Zumina's 04 Rodeo DI

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Re: Zumina's 04 Rodeo DI

Postby egagnon086 » Mon Apr 03, 2017 1:21 pm

Wow, that's a real adventure there. Make it work, With enough straps, zip ties and duct tape. Did you only break the inner TRE, or did the rack break? Glad you made it back to civilization, I guess that's what you call southern Utah.

Your truck keeps getting more and more stuff, its the EXPO ZU. You ever get a set of those flexy Tie rods made up?

In that first pic, it looks like something was rubbing your shock...
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Re: Zumina's 04 Rodeo DI

Postby ZuminaZX » Mon Apr 03, 2017 1:54 pm

I was able to find off-the-shelf rods in Price, Utah however much to mine and the mechanic's dismay they were much too long.
the broken rod:
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We discovered, and texts with Brandon confirmed, that this lift kit uses proprietary length rods and replacements would have to come from BTV/Thailand. I then had the rodeo towed a further 140 miles back to Salt Lake, hosed it off at a carwash, tucked in back in the hangar, then caught an early flight home.
My knee-jerk reaction at that time was to proceed with the SFA swap my builder friend and I had been discussing for a while. I started to collect parts but ultimately forced to delay. At the time I was in the initial stages of building my new home and living several thousand miles away would make overseeing the project and then testing/tuning it nearly impossible. At present I simply want it to work for my simple, fly-and-drive trips. So for the time being my builder and I are going to do some further modifications to this setup and go from there. My hope is that if we do end up going SFA, this complete suspension system will be dialed in to the point that it can easily be swapped under an Amigo or Axiom in the future.
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2004 Rodeo 3.5 DI
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Re: Zumina's 04 Rodeo DI

Postby ZuminaZX » Mon Apr 03, 2017 2:00 pm

Fast forward about 4 months.
I ordered a new set of tie rods from BTV however they too were the incorrect length. I sought a custom option through a hotrod company in southern californai that makes customer-defined length rods and they referred me to a local baja-buggy builder that makes rods using 1" DOM tubing, heim joints, and misalignment spacers. Their rods have almost unlimited range of motion (their buggies have 24" of wheel travel!) and this will make the balljoints and CVs the next failure point for wheel droop and up travel. I am now in the middle of testing a few samples they have produced for fitment. With these constraints in mind, using precise limiting straps and bumpstops are an absolute must.
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Here you can see that the original, kit rods were manufactured poorly due to the very abrupt taper leaving the socket. It's a miracle these lasted as long as they did.
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2004 Rodeo 3.5 DI
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Re: Zumina's 04 Rodeo DI

Postby ZuminaZX » Mon Apr 03, 2017 3:55 pm

Here are the new rods compared to the sample MOOGs:
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2004 Rodeo 3.5 DI
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Re: Zumina's 04 Rodeo DI

Postby ZuminaZX » Mon Apr 03, 2017 3:57 pm

Here's the old rod at full droop:
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as you can see it was perilously close to contacting the socket in a stationary position. I'm guessing the dynamic loading of the impact caused the control arms to move a bit more and snap the rod
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Re: Zumina's 04 Rodeo DI

Postby ZuminaZX » Mon Apr 03, 2017 4:07 pm

So the plan from here is to finish off the design for the new rods, install bilstein 5165 shocks all around (the previous pro-comps did not have enough/consistent compression damping) using JKS adapters, fab custom mounts for and install bilstein bumpstops w/bottom-out springs, install limiting straps for each front A-arm and 2 for the rear pumpkin to contol pinion angle (center strap will allow for max flex). I've been routing my return work flights from the west coast through Salt Lake when possible and I've spent a few days tinkering and installing some items. I'm hoping to have things wrapped up this month and be able to reattempt the trip that broke it in the fall.
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Re: Zumina's 04 Rodeo DI

Postby ZuminaZX » Mon Apr 03, 2017 5:16 pm

egagnon086 wrote:Wow, that's a real adventure there. Make it work, With enough straps, zip ties and duct tape. Did you only break the inner TRE, or did the rack break? Glad you made it back to civilization, I guess that's what you call southern Utah.

Your truck keeps getting more and more stuff, its the EXPO ZU. You ever get a set of those flexy Tie rods made up?

In that first pic, it looks like something was rubbing your shock...


The kit's bumpstop spacer was rubbing the shock.

Tie rods are complete.

I'm not sure if the rack is cracked but it doesn't leak or show any signs of dysfunction.
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Re: Zumina's 04 Rodeo DI

Postby btw1549 » Mon Apr 03, 2017 9:16 pm

All I can say is WOW. Keep up the good work and keep updating us with pictures :twisted:
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Re: Zumina's 04 Rodeo DI

Postby ZuminaZX » Tue Apr 04, 2017 10:18 am

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Re: Zumina's 04 Rodeo DI

Postby ZuminaZX » Tue Apr 04, 2017 10:19 am

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Re: Zumina's 04 Rodeo DI

Postby egagnon086 » Tue Apr 04, 2017 11:59 am

[quote="ZuminaZX
Tie rods are complete.[/quote]

I need the scoop, How are they? do they work ok? How much...$$?

