Coil/Radius arm SAS 1st gen Trooper - fine tuning/new mods

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Re: Coil SAS 1st gen Trooper - fine tuning and new mods

Postby paulevans76 » Sun Jul 31, 2016 12:15 pm

Picked up this little gem for little more than a song. Well, a long uncomfortable drive (about 650 miles total) and a couple bucks. Long time buddy bought it from a guy at his work for $60. I think it goes for around 4-5 times as much new.
Image

Also grabbed these from my buddy who borrowed them for a little while on his 4 runner (they are the overload and extra capacity leaves from my OME spring packs).
Image

Gonna pop the extra capacity leaf back on mine to compensate for the rear bumper/carrier.

The welder is a wire feed only, no bottle, but that's all I really need and want to deal with in the garage at this point. I did a little practicing and after a couple boogers I laid down a couple ok beads. Not bad for being out of practice. There's a mig conversion available, so I can always start fiddling with it if I outgrow it's current state. Just gonna do thinner <3/16" stuff with it anyway, so i should be ok.

My buddy did the hard parts of re-welding the shock mount that had ripped off (using his 220volt MIG set up) so I rode home on 4 shocks, talk about luxury!

Also, after this trip, I've decided to put my old seats back in the trooper and sell the Corbeau's. I'm just too big for them. Even if I lost 25-30 lb I'd still be too structurally large for them. I thought maybe over time we'd break each other in, but it's not happening - the steel frame is not going to move, and my bones are where they are :lol: I'll need the wide-load versions if I get another set of suspension seats. For now, the stockers will do. I'll swap the pass n driver sides on their frames to hide the rip on the old driver side and see how that goes for a while.
91 SAS Trooper - Neverending tinkering
Semi-hopped-up 3.4 + MUA5 + 3.07:1 low
Waggy D44 Front - 5.38's + RCV's + OX
Rodeo D44 Rear - 5.38's + Detroit
35" General Grabber X3's on Interco Birddogs
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Re: Coil SAS 1st gen Trooper - fine tuning and new mods

Postby paulevans76 » Sun Jul 31, 2016 5:34 pm

Getting ready for the Great Seat Swap-Back of 2016. Figured out how to swap the seat cushions around on the frames so that the old passenger seat bottom is now the driver. And the old ripped driver seat bottom is now on the passenger side, and the rip will be against the console. Not a difficult job at all. I'll pull the Corbeau's and pop the old stockers back in tomorrow.
91 SAS Trooper - Neverending tinkering
Semi-hopped-up 3.4 + MUA5 + 3.07:1 low
Waggy D44 Front - 5.38's + RCV's + OX
Rodeo D44 Rear - 5.38's + Detroit
35" General Grabber X3's on Interco Birddogs
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Re: Coil SAS 1st gen Trooper - fine tuning and new mods

Postby paulevans76 » Tue Sep 20, 2016 8:09 am

Fall projects:

- 3.4 swap
- New flywheel and clutch kit
- Dual cases

Currently getting the garage ready. Bought some dollies to go under the rotors to fit the rig in the garage and hopefully allow the hoist and engine to clear the engine bay. Picking up an auto case from Lorenzo and looking for a donor 4l30e tcase adapter. I'll get the trans and cases prepped for surgery, and hire a professional to do the welding.

The new rear case I believe will be a 2.05:1, so I'll have some great options between the front revo geared case and that. Good trail gear, good sand/snow gear, good low and super low ratio options.

Thinking of leaving the front case in its own oil, i.e., not drilling holes to share oil. I will try to only cut what is necessary from the output, saving whatever capacity I can, and run a high quality, high temp oil. If it gets roasted, it's only a quart or so to replace, rather than whatever it would be if I drilled holes to share oil. Don't really want to worry about a pump and cooler at this stage, as it would add more crap to go wrong. If I eventually need it, it could be addressed then.

