the ride height I want. I could just remove leafs from the All-Pro packs, but one of them has a bent top leaf.
http://img.photobucket.com/albums/v16/arizonaxj/F-Toy/frontsprings_1.jpg

[arizonaxj]

Just about finished with the front hanger. If I'm lucky, it should hold up!
http://img.photobucket.com/albums/v16/arizonaxj/F-Toy/hanger_gusset.jpg

[nblehm]

I've been looking around at the forumla toys... seems like a cool class. cant wait to see how yours turns out :thumbsup:

[arizonaxj]

I'm getting started inboarding and frenching the rear spring hangers, and making a new rear crossmember.
The Trail Gear hangers are super stout, but they are un-welded.
http://img.photobucket.com/albums/v16/arizonaxj/F-Toy/box_un-welded.jpg
Here are the hangers after grinding and welding.
http://img.photobucket.com/albums/v16/arizonaxj/F-Toy/box_welded.jpg

[Jeepin Jason]

nice looking welds! :thumbsup:

[arizonaxj]

nice looking welds! :thumbsup:

Thanks Jason!

Got a little more done...
According to F-Toy rules, the rear springs can be inboarded to the same width as the front springs, 29" on center. To avoid any conflict, I set mine up at 29-1/2".

First I tack welded the hangers to a piece of stock.
http://img.photobucket.com/albums/v16/arizonaxj/F-Toy/mock_up.jpg
Next, here are the hangers clamped to the frame.
http://img.photobucket.com/albums/v16/arizonaxj/F-Toy/mock_up_1.jpg
Here are some "U" shaped pieces welded in between tying the hangers to the frame, and leaving an opening at the bottom to access the bolt.
This area will still need alot of work. As it is now, it would probably tear off the frame on the first trip out.
http://img.photobucket.com/albums/v16/arizonaxj/F-Toy/box_welded_upper.jpg
http://img.photobucket.com/albums/v16/arizonaxj/F-Toy/box_welded_lower.jpg

[arizonaxj]

I made a new rear X-member, but I'm not sure if I should use it. It's made out of 3-1/2" X 3-1/2" 1/4" wall. It's a leftover from another job. It's a boat anchor!. I popped a bunch of go fast holes in it to take a little weight off, but it's still heavy.
http://img.photobucket.com/albums/v16/arizonaxj/F-Toy/rear_X-member.jpg

[arizonaxj]

She's a roller!
http://img.photobucket.com/albums/v16/arizonaxj/F-Toy/rear_X-member_1.jpg
http://img.photobucket.com/albums/v16/arizonaxj/F-Toy/perch.jpg
http://img.photobucket.com/albums/v16/arizonaxj/F-Toy/roller_1.jpg

[Jeepin Jason]

I know it'll settle down once it's finished, but man it sits tall like that!

[arizonaxj]

I know it'll settle down once it's finished, but man it sits tall like that!
Yeah, that's what I'm thinking too! I hope it settles at least two, maybe even three inches. Hopefully the motor, tranny and T-cases will be in by the end of next weekend, and go from there.

[nblehm]

Nice man...moving right along :thumbsup:

[KIAKillerXJ]

thats a neat class. looking forward to seeing your progress, looling great so far! :driving:

[arizonaxj]

This weekend I got the motor in the frame for a test fit. Right now it's set up for a flat belly with the motor mounts moved back 4-3/4" from stock. I'm not dead set on location yet. Once the radiator is mocked up, I can test fit the winch. I want the fairlead to mount even with the front cross member.
It seems like everytime I buy a fabbed part, it doesent fit. The motor mount brackets were no different. When I tried to mount them to the stock motor mounts on a 94 22RE, they didin't fit. Here are the mounts held up to the stock mount's on an 83 frame.
http://img.photobucket.com/albums/v16/arizonaxj/F-Toy/hendrix_mounts.jpg
With the engine setting close to being in place, I dropped the chassis down to where I would like it to fit. The centerline of the bottom tube is even with the top of the frame rails. Once the seats show up, I can get the height set for good. In this pic, the top of the cage is at 74" high. I would like to get the height down a couple more inches. I'm pretty sure a leaf will have to come out of the front springs. Hopefully that will do it.
http://img.photobucket.com/albums/v16/arizonaxj/F-Toy/test_fit.jpg

[nblehm]

nice... looks like its coming right along

[arizonaxj]

Thanks. I try to get a little done everyday. It's more work than it looks.

[nblehm]

Thanks. I try to get a little done everyday. It's more work than it looks.

yeah I know the feeling... work on something for 4-5 hours and step back and look and doesnt seem like anything really changed.

[arizonaxj]

Exactly! I picked up that motor last week. It's EFI and my old motor was carbed. The new one was pretty recently rebuilt too. By the time I pulled the valve cover, and oil pan off to have a look, put it back together, installed the clutch, tranny and T-cases and set it in the rig. The weekend was gone. I didn't even have anything really go wrong.

[arizonaxj]

The motor mount brackets are on. By the rules, you can move the engine back 8" and down one. I settled for moving it back 4-1/2" and down about 1/2". With a 107" WB, a flat belly and the motor moved back 8", the rear drive shaft angle was going to be super steep.
http://img.photobucket.com/albums/v16/arizonaxj/F-Toy/hendrix_mounts_1.jpg

[arizonaxj]

The T-case skid is done! I cheated and re-used my old Marlin T-case mount. First the sides had to be cut down to fit between the frame rails.
http://img.photobucket.com/albums/v16/arizonaxj/F-Toy/marlin_mnt.jpg
Next the inside of the frame rails were plated with 1/8" cold rolled, and some brackets were fabbed. Here is a before pick of how far down the Marlin skid set.
http://img.photobucket.com/albums/v16/arizonaxj/F-Toy/skid_before.jpg
Here is the after, I didn't go completly flat belly. With the skid setting 3/4" below the frame rails, the tranny and T-cases set parallel with the frame rails.
http://img.photobucket.com/albums/v16/arizonaxj/F-Toy/skid_after.jpg
A couple more from above and below.
http://img.photobucket.com/albums/v16/arizonaxj/F-Toy/skid_after_top.jpg
http://img.photobucket.com/albums/v16/arizonaxj/F-Toy/skid_after_bottom.jpg

[arizonaxj]

Finished a frame cross member behind the T-case.
http://img.photobucket.com/albums/v16/arizonaxj/F-Toy/X-member_mid.jpg
http://img.photobucket.com/albums/v16/arizonaxj/F-Toy/X-member_mid_rear.jpg

[nblehm]

Looks good. whats the belly clearance?

[arizonaxj]

It's 26-1/4". I'm guessing it's going to be a bit lower when all the weights on it, and I remove more leafs.

[Gabe Watt]

this is turning out to be one awesome rig!

[arizonaxj]

this is turning out to be one awesome rig!

Thanks!!