Are your tires 35x12.5 or 315/75s?
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Re: Zumina's 04 Rodeo DI

Postby ZuminaZX » Wed Apr 05, 2017 12:20 am

These are the 3" stroke bilstein bumps with mounting shells installed
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their approximate mounting location compared to the current setup. I'll most likely have a taller bash pad installed on the axle to mount them a bit higher
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the second version of the HD tie rods to be installed
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and it's previous stance. I have a new passenger side MOOG lower ball joint to install to correect it's shifting camber
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Re: Zumina's 04 Rodeo DI

Postby bradzuzu » Wed Apr 05, 2017 12:57 am

Lookin good man !!
91 amigo sas toy front leaf- traded off :(
2000 amigo sas d44 wagonear 4 link
custom built buggy ffor the dirty stuff

My build up page
Four link pics
Intake R&R - port and polish

Sometimes trying is all you can do, but when you succeed , that's something to be proud of...
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Re: Zumina's 04 Rodeo DI

Postby ZuminaZX » Wed Apr 05, 2017 11:53 am

Thanks Brad, I appreciate your help in selecting all of these new suspension parts!
Here are a few pics of the intended install. I would prefer to not notch the frame but we'll see what needs to happen.
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Re: Zumina's 04 Rodeo DI

Postby ZuminaZX » Wed Apr 05, 2017 11:54 am

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Re: Zumina's 04 Rodeo DI

Postby egagnon086 » Wed Apr 05, 2017 11:57 am

Nice, SO can I have your old bump stops...
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Re: Zumina's 04 Rodeo DI

Postby ZuminaZX » Wed Apr 05, 2017 6:48 pm

egagnon086 wrote:Nice, SO can I have your old bump stops...


of course :twisted:
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Re: Zumina's 04 Rodeo DI

Postby bradzuzu » Thu Apr 06, 2017 12:02 am

Haha everybody wants our parts !!!

You need to pan back so I can see the clearances ...

I bet that'll have a nice ride with those ..
91 amigo sas toy front leaf- traded off :(
2000 amigo sas d44 wagonear 4 link
custom built buggy ffor the dirty stuff

My build up page
Four link pics
Intake R&R - port and polish

Sometimes trying is all you can do, but when you succeed , that's something to be proud of...
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Re: Zumina's 04 Rodeo DI

Postby egagnon086 » Thu Apr 06, 2017 8:29 am

It could be that I just want both of your parts, I'm like a 2nd hand charlies of isuzu. I want Brads exo cage and Zumina's "old" suspension bits..
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Re: Zumina's 04 Rodeo DI

Postby ZuminaZX » Thu Apr 13, 2017 4:10 pm

Well I was hoping to avoid resorting to building a pin with integral eccentricity as it will add about $50-100 to the total cost but it must be done. I'm also going to have it set up for safety, drop-out spacer and a cotter pin for the top. I'm not sure how many other 2nd gen owners would be interested in a set at almost $400, and this doesn't (and never will) include any portion of the tooling/setup fees I've already paid.
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Re: Zumina's 04 Rodeo DI

Postby egagnon086 » Thu Apr 13, 2017 6:59 pm

So should there be some misalignment spacers on the hiem joint.
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Re: Zumina's 04 Rodeo DI

Postby ZuminaZX » Thu Apr 13, 2017 7:41 pm

egagnon086 wrote:So should there be some misalignment spacers on the hiem joint.

That can be done however the resultant angularity on the pin at full droop was thought to be too much. We opted for a 3/4" shank on this set for strength where we had previously used a 5/8" pin and misalignment spacers. This placed the sheer point lower on the pin and provided 32 degrees of misalignment. I'm not in a position to do any failure testing between the two configurations. The 5/8" pin may be more than strong enough (it's probably stronger than the knuckle itself!) but the manufacturer has volumes of experience and information using 3/4" pins on baja buggies and pickup trucks which makes them very leery of using smaller diameter parts. I'll keep you all updated. I'll have the new, forged, eccentric pins by the end of the week.
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Re: Zumina's 04 Rodeo DI

Postby ZuminaZX » Fri Apr 14, 2017 3:35 pm

all of these DOM parts and heims are much prettier than this
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Re: Zumina's 04 Rodeo DI

Postby ZuminaZX » Sat Apr 22, 2017 3:15 pm

much better
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Re: Zumina's 04 Rodeo DI

Postby egagnon086 » Sat Apr 22, 2017 6:25 pm

Wow, I want a set. Do they have any kind of guarantee due to breakage or are you on your own if they bend or break? That fancy offset pin looks super neat.
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