If things go smoothly and quickly (yeah right) I'm going to try and get the body lift cut down to 1.5"ish. Biggest obstacles are:

- clearancing the body crossmember above the gas tank (BF Hammer time!)
- cutting off and rejiggering the rock sliders since they are right up against the rocker panels (a big pain but not impossible)
- steering shaft adjustment
- shifters adjustments

As bad as I want the body lift reduction, it isn't the top priority for this phase, but good God one of these days it needs to happen.

More to come as things progress.
91 SAS Trooper - Neverending tinkering
Semi-hopped-up 3.4 + MUA5 + 3.07:1 low
Waggy D44 Front - 5.38's + RCV's + OX
Rodeo D44 Rear - 5.38's + Detroit
35" General Grabber X3's on Interco Birddogs
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Re: Coil SAS 1st gen Trooper - fine tuning and new mods

Postby lorenzo816 » Tue Sep 20, 2016 9:12 am

Looking forward to the modifications.

Thoughts, if you don't want to cut yours down;
you may want to see if Roger still is making his blocks, give him a shout. (I know it says 5 weeks but I bet he's got enough blocks laying around prolly)
http://www.4crawler.com/4x4/ForSale/Bod ... plications

I may have some bolts for you too if you cant cut yours down and have enough thread on the bolt.
1997 Solid Axle Rodeo :: Ar5 swap :: Revo 4Lo :: 5.29/5.36 :: Front OX :: Rear ARB :: Full Float
MY Pictures and Videos and Build: 3-link coilover front 44 & rear FZJ80 on 37's
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Re: Coil SAS 1st gen Trooper - fine tuning and new mods

Postby paulevans76 » Tue Sep 20, 2016 8:32 pm

Right on. And if not him I can probably find the pucks on amazon and grab some new hardware somewhere. Not sure if the 3" lift bolts will be too long, and I'm willing to bet a few may need replacing anyway.
91 SAS Trooper - Neverending tinkering
Semi-hopped-up 3.4 + MUA5 + 3.07:1 low
Waggy D44 Front - 5.38's + RCV's + OX
Rodeo D44 Rear - 5.38's + Detroit
35" General Grabber X3's on Interco Birddogs
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Re: Coil SAS 1st gen Trooper - fine tuning and new mods

Postby paulevans76 » Fri Sep 30, 2016 10:18 pm

Got a lot done and a lot of momentum going into this weekend - Lorenzo hooked me up with a 2nd case, Jerry sent me an auto adapter, the garage is prepped, and just as I'm about to swap on the lil roller tires to get the trooper into the garage, I discover my floor jack has up n quit on me! Dang it!
91 SAS Trooper - Neverending tinkering
Semi-hopped-up 3.4 + MUA5 + 3.07:1 low
Waggy D44 Front - 5.38's + RCV's + OX
Rodeo D44 Rear - 5.38's + Detroit
35" General Grabber X3's on Interco Birddogs
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Re: Coil SAS 1st gen Trooper - fine tuning and new mods

Postby paulevans76 » Sun Oct 02, 2016 10:42 am

Barely got it in the garage on the 31s. Actually scraped the roof rail bolts the last couple feet, but no big deal

20161001_141319.jpg


But, putting the dollies under it I ran into a small problem:

20161001_191542.jpg


Farts. Guess while the front drivers side still had the tire mounted and I had the front pass side jacked up to remove the tire, it put more than 1500lb to this corner. It was weird that it happened while I was letting the jack down on the pass front corner. New jack, just getting used to it, so it came down a little faster than I wanted, but dang. Now I gotta buy another set of dollies :( boo.
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91 SAS Trooper - Neverending tinkering
Semi-hopped-up 3.4 + MUA5 + 3.07:1 low
Waggy D44 Front - 5.38's + RCV's + OX
Rodeo D44 Rear - 5.38's + Detroit
35" General Grabber X3's on Interco Birddogs
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Re: Coil SAS 1st gen Trooper - fine tuning and new mods

Postby bradzuzu » Mon Oct 03, 2016 12:23 am

Ah just straighten them and reinforce the frame , be safer in the long run ...