So far the progress this weekend has been slow on my stuff. Today I had a couple guy's over bending up some of the new frame members for a 4-link project on a CJ we are working on. I'll get some pics of that up pretty soon.
I made up some plates to beef up the area where the Hendrix chassis is being tied to the frame. It's 1/8" cold rolled. The entire perimeter of each plate is welded, and plug welded in four spots. Since the chassis is 1-3/4" DOM, I used the same for the mounts.
http://img.photobucket.com/albums/v16/arizonaxj/F-Toy/chassis_tie_short.jpg
Right now it's mounted in three places on each side. I still need to do the front and rear mounts.
http://img.photobucket.com/albums/v16/arizonaxj/F-Toy/chassis_mnt_rear.jpg
I ended up mounting the bottom of the bottom rails of the chassis two inches above the top of the frame rails. Here is a shot with one seat just setting in it. I'm still going to be cutting it close on the three inch headroom rule.
http://img.photobucket.com/albums/v16/arizonaxj/F-Toy/chassis_mnt_w_seat.jpg

[arizonaxj]

Rear chassis mounts.....

http://img.photobucket.com/albums/v16/arizonaxj/F-Toy/rear_chassis_mnts.jpg

[arizonaxj]

I added some side panel bracing. This will allow the side panels to set sub-flush from the outside of the tube 3/4".

http://img.photobucket.com/albums/v16/arizonaxj/F-Toy/panel_bracing.jpg

[nblehm]

nice... looks like a buggy now.

[Hoofmann]

This thing is sick, I wouldn't mind having one myself ;)
Toyota love!

[arizonaxj]

Thanks! It's getting there SLOWLY.

[arizonaxj]

I got started making floorboards and seat mounts. the passenger side is easy, and pretty much done.
http://img.photobucket.com/albums/v16/arizonaxj/F-Toy/flrbrd_right.jpg
The drivers side isn't going to be as easy. After rotating the engine, tranny and all up to get a flat belly, the header is going to hit the floorboard pretty bad.
One suggestion is to heat the headers with a torch and bend it down a little.
Any other suggestions?
http://img.photobucket.com/albums/v16/arizonaxj/F-Toy/flrbrd_left_1.jpg
http://img.photobucket.com/albums/v16/arizonaxj/F-Toy/flrbrd_left_2.jpg

[arizonaxj]

After using a cheater bar and a come-along, I got the header pulled down most of the way. I chopped a big chunk out of the tube for the floorboard, but I still think the header needs to be bent a little more.
http://img.photobucket.com/albums/v16/arizonaxj/F-Toy/flrbrd_left_3.jpg

[arizonaxj]

This weekend so far, the steering box and radiator are mounted, the winch will be finished up this afternoon and most of the front stinger is done. Well, tacked anyway. Too damn hot to get much done! It's been 110 in the shade on my back porch the last two days.
http://img.photobucket.com/albums/v16/arizonaxj/F-Toy/stinger_1.jpg
http://img.photobucket.com/albums/v16/arizonaxj/F-Toy/stinger_2.jpg

[arizonaxj]

I added a couple more tubes and got the headlights in...
http://img.photobucket.com/albums/v16/arizonaxj/F-Toy/stinger_3.jpg

[HotSEXJ]

lookin great!

[IceXJ]

wooo. i love it.

what color is it gonna be?

[arizonaxj]

wooo. i love it.

what color is it gonna be?


Hmmnnnnn, I dunno. Maybe semi gloss black for the stock frame, yellow for the cage and blue side panels. I have been so busy building, I did'nt think about that too much.

This weekends progress so far. Got started bending up tubing to support the firewall.
http://img.photobucket.com/albums/v16/arizonaxj/F-Toy/Firewall_mount.jpg
X-brace behind the seats...
http://img.photobucket.com/albums/v16/arizonaxj/F-Toy/X-brace.jpg
And a 16gal RCI fuel cell from Crossed Up Offroad.
http://img.photobucket.com/albums/v16/arizonaxj/F-Toy/RCI_tank.jpg

[IceXJ]

:rock:

oh my god i want one.

seriously, if i had a welder and knew how to weld, it's all i'd be doing 24/7

[bogan]

that is fecking sick man. keep up the good work

[HotSEXJ]

did you get the header squared away?

[arizonaxj]

Mostly. I think I'm going to need to bend it down a little farther, and wrap it with some exhaust wrap. I'll probably try to build some kind of heat shield too.
Right now I'm having a hard time figuring out how, and where to mount the pedals. I have to push the firewall farther forward than I want to get enough leg room.

[arizonaxj]

Got started mocking up the pedals. I decided to go with a Wilwood pedal assy. It's got a 6.25:1 ratio and a ballance bar to adjust the bias between front and rear braking. I talked to the guy's at Wilwood and they suggested using 3/4" bore master cylinders for the front brakes, and the clutch, and a 7/8" bore for the rear. It's going to be super tight. Right now I only have 36" from the back of the seats to the front of the pedals.
http://img.photobucket.com/albums/v16/arizonaxj/F-Toy/pedals_1.jpg
http://img.photobucket.com/albums/v16/arizonaxj/F-Toy/pedals_2.jpg

[arizonaxj]

Close to finished pedal bucket....

http://img.photobucket.com/albums/v16/arizonaxj/F-Toy/pedals_3.jpg
http://img.photobucket.com/albums/v16/arizonaxj/F-Toy/pedals_4.jpg

[arizonaxj]

Remote mounted reservoirs.
http://img.photobucket.com/albums/v16/arizonaxj/F-Toy/reservoirs.jpg

[B E N]

lookin good man! :thumbsup:

[arizonaxj]

The steering is about 80% complete. I need to make one more bracket, and weld it up. Crossed Up Offroad was able to pretty much put together a steering kit, including the wheel, quick release, needle bearing U joints, oversize heim joints, 3/4" DOM tubing and some different brackets. It's a pretty sweet set up!
http://img.photobucket.com/albums/v16/arizonaxj/F-Toy/steering_2.jpg
http://img.photobucket.com/albums/v16/arizonaxj/F-Toy/steering_1.jpg

[HotSEXJ]

I've never seen dual master cylinders before - am I a n00b or is that just pimp?

[nblehm]

am I a n00b
:yes:


looks like its coming together pretty quick. I have been looking at the class online a bit, seems like a cool idea. Nice to see a class that doesnt cost an arm and a leg to be competitive in

[arizonaxj]

I've never seen dual master cylinders before - am I a n00b or is that just pimp?

They work great for engines that run at low rpm and have low manifold pressure. Fully mechanical, no vacuum booster.

[arizonaxj]

:yes:


looks like its coming together pretty quick. I have been looking at the class online a bit, seems like a cool idea. Nice to see a class that doesnt cost an arm and a leg to be competitive in

Not as quick as I was hoping. Too much OT at work.

The next Prorock in Cougar Buttes should have close to 15 F-toys. From what I hear, some other people are flying out to take a look before they start building theirs over the winter. For what it coast to build, an F-toy is hard to beat if you want a budget buggy, and you want to take a shot at competing.

