For this installment we began the frame and suspension buildup. For us, this is by far the most fun Because you know how much we like crazy suspension setups.
I wanted to do something different-yet again-so we decided to mix the cleanliness of a street rod with the insane beefy fabrication of a pre-runner. Bobby from Sadistic Iron Werks and I drew up a few ideas, and before you know it we were well on our way. Follow along to see just how Sadistic Iron Werks does a full frame build. For more information, contact the companies listed in the source box, and visit Minitruckinweb.com for more pics and video of the buildup.
1.After we stripped her down,...
1.After we stripped her down, here's what we were looking at.
2.Because we never really...
2.Because we never really learn our lesson, we decided to go with a full frame build. We took a stock wheelbase measurement, overall tire height, width, and a few other key measurements to build a set of mandrel-bent rails bumper to bumper.
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4.We got fairly crazy with...
4.We got fairly crazy with our bends and measurements so we drew up exactly what we wanted to see before having the rails bent. This many bends isn't necessary, but it sure does look cool!
5.We wanted our rails to start...
5.We wanted our rails to start narrow and bend out similar to the factory rails. And when the rails arrived we were pleased with the outcome. Tons of bends and not one little wrinkle or kink.
6.We began by leveling out...
6.We began by leveling out the table and then leveling out the frame. We built holding fixtures at the front and rear to properly set everything and clamp the rails in place.
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8.Once the rails were set,...
8.Once the rails were set, we tacked them to the fixtures to ensure they wouldn't move on us. Then we began by dropping in our donor 22R to see what we had to work with as the stock 18R is a tad smaller.
9.With the cab placement marked...
9.With the cab placement marked on the rails from our previous measurements, we then positioned the motor and built fixtures to place it where we needed it, leaving enough room in the front for a radiator.
10.Next, Bobby marked the...
10.Next, Bobby marked the exact placement of the motor mounts and bolted together some mockups to tack to the frame rails. Bobby opted to TIG weld most of this build to go along with the clean street-rod feel that we have planned.
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12.While the motor was in...
12.While the motor was in place, the new transmission crossmember was measured, marked, built, and then welded into place.
13.Yes, the cab had to come...
13.Yes, the cab had to come on and off a lot to double-check everything. It's a pain in the neck but worth it to ensure that the final fitment of everything comes out perfect.
14.TECH TIP In order to get...
14.TECH TIP
In order to get it right the first time since we're building everything from scratch, we decided to bolt the cab down and get EXACT measurements for the body mounts. We started by measuring out the back of the cab. With it perfectly even on both sides we welded a bolt to the frame table running up through the cab mount holes. Once all four corners were perfect we tightened them all down. This process takes a couple people (thanks Sean) to ensure the cab doesn't move.
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17.Next, it was crossmember...
17.Next, it was crossmember time. We cut three crossmembers to length then measured and drilled out our 2-inch holes.
18.Tubing was cut and TIG-welded...
18.Tubing was cut and TIG-welded flush in the holes that we wanted to fill. The other holes will be used later for some mounting points.
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20.In order to mix our clean...
20.In order to mix our clean street-rod look with the pre-runner fab we were after, we called in some reinforcements. We measured and drew up our suspension link system, and Joel from Mindliss Metalfab laser-cut our parts to spec.
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23.Bobby cut and cleaned the...
23.Bobby cut and cleaned the four-link ends because when TIG welding it is VERY important that everything is super clean to ensure the best possible weld. He then welded the ends in place using the link-bar jig he built to ensure both sides came out the exact same.
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25.For the upper link, we...
25.For the upper link, we built a beefy wishbone to blend in some of the pre-runner and mechanical fab work that we're going for with this build.
26.Carrying the same theme...
26.Carrying the same theme throughout the link bars and the frame, Bobby TIG- welded tubing through all of the holes then carefully ground everything smooth.
27.We couldn't wait until...
27.We couldn't wait until the end to check the placement and see how the wishbone is going to look.
28.It would take 100 buildup...
28.It would take 100 buildup stories to show you all of the work that went into this frame and suspension. We just don't have the room to show a pic and talk about every single step, so we decided to break this up into a few parts and focus on some of the "cool" stuff we did. Stay tuned for more on how we flush-mounted the wishbone into this crossmember.
29.Here's a grounds-eye view...
29.Here's a grounds-eye view on how all of the holes line up and how everything was built for a purpose. We're getting there slowly but surely.
30.We saved the two middle...
30.We saved the two middle holes to run 2-inch tubing through for the mounting points of the air tank, compressors, and battery. Here you can see that we leveled out the tank and then welded it in place.
31.We built plates on each...
31.We built plates on each side and dimple died them to line up with all of the holes. This is where the compressors will mount.
32.Everything was carefully...
32.Everything was carefully planned and drawn out before it was built to ensure that the finished product will not only function but also look as good as it works.
33.SNEAK PEAK Here's a look...
33.SNEAK PEAK
Here's a look at how the lower link bars and wishbone will look. The lower link bars are run on the outside of the frame because we will be building the 'bag setup in the space we left up front between the wishbone and the framerails.
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36.Again, from the top you...
36.Again, from the top you can see how everything lines up just like it does from the bottom.
37.And there you have it!...
37.And there you have it! The progress is looking pretty good and we don't want to jinx ourselves too bad, but so far so good! Stay tuned as we continue to crank on Project: Low Lux.