You my friend need a bigger garage lol
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: Coil SAS 1st gen Trooper - fine tuning and new mods

Postby paulevans76 » Mon Oct 03, 2016 9:19 am

bradzuzu wrote:You my friend need a bigger garage lol


True that! What I really need is a detached shop, but I don't have the space or HOA approval for one :lol:
91 SAS Trooper - Neverending tinkering
Semi-hopped-up 3.4 + MUA5 + 3.07:1 low
Waggy D44 Front - 5.38's + RCV's + OX
Rodeo D44 Rear - 5.38's + Detroit
35" General Grabber X3's on Interco Birddogs
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Re: Coil SAS 1st gen Trooper - fine tuning and new mods

Postby lorenzo816 » Tue Oct 04, 2016 9:40 am

sucks the dollies bent on ya.
Brad's good idea though, reinforce them.
Hate it when the floor jack lets go a little too fast. Can get scarey if you're not prepared for a rollaway.

On a positive note: Progress feels good don't it?!

As for getting in and out of the garage on 31's, let some air out your tires next time!!
:)
might get an inch lower to get you in/out without holding your breath.
1997 Solid Axle Rodeo :: Ar5 swap :: Revo 4Lo :: 5.29/5.36 :: Front OX :: Rear ARB :: Full Float
MY Pictures and Videos and Build: 3-link coilover front 44 & rear FZJ80 on 37's
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Re: Coil SAS 1st gen Trooper - fine tuning and new mods

Postby paulevans76 » Tue Oct 04, 2016 10:29 am

I had to see if it would go in without airing down, out of curiosity. Ordered another couple dollies, I can fix the other one and have it for lighter duty tasks. I'm sure I'll come up with some uses for the extras. Will be easier to move the engine pallet around, for one.

Progress so far:

pulled hood
removed air cleaner
removed battery

Slow progress beats no progress! I did that while lifting, between sets. Gotta maximize "me" time :lol: Today I'm gonna drain stuff and try to get at all the bellhousing bolts and measure to see if I'll be able to clear the engine bay with the loaded hoist all the way up, or if I'll need to pull body panels.
91 SAS Trooper - Neverending tinkering
Semi-hopped-up 3.4 + MUA5 + 3.07:1 low
Waggy D44 Front - 5.38's + RCV's + OX
Rodeo D44 Rear - 5.38's + Detroit
35" General Grabber X3's on Interco Birddogs
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Re: Coil/Radius arm SAS 1st gen Trooper - fine tuning/new mo

Postby paulevans76 » Wed Oct 05, 2016 12:08 pm

Another General promo with a few cameos of yours truly:

Watch on youtube.com


Same stuff just edited differently. Good times. Need to get this swap done and beat on it again!
91 SAS Trooper - Neverending tinkering
Semi-hopped-up 3.4 + MUA5 + 3.07:1 low
Waggy D44 Front - 5.38's + RCV's + OX
Rodeo D44 Rear - 5.38's + Detroit
35" General Grabber X3's on Interco Birddogs
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Re: Coil/Radius arm SAS 1st gen Trooper - fine tuning/new mo

Postby lorenzo816 » Wed Oct 05, 2016 2:07 pm

Cool promo Paul.
Wish they had shown more of the troop when it was in view
1997 Solid Axle Rodeo :: Ar5 swap :: Revo 4Lo :: 5.29/5.36 :: Front OX :: Rear ARB :: Full Float
MY Pictures and Videos and Build: 3-link coilover front 44 & rear FZJ80 on 37's
Uwharrie was my backyard - PM me if you need anything
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Re: Coil/Radius arm SAS 1st gen Trooper - fine tuning/new mo

Postby paulevans76 » Wed Oct 05, 2016 3:33 pm

lorenzo816 wrote:Cool promo Paul.
Wish they had shown more of the troop when it was in view