[arizonaxj]

I started beefing up the fixed end of the rear spring hangers. After inboarding the springs, it makes for a pretty weak set-up. All the attaching points on the frame are plated with .12" cold rolled, welded 100% (or will be, some of it's still just tacked) and plug welded in three places. Then some 1-1/2" 11ga tubing gussets are tied to the frame.
I may put another tube from the top of the hanger to the cross member, but it's probably overkill.
http://img.photobucket.com/albums/v16/arizonaxj/F-Toy/hanger_brace.jpg
This is a shot from the bottom...
http://img.photobucket.com/albums/v16/arizonaxj/F-Toy/up_skirt.jpg
And a new crossmember. This picture got me a little spooked. It looks like the hangers are bent/warped up. It's just the pic.
http://img.photobucket.com/albums/v16/arizonaxj/F-Toy/X-member_new.jpg

[KIAKillerXJ]

i hadn't checked in on the build in a while. very nice progress! if only I had time, money, skills, and a place to wheel it when I was finished ;)

[arizonaxj]

i hadn't checked in on the build in a while. very nice progress! if only I had time, money, skills, and a place to wheel it when I was finished ;)

Thanks...

Tonight I got the rear shock mounts tacked in. The back half is almost done.

http://img.photobucket.com/albums/v16/arizonaxj/F-Toy/shockmounts_rear.jpg

[nblehm]

so is it done yet? :lol:

[Lubes]

SICK fab work, great ideas and chit you have going into it, and great progress pics, but I fukking hate F-Toys with a severe passion.

[arizonaxj]

Thanks, but why do you hate F-toys?

[arizonaxj]

so is it done yet? :lol:

I wish! My friends have been getting out almost every weekend, and doing a lot of night runs. I'm jonsin to go. I havn't been wheeling since the first part of April.

[arizonaxj]

I'm down to the point where all I have left is little stuff...... Lot's of little stuff. I worked on it all day for the last three days, and every night after work, and it doesn't really look any different. I stripped all the factory brackets off a newer rear axle, It's 3" wider than my old 85 axle and got it mounted.
Today I made up a bunch of little mounts for the fire wall and floor pans.
http://img.photobucket.com/albums/v16/arizonaxj/F-Toy/tabs.jpg
Got the firewall done and battery box mounted. The pic only shows half of the firewall. Most of the firewall will be .093 thick 5052 alum. The battrey box is from Blue Torch.
http://img.photobucket.com/albums/v16/arizonaxj/F-Toy/firewall.jpg
Also started beefing up the cage in a few spots. Here I added some "wing window" bars, and some more gussets, and trick tabs for the roof. The gussets are hard to see.
http://img.photobucket.com/albums/v16/arizonaxj/F-Toy/wing_window.jpg

[arizonaxj]

This is the rest of the firewall. The footbucket area is 18ga cold rolled. It's a lot easier to work with and weld than alum. That is with the tools I have anyway.
http://img.photobucket.com/albums/v16/arizonaxj/F-Toy/firewall_1.jpg

[arizonaxj]

I'm finally starting to get close. Most of the fab is finished. The front shock mounts were the last major thing left to do and that's done.
I still need to burn them in but that wont take much.
http://img.photobucket.com/albums/v16/arizonaxj/F-Toy/shockmounts_front.jpg
The dash, fire wall, and floor are done too. I still need to make a tranny tunnel, but I'll do that a little later. I'm planning to keep the interior very basic. Still needs gages and a switch panel. That was all ordered today.
http://img.photobucket.com/albums/v16/arizonaxj/F-Toy/dash.jpg

[arizonaxj]

This is the drivers side shock mount. I had to bend one of the uprights to clear the steering shaft. And the sheetmetal pedal bucket in the background.
http://img.photobucket.com/albums/v16/arizonaxj/F-Toy/shockmounts_front_ds.jpg

[snocross2xtremes]

that thing is bad ***! iv always wanted to find at older toy like that but there like imposible to find in mich well at least thats not rusted away lol

[arizonaxj]

Thanks!
yeah down here is southern AZ their are lots of old cars on the road. If you see rust on anything, it's from someplace else.

[HotSEXJ]

Seabass for the switch / gauge panel?

[arizonaxj]

Seabass for the switch / gauge panel?

Funny you should say that. Look what showed up today.
http://img.photobucket.com/albums/v16/arizonaxj/F-Toy/switch_panel.jpg
Here is the back, pre-wired and ready to go.
http://img.photobucket.com/albums/v16/arizonaxj/F-Toy/switch_panel_2.jpg
I got a bunch of other stuff from seabass too, http://www.12voltguy.com/
More later....

[nblehm]

nice i like that switch panel

[arizonaxj]

nice i like that switch panel Seabass make some cool stuff.


No progress for me this weekend. My welder took a dump. It started having problems when I was doing some tab work, so I think all the fab work that is already done is fine. The problem is very apperent, and it just started. I first noticed it with tack welds last week. They just didn't want to hold. I keep turning up the voltage till they would, but then the voltage was almost all the way up. Never had this problem before. The liner is pretty fresh and I change tips right away whenever I have any problems.
I welded up a test piece out of 1x2x.12 wall, and 1-1/2" 11ga and did a "hammer test".
I had to beat the crap out of it with a 8lb sledge but......
http://img.photobucket.com/albums/v16/arizonaxj/junk/hammer_test_1.jpg
I went over everything looking for an obvious probelm and couldn't find anything.
Then I double checked all my settings, put on a new tip, re adjusted the drive roller and did another test, running it hot too......
http://img.photobucket.com/albums/v16/arizonaxj/junk/hammer_test_2.jpg
I think the voltage regulator is shot. I'm going to take it into industrial welder repair tomorrow.

[Vetteboy]

I think the voltage regulator is shot. I'm going to take it into industrial welder repair tomorrow.

Mine sometimes starts running cold like that - turns out it's one of the diodes connecting the main power source to the capacitors. They'll go when a) the welder is operated under-powered for a long period of time (like on a weak supply line or not enough amps available) or also if you have a crappy ground and there's a lot of spatter happening. I recently just blew up a second one so I've taken to keeping a spare around. Gonna look into wiring in a new 30A breaker just for the welder too.

[arizonaxj]

Mine sometimes starts running cold like that - turns out it's one of the diodes connecting the main power source to the capacitors. They'll go when a) the welder is operated under-powered for a long period of time (like on a weak supply line or not enough amps available) or also if you have a crappy ground and there's a lot of spatter happening. I recently just blew up a second one so I've taken to keeping a spare around. Gonna look into wiring in a new 30A breaker just for the welder too.

My main service is 200A. From my main, I have a 50' run of 6ga stranded wire to my shop. From there I have a 30A breaker and then about 12' of 6ga to my outlet. I should probably check that out and see if that's a big enough drop to cause me problems. Thanks!

[arizonaxj]

I think I took care of the welder problem. Picked this up today. The price was right, so time will tell.
http://img.photobucket.com/albums/v16/arizonaxj/junk/New_welder.jpg

[arizonaxj]

So far the new welder is working great. I dont have a lot of time to work on this right now, so the progress is SLOW!!!!
I did get the front bump stops on today. I got them from Mike at Crossed Up. I think they are going to compress about 1 to 1-1/2". I set them up with 1" clearance setting on flat ground. When they fully compress, I'm expecting about 2" or a little more compression at the bump stop and about 6" travel on the shock. I'm sure I'll have to dial it in a little more. My gut feeling is that I'll have to add a spacer and limit up travel a little more.
http://img.photobucket.com/albums/v16/arizonaxj/F-Toy/bumpstop_front.jpg
I also made up some mounts for my switches. More "speed holes"
http://img.photobucket.com/albums/v16/arizonaxj/F-Toy/switch_mounts.jpg

[Timmay]

Nice welds. Props to ya for a nice rig too. :thumbsup:

[arizonaxj]

Nice welds. Props to ya for a nice rig too. :thumbsup:

Thanks Timmay! I have been checking out your work for a while now. Nice!!!

