The last stage of this rebuild is completed and am very happy with the trail runs so far. Will be posting more pics next week cos my phone camera has gone nuts. The upgrades done are explained below.
To Beboy John sir for personally sparing his time and resources in helping me to complete this phase. First pic thanks to you.
3m antirust: Got the entire body and firewall coated with 3m anti corrosive paint. Costs Inr 410 a litre and lets see how well it works. Also when insulating firewall at the liner's shop, they have thermocol sheets of varying thickness (5mm to 10mm and so). Didnt know that earlier and have used the thicker sheets.
Dynamat extreme: Insulated inside the cabin with dynamat extreme. I would say that it definitely cuts out the 90% heat. As far as the noise is concerned, the clatter of the Di becomes a murmur inside the cabin. Satisfactory results maybe due to the open KMT and gearbox shield openings.
The major issues with SOA lift affects the steering geometry due to the angle on dragling and steering arm(pitman arm). With my current phase of rebuild the problem just got a lot worse.
I had been running the above setup of SOA with a bent draglink(not the one in above pic) near the leaf springs. It did serve me well for a couple of OTRS but then gave way in the middle of the trail(pic above). On a rocky trail the drag link couldnt hold it much longer and lost its strength. This had me trek down for two hours and trek back with a mechanic and tools. I was looking to strengthen the next one but didnt find much material online and dropped the idea.
(Pics source: Google images. For reference. )
Had this thought for a long time in my mind about extending one end of the pitman arm to correct the angle of drag link but found help on google. As I was searching for mods on pitman arm i came across this set up called drop pitman arm. The pics explain how this setup is and has been used on lifted vehicles in many forums.
I picked up a DCM toyota pitman arm for this purpose and got it forged at the local blacksmiths as in picture. The DCM arm is a good three-four inches longer than the MRCBT arm which gives a good drop for the drag link. The arm is heated to cherry red for about half an hour or so with coal in the hand run blowers and bent so that the ends of both pitman arms fall in line and allowed to cool slowly. The milling of the Dcm unit is removed to accomodate the milling body of the original arm and welded together. The other end of the pit man arm is reinforced with copper bushing for the end of the drag link to sit. A good lathe shop should be able to do this I guess. Currently running this setup.
Did come across another set up called hi steer, where both the tie rod and drag link move above the leaf springs in SOA. A special fabrication is required at the knuckles but dont have the resources to try this one.
Moving over to leaf springs:
Had run the original six pack leaf spring of the chassis on SOA and it was ok. Under articulation however the leaf packs find it harder when the vehicle is tilted due to the weight transfer. Re-chambered with two second main leafs now and the Jeep has a sort of nose up stance a bit. Monstering over bad roads has never been much more fun. It kinda takes it all in the stride without transfering much inside and surprised by how much you can change by playing around with them.
Unfortunately for rear got the wrong ones - pick up ones with six leafs(8mm atleast). Got to almost throw up after the first 100 kms and recambered with only three main and one short leafs. Ride has improved tremendously and is a joy on bad sections but still lacks that little bit on the highways. Will be reverting to Bolero rear springs in a while.
Other headaches: Got to increase the bed of the rollcage as I have gone for OE bushes for the cabin (used local rubber mounts before). This has reduced the cabin-roll cage space but shouldnt me that much of a mess.
TO other mods as and when time and money permits:
33/35 inch mts - Dont know bighorn or dynapro.
Power steering from pickup.
Ac at Wecool Bangalore.
Front and back Lockers from Gautham.
Fabricate a heavy duty tire carries, bumper and rock slider.
And. Amen.
Regards,
Barani.