2002 Nissan Frontier Desert Runner - Front Air Suspension - Project Desert Dragger: Episode II

Nose To The Grindstone

By Lance Martz

Photography by Lance Martz

Project Desert Dragger Nissan Desert Runner

In this, our second round of tech involving the Nissan Desert Runner, we were commissioned by Nissan and our brother publication, Sport Truck, to lay out, customize, and prepare the truck for the upcoming SEMA Show in Las Vegas. We'll make the newly transplanted frontend of the truck lay flat using air springs from Mac's Spring and the help of Suspension Dimension in San Bernardino, California. We used the front frame clip from an '87 Nissan Hardbody to allow the truck to sit closer to the ground as well as make it narrower to allow the wheels to tuck. You can use the following information to install 'bags in any Nissan Hardbody ever made with exactly the same results. Follow along as we lay out the nose of the truck in true hardcore MT fashion. For more information, please contact the companies that have assisted us. You'll find their information listed in the source box of this article.

1. We began with the freshly... read full caption 1. We began with the freshly installed '87 Hardbody front suspension clip minus its spindles and braking system to better allow us to see all of what's going on.	2. The first thing we modified... read full caption 2. The first thing we modified was the shock mount on the lower control arm. Using a torch, this was blazed off the arm to give us room to work.	3-4. Along with the shock... read full caption 3-4. Along with the shock mounts, the factory upper and lower bumpstop mounts were torched off the frame.
	5. The leftovers from the... read full caption 5. The leftovers from the no-longer-needed mounts were then ground smooth with a hard wheel grinder, giving us a clear area to work in.	6. Next, the area we would... read full caption 6. Next, the area we would need to fabricate our airbag mounts in was cleaned of its factory powdercoating using an angle grinder with a medium-grit roll-on wheel.
7. This is what the front... read full caption 7. This is what the front suspension should look like just before you begin to install new airbag mounts.	8. When we cut out all of... read full caption 8. When we cut out all of the original bumpstop mounts, there was a huge hole left in the side of the truck's frame.	9. Since the hole would mean... read full caption 9. Since the hole would mean a seriously weakened frame, we made a filler panel for it and test-fitted it to make sure it would fit perfectly within the area so as not to protrude into the area needed for the airbag.
10-11. When the panel fit... read full caption 10-11. When the panel fit perfectly, it was welded completely into place, actually making that part of the truck's frame stronger than it had been in its factory configuration.		12. All laid out, this is... read full caption 12. All laid out, this is Suspension Dimension's prefabricated weld-in kit to install airbags into the front of any Nissan Hardbody mini-truck. It comes complete with upper and lower 'bag mounts and a pair of gussets for added rigidity. Unfortunately, the airbag is sold separately.
13-14. The rounded mount with... read full caption 13-14. The rounded mount with three holes in it is used for the upper 'bag mount and is temporarily bolted to the top of the airbag. The rectangular mount with a short, 90-degree bend and a single hole is used for the bottom mount and is bolted up as well.		15. Assembled, the airbag... read full caption 15. Assembled, the airbag and mounting assembly should look like this before you proceed.
16. The airbag and mounts... read full caption 16. The airbag and mounts were then test-fitted to the area between the upper and lower control arms.	17. When the optimal area... read full caption 17. When the optimal area has been determined for the upper 'bag mount, the upper mount itself was tack-welded into place to hold its position.	18-19. To add strength to... read full caption 18-19. To add strength to the upper 'bag mount, a pair of gussets was tacked in place, and once the airbag was removed, the whole assembly was welded in completely.
	20. With the upper mount welded... read full caption 20. With the upper mount welded in, and the 'bag temporarily reinstalled, the suspension was completely cycled to make sure that the 'bag was positioned properly. From this motion, we were able to determine where to weld the lower 'bag mount on the lower control arm. The lower mount was then tacked in place.	21. When we were sure of where... read full caption 21. When we were sure of where the lower 'bag mount needed to be positioned, the airbag was removed.
22. To make room for adjustment,... read full caption 22. To make room for adjustment, and to gain access to the lower 'bag mount's bolt hole, a clearance hole was cut in the lower control arm, as shown here.	23-24. Next, the lower 'bag... read full caption 23-24. Next, the lower 'bag mount was completely welded into place along the outside and inner edges.
25. With the truck's front... read full caption 25. With the truck's front suspension completed, we moved on to the next step: adding shocks to the truck's frontend. We decided to use a pair of short, nitrogen-charged Doetsch Tech shocks, which are perfect for the small distance between the frame and the lower control arm. Along with Suspension Dimension's upper shock mount, this was the easy part of 'bagging the truck.	26. Completed, the Nissan... read full caption 26. Completed, the Nissan Frontier/Hardbody hybrid we're building is now capable of laying frame...well almost. We have another inch and a half to go until it lays frame up front. With the pair of Chassis Tech spindles that we'll be installing soon, along with new ball joints, brake pads, and brake rotors, the frontend will lay completely and operate as new as the frame clip we cut off and tossed into the trash.