[nblehm]

anything new?

[arizonaxj]

anything new?

Unfortunatly no! I'm slammed at work, and don't have much free time right now. I'm hoping to finish the rest of the Fab this weekend and start tearing it down for paint. I really need ot get it done soon. Wheeling season in AZ is starting to really get going.....

[arizonaxj]

I got a little bit done today. Just small stuff, but that's mostly what I have left to do.
Mounted the radiator overflow res. Found a good spot to get it out of the way.
http://img.photobucket.com/albums/v16/arizonaxj/F-Toy/res.jpg
I'm not quite finished with the air intake. I needed to relocate the MAS, and I don't have room for the stock air box. This is a piece of 3" exhaust tubing that was mandrel bent to a "U" shape. I cut it in two, right in the middle. I got it from a hot rod shop.
http://img.photobucket.com/albums/v16/arizonaxj/F-Toy/u_bend.jpg
This is after adding a piece in the middle, trimming the ends and welding it up.
http://img.photobucket.com/albums/v16/arizonaxj/F-Toy/u_bend_extended.jpg
Here it is zip tied in place. I still need to make a bracket and get an air filter. I'll probably use a 3" K&N cone filter.
http://img.photobucket.com/albums/v16/arizonaxj/F-Toy/u_bend_mounted.jpg

[Vetteboy]

Isn't it funny how that kind of stuff demotes itself to the bottom of priority list?

My exhaust is gonna be a *****. I know it is, I've looked at it already. However I've somehow decided to wait forever until dealing with it.

Finally I got my wheelwell stuff started today, that was another ***** thing that I put off for months.

Your thing is lookin good there - can't wait to see it move from the garage. :D I got my front axle on springs the other day and that was just about the coolest feeeling ever.

[XJ Fanatic]

that birds nest over to the left side of that pic looks like its gonna be fun.....

[arizonaxj]

Isn't it funny how that kind of stuff demotes itself to the bottom of priority list?

My exhaust is gonna be a *****. I know it is, I've looked at it already. However I've somehow decided to wait forever until dealing with it.

Finally I got my wheelwell stuff started today, that was another ***** thing that I put off for months.

Your thing is lookin good there - can't wait to see it move from the garage. :D I got my front axle on springs the other day and that was just about the coolest feeeling ever.

All the things I have been puttin off are piling up. The little stuff like the air intake, power steering res, and mounting the igniter is taking me forever. I can't really find a decent place for the steering res, where it's the highest point in the system.
It's going to be great to get it out of the garage!
Good job on the springs!

[arizonaxj]

that birds nest over to the left side of that pic looks like its gonna be fun.....

I'm NOT looking forward to that!

[arizonaxj]

Here are a couple more progress pics. The front end and winch mount is finished. I added some expanded metal to go between the radiator and the winch to keep the cable out of there.
Also the hydro assist steering is on. I still need to mod the steering box.
http://img.photobucket.com/albums/v16/arizonaxj/F-Toy/front_1.jpg
The tail light and license plate mounts are done too. The fab work is almost finished. I just need to make an anti wrap bar for the rear and a place for the cooler, tools and a place for my dogs to ride.
http://img.photobucket.com/albums/v16/arizonaxj/F-Toy/tail_lights_1.jpg
Here is one with the LED's in. I had to cover up the plate because the reflection was making my camera screw up.
http://img.photobucket.com/albums/v16/arizonaxj/F-Toy/tail_lights_2.jpg

[arizonaxj]

Got this Trail-Gear rear diff cover a couple days ago. For the money, it's pretty sweet!
http://img.photobucket.com/albums/v16/arizonaxj/F-Toy/TG_rear_diff_cover.jpg
Here is an installed pic. I like the way it fit's on axles that have relocated spring perches to correct pinion angles. The bottom stays pretty flat, where the pipe cap covers tend to hang down a bit lower. Evnetually I'll cut the bottom of the diff and plate it to gain a little ground clearance, but for now, I just want to get it on the trail.
http://img.photobucket.com/albums/v16/arizonaxj/F-Toy/TG_rear_diff_cover_installed.jpg

[B E N]

:pimp:

[arizonaxj]

Thanks BEN!

Deer season is over, so I'm getting back to work on my rig. It's only going to be a two seater so I built an area behind the seats for storage and for the dogs to ride. I picked up some ammo cans and mounted them behind the seat too. My wife is going to make a big padded cover to go over the expanded metal.
http://img.photobucket.com/albums/v16/arizonaxj/F-Toy/ammo_can_mount.jpg
http://img.photobucket.com/albums/v16/arizonaxj/F-Toy/rear_storage.jpg
The anti wrap bar is finished too. The tubing is 1-1/2" x 1/4" wall DOM mounted with heims. The heim at the shackle end has high misalignment spacers and should have no clearance issues. The shackle is made out of 2" wide x 3/8" thick hot rolled, mounted with Toyota leaf spring bushings and an 18MM shackle bolt. Still need to make up some spacers so I can get rid of the big stacks of washers.
http://img.photobucket.com/albums/v16/arizonaxj/F-Toy/wrap_bar_1.jpg
http://img.photobucket.com/albums/v16/arizonaxj/F-Toy/wrap_bar_2.jpg
http://img.photobucket.com/albums/v16/arizonaxj/F-Toy/wrap_bar_3.jpg

[Vetteboy]

I'm not sure I entirely like the idea of having the wrap bar mount below the shackle pivot point. Seems like it leaves the possibility of having the axle wrap and try and invert that shackle up.

Definitely coming along though! Keep it up.

[arizonaxj]

I don't like it either, but I couldn't find a good way to mount it the other way around. Or at least a way that I liked. The shackle is 3" center to center, and at ride height is vertical. I don't think it can move far enough for and aft to invert.

[KIAKillerXJ]

I'm not sure I entirely like the idea of having the wrap bar mount below the shackle pivot point. Seems like it leaves the possibility of having the axle wrap and try and invert that shackle up.

Definitely coming along though! Keep it up.

whew! glad I'm not crazy. I'm trying to visualize the movement in my head, and I just confused myself:lol:

the build is looking great, I bet you can't wait to get it on the trails!

:ineedashop: :mad:

[Vetteboy]

whew! glad I'm not crazy. I'm trying to visualize the movement in my head, and I just confused myself:lol:

Well, there were two cases I was thinking of, not sure which one would do it because it depends on the shackle angle and length for the rear springs.

