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Author Topic: 07 sas'd frontier  (Read 21453 times)
penski61
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« on: February 23, 2013, 04:19:49 PM »


went thru the entire thing , swapped out the massive dual piston calipers for single large piston calipers and made new brackets for them

installed an eaton e-locker with all new beaings and setup the gears


had a custom slip yoke eliminator(sye) made up , then made a custom tone ring that i pressed on the sye .

tone ring in the pic is not the one being used

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penski61
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« Reply #1 on: February 23, 2013, 04:20:24 PM »

here are the adjustable brackets that i made up to mount the abs sensors to




once i got the rear axle and sye  squared away i pulled the front suspension and cut off the stock brackets

steering was still in the pic cause i had to make up a cross member up front before it and its cross member came out


what ive got done for the front axle
shaved the bottom of the housing and modified the ruff stuff cover and made a upper link bridge
also had to re-center the diff to a snowfighter 60 because the ball joint 60 diff was under the frame





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penski61
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« Reply #2 on: February 23, 2013, 04:20:53 PM »





the coilover spacers weren't installed in these pics which is why the shock angle looks rear bad


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penski61
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« Reply #3 on: February 23, 2013, 04:21:22 PM »

started on the brake system today
drained the fluid from the lines and the master cylinder , checked to see if the dodge master cylinder would bolt up and it did not . 2nd gens have a weird mounting pattern so i had to remove the brake booster , drill and tap the booster then install studs to run the dodge mc
after i got it bolted up found there wasn't any way of adjusting the push rod to get it set correctly for the dodge mc so i used a dremel and cut the end of the push rod off and found it was an insert . removed the insert and found a portion of the push rod was hollow so i drilled and tapped it then installed a thread push rod
now that the mc is taken care i need to order and adapter so i can run the pressure off a tee in the line



all bolted up

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penski61
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« Reply #4 on: March 03, 2013, 05:26:34 PM »

got the brakes bled , little soft but will see how they are on road
decided to move all the abs sensors to one wheel because we are getting an atlas i didn't want to mess with making a new cross member and bracket along with pressing on a tone ring

so i made a custom tone ring   that fits over the rear hub , tone ring started as 1/4" flat stock

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penski61
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« Reply #5 on: March 03, 2013, 09:06:03 PM »

here are the mounts and then the abs sensors installed

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theking
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« Reply #6 on: March 03, 2013, 09:43:29 PM »

neat!  I like the method!  I'm thinking that those gaps aren't wide enough for the sensors to read, though.

     
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penski61
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« Reply #7 on: March 03, 2013, 10:41:22 PM »

ill find out in a couple days , if they dont read i can just widen the gaps with a grinding wheel instead of the cut off wheel
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penski61
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« Reply #8 on: March 04, 2013, 07:24:27 PM »

well the test worked out good enough to spend the money to get a machine shop to make a tone ring
anyone know any good machine shops lol
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theking
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« Reply #9 on: March 04, 2013, 08:15:08 PM »

If you had a torchmate you could stack a few gear patterns together to make a nice tone ring.  


btw, i'm getting a torchmate.   Grin
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« Reply #9 on: March 04, 2013, 08:15:08 PM »

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penski61
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« Reply #10 on: March 26, 2013, 06:16:57 PM »

one of the guys at Natalie's work offered to design and cut the tone ring
here it is , done with an edm machine


then almost done with the bumper , i was able to salvage the bumper i had before with the body lift
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theking
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« Reply #11 on: March 26, 2013, 09:21:42 PM »

wow!  that some precise cutting!  What do they normally do there with that EDM machine?
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penski61
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« Reply #12 on: March 26, 2013, 09:31:05 PM »

manufacturing parts of a mold for medical devices
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penski61
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« Reply #13 on: April 16, 2013, 07:44:40 PM »



start of the rear bumper


decided to change out the square tube trans cross member didn't flow to well ,  i guess im not much of a fan of square tube

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theking
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« Reply #14 on: April 16, 2013, 08:52:53 PM »

Hey Aaron.  why not make the x-member one piece instead of bolting the front and back with bushings? That upper is gonna torque on those bushings.  But, the upper link tabs aren't very tall so it's probably be Ok like that.  But I think if you weld the two together it's be more rigid.   cents   
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penski61
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« Reply #15 on: April 16, 2013, 09:06:59 PM »

they aren't bushings  Grin its all rigid
used a hole saw and cut a bunch of 1-1/2 holes out of 3/16 . used the pieces that fell out and welded them to the end of the tubing instead of using bushings then just drilled the holes out for 1/2"

only bushing is in  the trans mount , also i didn't want to make it once piece because if i have to take the atlas out i have to take the entire cross member out and then support the trans
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penski61
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« Reply #16 on: April 16, 2013, 09:27:54 PM »

ill probably add another cross brace from the tube behind the upper link to the frame for a little more strength
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