There's a little more of it in the previous videos I posted earlier. I found this one while I was checking their youtube page to see if they had done any new media or events around the new tire. Be nice to see more off-road product marketing in general with other non-JK's, but that seems to be asking a lot these days :blackeye: I'm sure the JK's and brodozers make up 95% of the customer base, but I'm still proud that they decided to pick out an old beater to toss in the mix.
91 SAS Trooper - Neverending tinkering
Semi-hopped-up 3.4 + MUA5 + 3.07:1 low
Waggy D44 Front - 5.38's + RCV's + OX
Rodeo D44 Rear - 5.38's + Detroit
35" General Grabber X3's on Interco Birddogs
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Re: Coil/Radius arm SAS 1st gen Trooper - fine tuning/new mo

Postby paulevans76 » Mon Oct 10, 2016 9:40 am

Well, I got the exhaust mostly out of the way and all the bellhousing bolts off (not too bad with the dumb body lift on there), as well as the driveshafts and output nuts loosened up, boots and shifters out of the way. Gotta pull the slave cylinder off and move some wiring and the trans should be ready to slip out of there. Hope to get it done this week.

When I pull the back cover, I'll be able to tell whether or not the dual cases will happen now or later. Lorenzo warned me that the revo low gear cluster may be too big to allow enough of a cut to clear the driveshaft from the 2nd case. I'm going to stick the 2nd case on there and see what it looks like once I have everything on the ground and make a decision.

Regardless of what happens with that, I've still got to get the 2.8 out too, and that process ought to move right along over the next week.
91 SAS Trooper - Neverending tinkering
Semi-hopped-up 3.4 + MUA5 + 3.07:1 low
Waggy D44 Front - 5.38's + RCV's + OX
Rodeo D44 Rear - 5.38's + Detroit
35" General Grabber X3's on Interco Birddogs
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Re: Coil/Radius arm SAS 1st gen Trooper - fine tuning/new mo

Postby bradzuzu » Mon Oct 10, 2016 5:17 pm

I know that gears bigger but I think I could fit a set into mine if I wanted to , the plate is is so think it could take a buzz of material taken off if not ...

I'm happy for you !! Finally getting done what you've been talking about for the longest time :)

So you where working out while working on the truck ? lol I can picture it !!
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: Coil/Radius arm SAS 1st gen Trooper - fine tuning/new mo

Postby paulevans76 » Mon Oct 10, 2016 9:50 pm

Yeah my 3rd car bay has my little gym area, and I hop over to the troop while I'm between sets haha :D

Didn't get diddly done tonight but I have some time tomorrow to chip away at it.

Thinking about grabbing an engine leveler for the hoist but then who knows if I'll be able to clear the fender/grill with the extra length. We shall see!
91 SAS Trooper - Neverending tinkering
Semi-hopped-up 3.4 + MUA5 + 3.07:1 low
Waggy D44 Front - 5.38's + RCV's + OX
Rodeo D44 Rear - 5.38's + Detroit
35" General Grabber X3's on Interco Birddogs
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Re: Coil/Radius arm SAS 1st gen Trooper - fine tuning/new mo

Postby paulevans76 » Mon Oct 17, 2016 8:48 am

Got the rest of the exhaust out of the way and the rest of the last few other little things, and with the help of my brother, we easily slid the trans out after doing a little "engineering" involving a ratchet strap, the floor jack, and a big-ass pry bar. Forgot that the engine was going to lean back and the damn thing was resting against the firewall on the distributor cap...oops...popped the floor jack under the oil pan for now.

This week I'll be pulling the case partially apart and yanking other little parts off the block to get it ready for the pull.
91 SAS Trooper - Neverending tinkering
Semi-hopped-up 3.4 + MUA5 + 3.07:1 low
Waggy D44 Front - 5.38's + RCV's + OX
Rodeo D44 Rear - 5.38's + Detroit
35" General Grabber X3's on Interco Birddogs
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Re: Coil/Radius arm SAS 1st gen Trooper - fine tuning/new mo

Postby bradzuzu » Wed Oct 19, 2016 11:32 pm

Hey where's the pictures of this said progress mr !!