If the axle's drooped and this causes the anti-wrap shackle to get pulled towards the rear of the truck, if it tries to wrap, it could flip the shackle up a little more which would force the axle down slightly more and it might get to a point where it would bind up or invert - with the shorter anti-wrap shackle this is more of a possibility but I don't know how likely it is.

If the axle's stuffed and this causes the anti-wrap shackle to get pulled towards the rear of the truck, I think you'd have a better chance, because you've got the weight of the vehicle preventing the wrap bar from trying to force the axle up further.

Make sense? Like I said, I dunno how much of an issue it would really be. Also it depends on how much the springs can resist wrap on their own.

[arizonaxj]

Oh yeah, that makes sense. I have been thinking the exact same thing. That's why I went with a little longer shackle. The springs are pretty soft, and I think they are going to want to wrap up pretty bad. Hopfully it's going to work, it's wheeling season here, and I'm tired of working on it.

[Vetteboy]

Oh yeah, that makes sense. I have been thinking the exact same thing. That's why I went with a little longer shackle. The springs are pretty soft, and I think they are going to want to wrap up pretty bad. Hopfully it's going to work, it's wheeling season here, and I'm tired of working on it.

Yeah it probably will. I'm probably over-thinking it like usual.

Tired of working on it? Tell me about it. It's becoming an F'ing chore to go over to the shop every day after work and get something done on mine. It's all coming together though, slowly.

[arizonaxj]

Yeah it probably will. I'm probably over-thinking it like usual.

Tired of working on it? Tell me about it. It's becoming an F'ing chore to go over to the shop every day after work and get something done on mine. It's all coming together though, slowly.

It's tough but you just got to get a little done everyday if you can. It's funny, some of the stuff I used to like making like cool little gussets and brackets, I avoid now. I would rather spend a few bucks and buy them.
Keep at it. You'll get there! At least thats what I tell myself.

[PhatYJ]

I probably would have moved the upper shackle mount back a little further (or make the traction bar longer), thus making the traction bar closer to a 90deg angle with the shackle. That would help a lot with that setup.

Looks fawkin sweet.

[arizonaxj]

I probably would have moved the upper shackle mount back a little further (or make the traction bar longer), thus making the traction bar closer to a 90deg angle with the shackle. That would help a lot with that setup.

Looks fawkin sweet.

Some of the traction bar is poor planning on my part. It was kind of an afterthought. Without a lot of work, it would be hard to make the bar longer, and have anything substantial to mount it to. I'm hoping it works okay here, but it could be better for sure.

[arizonaxj]

The dates have been released for the Formula Toy events, east and westcoast with an east/westcoast shootout at Boyd Texas in Sept. This is great for me. Two of the Westcoast events are in Arizona and less than 2 hours away. http://www.pirate4x4.com/forum/showthread.php?t=527671
Also, there is now an official Formula Toy chassis vendor on the east coast. http://www.pirate4x4.com/forum/showthread.php?t=527595
For those interested in competing, this is probably the cheapest way to do it.

[nblehm]

Rig looks good, getting ever closer :thumbsup:


the boyd texas course is cool.

[arizonaxj]

Rig looks good, getting ever closer :thumbsup:


the boyd texas course is cool.

Thanks! Still taking forever as you can see. If I had two weekends to work on it it would be finished. I better get it done soon. That first comp is only 7-8 weeks away.

[IceXJ]

:ineedashop: :mad:

i'm 100% with you on that one.

Arizona, it looks freakin' :pimp: !!!

[arizonaxj]

i'm 100% with you on that one.

Arizona, it looks freakin' :pimp: !!!

Thanks!

[arizonaxj]

Today I got about all the fab finished, and the paint is almost finished. Many thanks to one of my friends Doug for coming over and helping with the paint.
Still have a wiring nightmare to get thru, but damn it's getting close.
http://img.photobucket.com/albums/v16/arizonaxj/F-Toy/paint.jpg

[nblehm]

looks great man.... paint made it look like a complete rig for sure, I'm sure you're dying to wheel it now :lol:

[arizonaxj]

looks great man.... paint made it look like a complete rig for sure, I'm sure you're dying to wheel it now :lol:

Oh man it's killing me! I finished the exhaust yesterday too, but I still have quite a bit to do. I'm shooting for getting it out the Saturday but I still need to plumb and wire it. The wiring is going to kick my azz. I have no skills in that area.

[arizonaxj]

I was making pretty good progress till I got to the wiring. Anyone want to come fix this for me?
http://img.photobucket.com/albums/v16/arizonaxj/F-Toy/rats_nest-1.jpg

[Vetteboy]

:wave:

I'd do it, but I already passed that part.

http://www.phatserver.net/~chris/bronco/wire.jpg

Unless of course, someone was willing to pay airfare, food, and beer costs. Then I might be persuaded. :)

FWIW I just spent nearly 6 hours doing overhead welding w/fluxcore under my XJ. I feel no sympathy for wiring right now. :f2:

[arizonaxj]

Oh damn!!! Since every time I leave the house I end up spending between $150 and $200 (I left the house 4 times this weekend) I don't think I can afford even the pizza. I guess I'm on my own!
Flux core? Why?

[nblehm]

yikes... wiring is not my favorite, glad I wont be doing any :f2:

[Vetteboy]

Oh damn!!! Since every time I leave the house I end up spending between $150 and $200 (I left the house 4 times this weekend) I don't think I can afford even the pizza. I guess I'm on my own!
Flux core? Why?

MIG's busted (still trying to troubleshoot electrical issues), and overhead SMAW would have been an even more exquisite form of torture, especially since half of it was welding to unibody sheetmetal.

[arizonaxj]

yikes... wiring is not my favorite, glad I wont be doing any :f2:

Yeah, wiring pretty much sucks!

[arizonaxj]

MIG's busted (still trying to troubleshoot electrical issues), and overhead SMAW would have been an even more exquisite form of torture, especially since half of it was welding to unibody sheetmetal.

It seems that none of this stuff is ever easy, or cheap....

So your probably getting a pretty good collection of welding scars.

[Vetteboy]

It seems that none of this stuff is ever easy, or cheap....

So your probably getting a pretty good collection of welding scars.

Yeah. Looks like I've come down with some sort of inverted chicken pox. Luckily this stuff's about 90% done so I can begin the healing process shortly.

[Timmay]

Pussies. :f2:

Nice looking buggy man. :thumbsup: Wanna send me your bender?

[arizonaxj]

Pussies. :f2:

Nice looking buggy man. :thumbsup: Wanna send me your bender?

You NEED a bender!

Thanks

[Scott-XJ]

I was making pretty good progress till I got to the wiring. Anyone want to come fix this for me?
http://img.photobucket.com/albums/v16/arizonaxj/F-Toy/rats_nest-1.jpg
Mmmm Spaghetti! :p

[arizonaxj]

Finally, it runs!!!!

I bought an engine harness from Off Road Solutions (ORS). http://www.offroadsolutions.com
They were awesome to deal with. My harness came out great! It took me all of about 2hrs to put it in. It took that long because I'm super slow with electrical stuff. Turned the ignition on, pushed the start button and it fired right up. I couldn't belive it. I thought sure after 6 months of sitting in my garage the motor would take a little bit to get it running.