I'm pleased to hear you've made more productive productivity !! Lol keep it up Paul
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: Coil/Radius arm SAS 1st gen Trooper - fine tuning/new mo

Postby paulevans76 » Thu Oct 20, 2016 11:24 am

My computer at home bit the dust so now that there are extra steps involved in posting photos from work or phone I am being lazy about it. I'm on the instagrams - about 5 years after it was cool - my handle is poundcakemalkovich and I usually post trooper stuff there for now. If there's anything mega awesome to post up I'll do it here.

I am working on it a little tonight and tomorrow and this weekend, so hopefully getting some more significant progress. Gonna aim to get the trans and cases ready to drop off at the shop - front output pulled, gameplan for the adapter, etc. Bonus if I have the 2.8 out as well.

Once I have the 2.8 out I'm going to have to go through and check the accessories between it and the 3.4 and pick the best ones to install. Need to pickup a few other gaskets, exhaust manifold hardware, etc.

I'll be honest, I was initially aiming for Fall Uwharrie trip and I'm going to keep that the goal, but once the trans and case are dropped off (already running behind on that) it's a little out of my hands, and then after it's back in, there's still driveshafts and exhaust changes that need to happen. It will def be done in time for a late November/December trip of some sort though!

On a side note, I'm thinking I should re-jigger my coil springs - mounts, spring rate, etc. It came up on another board but I was talking about how my coils are a great spring rate but they are coming unseated at the end range of my suspension droop, even with the limit straps limiting what the front end is capable of. So once I have the longer front driveshaft, I'm going to want to play with that sweet new suspension range. Someone asked if my coils were anywhere close to binding at ride height - negative, I have a ton of compression available in the spring that I'm not using because uptravel is limited by my frame interference.

So, offroad-wise, I could go for a lighter rate with more winds, but using a lighter rate, I'm going to be dealing with a bit of brake dive and extra lean around the corners. Then there's a dual rate coil with few winds of sort of a zero-rate up at the top that won't provide any extra control, but will keep the coil from unseating.

But what I'd like to do is set up the spring a couple inches or so from binding just as the bumpstops fully kick in, leaving a little extra for articulation, and that will give me the most out of whatever spring I choose. Now, I still might have the run a slightly lighter rate or lower lift spring, but if I can balance out the rear suspension a little - stiffen it up a touch to help control diving/leaning, then I'll probably end up in the best shape I can ask for short of going with a coilover/ORI/etc.

Regarding the rear, I have an idea for that as well, but I'm going to save that project for another time and just pop the extra load spring back in the OME packs I already have.

If I manage to get those things done (and maybe rejigger the panhard and steering for a little more uptravel), along with the 3.4 and dual cases, and man this thing will be a seriously trail-ready machine, only limited by driver talent! :D
91 SAS Trooper - Neverending tinkering
Semi-hopped-up 3.4 + MUA5 + 3.07:1 low
Waggy D44 Front - 5.38's + RCV's + OX
Rodeo D44 Rear - 5.38's + Detroit
35" General Grabber X3's on Interco Birddogs
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Re: Coil/Radius arm SAS 1st gen Trooper - fine tuning/new mo

Postby paulevans76 » Tue Oct 25, 2016 1:30 pm

So here's what's been happening lately.

I've got a line on an already completed dual case that I could much more easily and cheaply and quickly use in my rig, and since I've been trying to reduce the uncertainty of this project taking forever and costing more than I'd envisioned, I was really leaning hard that way. But then there was a large uncertainty around when I could actually get the unit (owner still needs to pull it, crate it, ship it, etc), so I was leaning back toward having the shop do the cut n weld. Decisions!

But I think that what will be best for now is actually to find another MUA5 entirely to start the dual case project with and pop my single case unit back in for the time being, so I can actually enjoy some fall wheeling, and then do the dual cases over the winter for the spring wheelin' season. I mean what kind of idiot starts a big project in prime fall wheelin' time?! :mrgreen:

Starting with another unit also allows me to sell my unit as a whole when I do the swap, should I want to do that.

Sorry to disappoint, but I really really really really really really really really really really hate projects that take way too long and by the time all the big items are finally in for I forgot how something went back together somewhere else or I misplace a bolt or something. Not gonna do it.