I'm down to a little wiring like the alternator and tail lights. Then the roof, hood and side panels, and it's built.

Sunday is going to kick ***! I havn't been wheeling since the last weekend of April!

[nblehm]

sweet :rock:

I was just wondering about this build

[DrSpaz]

I was making pretty good progress till I got to the wiring. Anyone want to come fix this for me?
http://img.photobucket.com/albums/v16/arizonaxj/F-Toy/rats_nest-1.jpg


That's what my Hella 500's looked like half way through my install.

[arizonaxj]

Today was the first time out with the new ride. I need to fix up a couple little suspension issus. the front springs are not flexing very well. I need to move the bump stop up about 1" and open up the spring clamps to let them droop a little better.
Here are a couple pics.
http://img.photobucket.com/albums/v16/arizonaxj/F-Toy/First_trip_1.jpg
http://img.photobucket.com/albums/v16/arizonaxj/F-Toy/First_trip_2.jpg
http://img.photobucket.com/albums/v16/arizonaxj/F-Toy/First_trip_3.jpg
And one of my Wife driving. I missed the good shot, and here it looks pretty flat. Still pretty cool!
http://img.photobucket.com/albums/v16/arizonaxj/F-Toy/kris_1.jpg

[Jeepin Jason]

:rock: :driving: :chug: :thumbsup:

[Timmay]

Tits!!! Good job man, looks good.

Oh, btw, i'll have a bender and some bend tech software soon enough. ;) Watch out... i'm about to go crazzyyy with the tube.

[Vetteboy]

Nice work, Pat! Gotta be a great feelin to have it rollin on its own again.

Just got mine sittin on 4 springs & tires over the weekend, hopefully it won't be too long now...

[arizonaxj]

Tits!!! Good job man, looks good.

Oh, btw, i'll have a bender and some bend tech software soon enough. ;) Watch out... i'm about to go crazzyyy with the tube.

Your going to love having a bender. Be sure to put up some pics, with your welding skills, I'm sure whatever you make its going to kick ***.

[arizonaxj]

Nice work, Pat! Gotta be a great feelin to have it rollin on its own again.

Just got mine sittin on 4 springs & tires over the weekend, hopefully it won't be too long now...

Oh man, I was working on it till 2 this morning and ended up kind of hacking some of the wiring together just so I could go. It felt great to be wheeling again. By next weekend I think I'll have the wiring done up a little better and the roof, hood and side panels on.

Keep at it Vette, youre going to get there. When does your wheeling season start there? For us, it's on right now!

[Vetteboy]

Wheelin season? :lol:

Just depends on how well you can deal with cold weather and snow. ;)

[offroadman83]

Props man that thing is sweet:rock: -----------Kyle

[arizonaxj]

Here it's dealing with the heat. Today it was almost 80 this morning and then it cooled off to about 65-70. As soon as it gets cold and/or wet...... I go home. I'm not prepared for that kind of stuff. I would be wanting my XJ back. Oh yeah, windows up, heater on.....

[arizonaxj]

Props man that thing is sweet:rock: -----------Kyle

Thanks!!!

[Vetteboy]

Here it's dealing with the heat. Today it was almost 80 this morning and then it cooled off to about 65-70. As soon as it gets cold and/or wet...... I go home. I'm not prepared for that kind of stuff. I would be wanting my XJ back. Oh yeah, windows up, heater on.....

Yeah, exactly. 'Cept I hate having the windows up. Blower on hi usually takes care of the rest. That and a few truckloads of palettes back at camp. I like goin out in the winter, the snow turns even the easiest stupid trails into new challenges.

Summer here never gets bad enough that you can't handle it comfortably with half-doors and a t-shirt, and the A/C in my stupid XJ still blows ice-cold. :)

[nblehm]

Nice :rock: I like the look of that thing. SO overall are you glad you went this way?

[arizonaxj]

Nice :rock: I like the look of that thing. SO overall are you glad you went this way?

That's still hard to say. I'll know more after my first comp. If I was building strictly a trail rig, I don't think I would go to this much work and not link it.

[RuggedJeep]

you gonna stick with the MT/R's for the comps ? I could see them working well in AZ as they do here on really hot summer days, they get super sticky.

[arizonaxj]

you gonna stick with the MT/R's for the comps ? I could see them working well in AZ as they do here on really hot summer days, they get super sticky.

I'm going to run them for now. They work great out here, but the sidwalls cut pretty easy. I wasted three of them last year.

[nblehm]

mt/rs are decent until they get wet... but being in az you dont have a problem with that :lol:

[arizonaxj]

mt/rs are decent until they get wet... but being in az you dont have a problem with that :lol:

No doubt! It never f'n rains here.

[arizonaxj]

We got out today for the first real trail run. We hit Highway to He!! near Florence AZ.
So far the buggy is working great, other than driver error.
One week to PUSU. Should be fun getting my azz handed to me by the unlimited guy's.
Here are a couple pics from today.
http://img.photobucket.com/albums/v16/arizonaxj/F-Toy/F-toy_1.jpg
http://img.photobucket.com/albums/v16/arizonaxj/F-Toy/F-toy_2.jpg
And the driver error on my less than 24hr old sheetmetal.
http://img.photobucket.com/albums/v16/arizonaxj/F-Toy/oops.jpg

Here is a link to the rest of the pics....
http://www.kodakgallery.com/Slideshow.jsp?mode=fromshare&Uc=5chs2wt.a0ufge7x&Uy=n30fsj&Ux=1

[RuggedJeep]

Awesome pics! Man i love the AZ trails, alot like socals, hopefully ill get out there next year on my journey to colorado.
Nice body work to :lol:

[arizonaxj]

We were running with a bunch of guy's from socal. They came out and camped for about a week.
If you make it thru here, be sure to look me up. We'll get a run together!

[RuggedJeep]

Cool, i was checking out the pics of the Socal guys.. looks like a fun trip. http://good-times.webshots.com/album/556714233vpMTjU?start=0

[nblehm]

Cool man... be sure to post up pics from PUSU!

[arizonaxj]

Cool, i was checking out the pics of the Socal guys.. looks like a fun trip. http://good-times.webshots.com/album/556714233vpMTjU?start=0

Cool! Where did you find those?

[arizonaxj]

Cool man... be sure to post up pics from PUSU!
You know it!

[RuggedJeep]

Cool! Where did you find those?
On another board im on. There are links to several albums http://www.jeepaholics.com/support/topic.asp?TOPIC_ID=52445

[Hoofmann]

That Toy is sweet! Nice work.

[RuggedJeep]

Any updates. ? Hows the toy doin ?

[arizonaxj]

Any updates. ? Hows the toy doin ?

No real big updates. I did Put Up or Shut Up early in January and had some breakage. The courses were not F-toy friendly at all, but I expected that. Day one I broke a rear axle. A friend brought me one of his spares in the middle of the night so I could run Sunday. On my third course Sunday, I broke a front ring and pinion and that ended my day.