So I'm gonna drop this 3.4 in, bolt up my trans, and enjoy chirping the tires every time I go into 2nd for a while :lol:

Latest progress on that has been getting the harness peeled back off of everything. So it's just coolant hoses, oil cooler lines, motor mounts and I think that's it.
91 SAS Trooper - Neverending tinkering
Semi-hopped-up 3.4 + MUA5 + 3.07:1 low
Waggy D44 Front - 5.38's + RCV's + OX
Rodeo D44 Rear - 5.38's + Detroit
35" General Grabber X3's on Interco Birddogs
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Re: Coil/Radius arm SAS 1st gen Trooper - fine tuning/new mo

Postby paulevans76 » Wed Oct 26, 2016 1:19 pm

2.8 is out! Hope to get accessories swapped over as well as the flywheel and clutch kit the next couple of days. Outta town this weekend, but next week maybe I'll get everything buttoned back up. Uwharrie isn't out of the question, but we'll see how things go.
91 SAS Trooper - Neverending tinkering
Semi-hopped-up 3.4 + MUA5 + 3.07:1 low
Waggy D44 Front - 5.38's + RCV's + OX
Rodeo D44 Rear - 5.38's + Detroit
35" General Grabber X3's on Interco Birddogs
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Re: Coil/Radius arm SAS 1st gen Trooper - fine tuning/new mo

Postby paulevans76 » Sat Nov 05, 2016 6:15 pm

Slow progress. Had a busted motor mount, probably the cause of some of my issues on the trail, so I got both sides and a fresh trans mount. Gotta helicoil two exhaust manifold mounting holes so far, plus a few bolts, and replace an intake manifold stud. Currently trying to ez out a broken bolt shank in the back of the head, it was one if the mounts for the coolant hard lines back there.

Once I have it off the hoist I'm going to pull the valve covers to check rocker arm lash, check/torque the head bolts, retorque intake.

I have remflex gaskets for the exh-mani's, gotta get donuts from Jerry, and i think I'll get the rest of the system just bolted back in for now to get it to a shop and have them bend me up something new.

Hopefully i can get this thing installed and have everything connected at least by the end of this coming week.
91 SAS Trooper - Neverending tinkering
Semi-hopped-up 3.4 + MUA5 + 3.07:1 low
Waggy D44 Front - 5.38's + RCV's + OX
Rodeo D44 Rear - 5.38's + Detroit
35" General Grabber X3's on Interco Birddogs
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paulevans76
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Re: Coil/Radius arm SAS 1st gen Trooper - fine tuning/new mo

Postby paulevans76 » Sun Nov 13, 2016 8:13 pm

Helicoil'd 3 exhaust manifold mounts and replaced a stripped intake stud with one from the old motor. Still can't get the friggin broken bolt extracted off the back of the drivers side head (coolant hose bracket and ground strap mount to it). I'm thinking of skipping it and running the ground strap elsewhere. Got a new rear main seal, flywheel, clutch kit and a few accessories installed. I'd bought new flywheel bolts a year or so ago in preparation for the job, but they ended up being the wrong size! So I took the best ones I had and cleaned em up real good and loctited and torqued everything to spec. Let's hope it all holds up :D

Just about ready to drop it back in, and then I can get the valve covers off and check the head bolts and rockers and stuff in there. I need a solid couple days work to get it going, but those solid days only get done about 1 hr at a time whenever the stars align with the youngins and the Mrs :lol:
91 SAS Trooper - Neverending tinkering
Semi-hopped-up 3.4 + MUA5 + 3.07:1 low
Waggy D44 Front - 5.38's + RCV's + OX
Rodeo D44 Rear - 5.38's + Detroit
35" General Grabber X3's on Interco Birddogs
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paulevans76
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Re: Coil/Radius arm SAS 1st gen Trooper - fine tuning/new mo

Postby bradzuzu » Thu Nov 17, 2016 2:24 am

Progress !!

Need to see some pics though .. I watched the video , they didn't show your rig very much the butt heads !!

Keep it up !!
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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