This weekend is WE-rock Vegas. I'm pretty stoked to be going. The rig is pretty much ready to go. I added a twin stick to my second T-case, new front R&P and new Poly Performance 4340 Forged Chromoly Axles. I'm trying to find the time to plumb and wire in solenoid valve line locks to my front and rear brakes but that may have to wait till I get back.

I started putting together our team page, but it still needs head shots. http://www.we-rock.cc/team_list.php?wts=show&wvalue=292

Here are a couple from PUSU. I'll post some from Vegas when I get back.
This is where I broke the R&P...
http://img.photobucket.com/albums/v16/arizonaxj/pusu/pusu_pat_4.jpg
http://img.photobucket.com/albums/v16/arizonaxj/pusu/pusu_pat_3.jpg
Gave my sheet metal a little lovin here.
http://img.photobucket.com/albums/v16/arizonaxj/pusu/pusu_pat_2.jpg

[Jeepin Jason]

No real big updates. I did Put Up or Shut Up early in January and had some breakage. The courses were not F-toy friendly at all, but I expected that.

how so? designed for the smaller moon buggies or something?

[arizonaxj]

how so? designed for the smaller moon buggies or something?
It was a "run what you brung" type event, no seperate classes. The courses were designed to put moon buggy's on their lids. Lot's of people timing out on courses in very built Pro mod cars and moon buggys. For most of the F-toys, and a lot of other folks it wasn't about completing a course, it was more about getting a couple progression points before timing out and being happy with a 38. F-toy's are fun, and probably the cheapest way to compete, but they are still on leaf springs, Toyota driveline parts, low HP, high COG, and we can't do front digs. Well, if you had a rear driveline dissconect you could have used it at PUSU, but it's not legal in regular F-toy comps.
Vegas should be a lot better for me because I will be in the F-toy class, and on courses that I have a better chance of completing.

Here are the scores from both days. Most of the courses were killing everone. I spent so much time broken, I have a lot of 40's. And I was miss scored once and given a 50.

Day 1
http://img.photobucket.com/albums/v16/arizonaxj/pusu/day1.jpg
Day 2
http://img.photobucket.com/albums/v16/arizonaxj/pusu/scores3pm.jpg

[Lubes]

The courses were evil, for sure.

[arizonaxj]

The courses were evil, for sure.

You gunna be in Vegas?

[arizonaxj]

Now that I went to a newer rear axle assy, it's 3" wider than the 85 and older. I had to add 1.5" spacers to each side up front to even it out with the rear. With 2" BS wheels it's WIDE!!! I'm going to 3-3/4" BS, and weld on bead locks. That's a total of 3-1/2" narrower. I'll lose a little bit of sidehill, but it should steer a little better.

I got some Black Rock Crawler wheels from Crossed Up Offroad and started designing my own outer rings. I already have the inner rings so I'm going to go ahead and use those. The outer rings will be made at Crossed Up.
Here are some models of the rings I'm planning to use. Pretty basic, nothing too fancy.

The inners,
http://img.photobucket.com/albums/v16/arizonaxj/DIY%20Beadlocks/15in_ring_rockstomper.jpg

Outers,
http://img.photobucket.com/albums/v16/arizonaxj/DIY%20Beadlocks/15in_outter_spline.jpg

And the complete assy including hardware,
http://img.photobucket.com/albums/v16/arizonaxj/DIY%20Beadlocks/spline_assy.jpg

I already made a DXF file of the outer ring and sent it to Mike at Crossed Up so they can program it and cut it out on their CNC plasma table. I should have them next week sometime and I'll post up some pics of the finished parts.

[RuggedJeep]

very cool design, like that sprocket look.

[arizonaxj]

very cool design, like that sprocket look.

Thanks! I've seen a lot of pretty wild designs lately. I wanted to keep mine pretty simple. I thought it kind of looked like a spline.

[KIAKillerXJ]

15's?

[arizonaxj]

15's?


Yup!

[KIAKillerXJ]

care to send the DXF's my way?

[arizonaxj]

care to send the DXF's my way?

Sorry but I already made a deal on the design, and agreed not let anyone else buy or have it.

[arizonaxj]

Got the first set off the plasma table today.
http://img.photobucket.com/albums/v16/arizonaxj/DIY%20Beadlocks/unpainted.jpg

[arizonaxj]

Got them painted and all mounted up. 32 bolts per wheel = PITA
http://img.photobucket.com/albums/v16/arizonaxj/DIY%20Beadlocks/mounted.jpg

[KIAKillerXJ]

those look sweet!

[arizonaxj]

A while back I bent my rear axle housing. I decided to replace it with one from Crossed UpOffroad. This thing is pretty beefy!

The center section was fabricated from 1/4' plate and the axle tubes are 3" diameter x 3/8" walll DOM. The axle flanges are designed by Crossed Up and machined from billet by Tim Brown of Metal Works. Here are a few pics.

Flange and DOM axle tube.
http://img.photobucket.com/albums/v16/arizonaxj/F-Toy/Flange_Tube.jpg
Flange after welding.
http://img.photobucket.com/albums/v16/arizonaxj/F-Toy/Flange.jpg
http://img.photobucket.com/albums/v16/arizonaxj/F-Toy/Flange_Weld.jpg
This is the center section and billet aluminum oil fill plug. These things are pretty sweet. It's a machined steel piece threaded to fit the X-up cap, and is sealed with an O ring.
http://img.photobucket.com/albums/v16/arizonaxj/F-Toy/Raw_Housing.jpg
This is the full housing.
http://img.photobucket.com/albums/v16/arizonaxj/F-Toy/Raw_Housing_1.jpg
Mike also set up this diff. V6 housing, 5.29,s and an ARB.
http://img.photobucket.com/albums/v16/arizonaxj/F-Toy/Chunk.jpg
I still need to finish cleaning up the brake lines, but as it sits right now, I have 13" between the bottom of the housing and the floor. The tires are 37"s with 10psi in them. They measure just under 35" tall.
http://img.photobucket.com/albums/v16/arizonaxj/F-Toy/Axle_Installed.jpg

[nblehm]

sweet man! hows the formula toy class treating you?

[arizonaxj]

The F-toy class is treating us okay. It's been a big learning curve as far as driver, spotter and rig set up. I went into the season on DOT tires, a spool in the rear and way too wide. The spool was killing me on off camber climbs. I couldn't turn, it would just push me in a straight line. Now I have an ARB in the rear and soon I'll have one in the front. Next, I really need tires and wheels. All the top guy's are on stickys. Over all it's not that big a deal but it always seems like you have that one course with one obstacle that you just can't make on DOT tires, and most of the guy's on stickys do. If you end up with a 39 or a 40 two times over a weekend that the top guy's are getting -12 on, next thing you know you are way down the list of the "also rans".
Hopfully nest year I'll get to run the entire season, but we'll see.

Some bad news from the weekend. I knocked my new axle housing off the jackstands it was setting on. It crushed the big toe on my left foot. I went to a doctor today. He said I came real close to having to have it amputated. Sucks for sure....

[RuggedJeep]

Ouch man, sucks. Axle looks good though, my friend just got a set of diamonds for his toy with 30spline birfs 5.28's Arb's and 42's
http://www.rockcrawlintoy.com/images/600_IMG_0142.JPG
http://www.rockcrawlintoy.com/images/600_4D2s_and_Tundra_pics_029.jpg

[xj_man_646]

how much for set of beadlocks :brows:

[arizonaxj]

how much for set of beadlocks :brows:

I don't know what they charge for beadlocks. I'll get a price and post up.

[arizonaxj]

I have a couple of pics of the toe carnage.
Warning, open at your own risk, it's pretty frickin nasty! The doc said if it was much worse, his recomendation would be to remove it. One of the bones is completly crushed.
This is Saturday night in the ER.
http://img.photobucket.com/albums/v16/arizonaxj/Toe_/Toe_Damage_1.jpg
Sunday morning.
http://img.photobucket.com/albums/v16/arizonaxj/Toe_/Toe_Damage_2.jpg
http://img.photobucket.com/albums/v16/arizonaxj/Toe_/Toe_Damage_3.jpg

[xj_man_646]

I don't know what they charge for beadlocks. I'll get a price and post up.
that'd be awesome. i really like that design.

[arizonaxj]

that'd be awesome. i really like that design.

I talked to the guy's at Crossed Up. He said for a 15" wheel it would be $70 per wheel with no hardware.
The rings would be CNC Plasma cut out of 1/4" plate and require 32 bolts.

The inner ring would look like this
http://img.photobucket.com/albums/v16/arizonaxj/DIY%20Beadlocks/15in_ring_rockstomper.jpg
And the outter
http://img.photobucket.com/albums/v16/arizonaxj/DIY%20Beadlocks/15in_outter_spline.jpg


-pat

[RuggedJeep]

Not a bad price for a good looking ring. hmmm :thinking:

[xj_man_646]

70/wheel? That isn't too bad I guess. Might be worth paying more for a better looking ring. I'll have to see where funds take me once I get the Jeep going again.

[nblehm]

Some bad news from the weekend. I knocked my new axle housing off the jackstands it was setting on. It crushed the big toe on my left foot. I went to a doctor today. He said I came real close to having to have it amputated. Sucks for sure....


I dropped my rear 60 in my right big toe last winter. That shiit hurts, I never went to the doc though :dunno:

[arizonaxj]

I dropped my rear 60 in my right big toe last winter. That shiit hurts, I never went to the doc though :dunno:
Did you see the pics I linked on the last page? That sh it sucked!

[xj_man_646]

Did you see the pics I linked on the last page? That sh it sucked!
:shudder:

[nblehm]

Did you see the pics I linked on the last page? That sh it sucked!

ouch dude! I just had a huge blood blister deal under my nail that I had to take a drill bit to the toe nail to get it out, and it shot out :lol: I donno how mine didnt look like yours though, I was only wearing skate shoes

[arizonaxj]

ouch dude! I just had a huge blood blister deal under my nail that I had to take a drill bit to the toe nail to get it out, and it shot out :lol: I donno how mine didnt look like yours though, I was only wearing skate shoes

Yeah, It was pretty bad. I had the housing with the 3rd member in it sitting up about 3' off the floor on tall jackstands. I finished painting it and was going to leave it there till the next day. My wife and I were going thru the garage on our way to go out, so I was wearing flip flops. She asked me a question about the pinion angle so I grabbed the pinion flange and lifted it about 1" and the entire housing started to fall. I tried to catch it but it got away from me and landed on my toe. At first I was kind of hopping on one foot going dam that hurt, then I looked down and saw how smashed it was and was more like oh FAWK! So much for going out.

[xj_man_646]

so, when the time comes, if i want a set of those beadlocks should i just contact you?

[Hoofmann]

Holy crap, that looked like it hurt. . . My roomates make fun of me for working on my junk in steel toes. :lol:

[jeepkid05]

thats nasty

[phillyzj]

thats nasty

he's had 6 months, hopefully it's healed by now :f2:

[arizonaxj]

he's had 6 months, hopefully it's healed by now :f2:

Oh man that sucked BAD. Since then it developed a bone infection and they had to chop about half of it off. Still got enough big toe left to hold a flip flop on, but that's about it.

[phillyzj]

Oh man that sucked BAD. Since then it developed a bone infection and they had to chop about half of it off. Still got enough big toe left to hold a flip flop on, but that's about it.

holy crap that does suck! can you walk ok with it the way it is?

[arizonaxj]

I can walk fine, and I can ride my bike. I used to do a lot of rock climbing. I don't think I could do that anymore. For the most part it's okay, but it has this weird almost buzzing/vibrating sensation. Hard to explane.

[arizonaxj]

We just got back from WE Rock Cedar City. The F-toy is working pretty well. We ended up 5th. Our 4th course Saturday killed us. We flopped and ended up timing out on the easiest course of the day. Sunday we had a great day and ended up moving up a few places.
Here is a sequence from C3 on Sunday. We cleaned this one and hit no cones!! My spotter was kicking azz. It's way steeper than the pics make it look. Also, we backed into this one. I hate the back in courses...
http://img.photobucket.com/albums/v16/arizonaxj/Cedar%20City%202008/Pat_C3_1.jpg
http://img.photobucket.com/albums/v16/arizonaxj/Cedar%20City%202008/Pat_C3_2.jpg
http://img.photobucket.com/albums/v16/arizonaxj/Cedar%20City%202008/Pat_C3_3.jpg
http://img.photobucket.com/albums/v16/arizonaxj/Cedar%20City%202008/Pat_C3_4.jpg
http://img.photobucket.com/albums/v16/arizonaxj/Cedar%20City%202008/Pat_C3_5.jpg
http://img.photobucket.com/albums/v16/arizonaxj/Cedar%20City%202008/Pat_C3_6.jpg
http://img.photobucket.com/albums/v16/arizonaxj/Cedar%20City%202008/Pat_C3_7.jpg
http://img.photobucket.com/albums/v16/arizonaxj/Cedar%20City%202008/Pat_C3_8.jpg
http://img.photobucket.com/albums/v16/arizonaxj/Cedar%20City%202008/Pat_C3_9.jpg

[Hoofmann]

Nice Krawlers. . . Stickies I presume?

[arizonaxj]

Nice Krawlers. . . Stickies I presume?

Yup, red lable!! I met Wade from FlatIron out there. I think he followed me most of the day Saturday in Stock Mod. Nice guy, and I really like their Stock Mod!! Talked to Lubes a little Sunday. I was kind of suprised he wasn't hanging it camp Saturday night. It got pretty wild with Jason S. and Nick Campbell putting on a pretty good show, then breaking the rig bad. I have video that I'll get posted up pretty soon.

The Krawlers work great! Huge difference from the old IROKS.

http://img.photobucket.com/albums/v16/arizonaxj/F-Toy/Red_Label.jpg
http://img.photobucket.com/albums/v16/arizonaxj/F-Toy/Krawler-irok.jpg

[Hoofmann]

I love Krawlers. Are you allowed, by F-Toy rules to link your suspension?

[nblehm]

no

[arizonaxj]

I love Krawlers. Are you allowed, by F-Toy rules to link your suspension?

Nope! We have to stay with the chuck wagon springs. For a budget class I think it's a good idea.