Once a Postal 67 800 Build

Next was to start on the suspension, we lifted the scout up in the air with some horses I built and pulled the old beam axle and leaf springs out from under the truck.

I then began to cut up my new axle: a balljoint dana 60 from an f-350 that was fresh from the local junkyard for only $275. I started by throwing it under the truck in order to figure out where it worked best. Apparently by placing it where I had to cut 5 inches off the long side allowed me to match the width of the rear c&c 14 bolt and also put the pumpkin where I would have far more uptravel.

I cleaned off the stock brackets, and trimmed 5 inches off the long side. I sent the long side shaft up to dutchman to get shortened. They did a very nice job sorry no pictures. I also did a cut and turn on the passenger side for better caster/pinion angles. I then notched the driver side a little for the radius arm bracket, I cut around 3/8 of an inch to either side to allow for a better weld to the tube and cast.

I then tacked up some brackets and cut some tube to get the axle located. I used Johnny joints on the frame and barnes forged bushings on the axle and link ends. The brackets are all from barnes except for the radius arm bracket on the axle it is from ballistic. I then had to bend the panhard in order to clear the massive dana 60 pumpkin at full stuff.
Once I had the axle setup where I wanted it I pulled it apart and welded the brackets on then painted it and the links.

I then threw some old worn out 35s on it in order to get an idea of how it would sit. The next order of business was the steering, which utilized a steering box from a zj and a steering kit from barnes. I mounted the box by running some small tubes through the frame then plating the top tube as it sat on top of the frame. I shortened the stock scout steering column then ground it square so I could use the collapse able zj steering shaft.

For the transmission mount I was able to use the stock crossmember, I just removed the old mount and drilled two holes for the gm mount on the nv3500. I notched it to clear the mount and also the front CV yoke. The shifter sits where I wanted it although it needs to get bent out in order to clear the steering wheel when shifting into first. I also had to cut out the floor some in order to fit the transfer case and CV joint.

The coilover mounts use hoops from barnes and go through the frame. They are also played on the frame for maximum strength. I welded them on the bottom to prevent fatiguing of the welds. I welded in a crossover piece to keep them from bending in and painted them. I then dropped the frontend on it's own weight for the first time.

I flipped it around in my garage for prepreation on the rear 4 link and dropped the old dana 44 in prepreation for the 14 bolt. I did the sye on the transfer case. Nice part from tom woods went together easily. The johnny joints for the rear end, also very nice.
And that is how it sits as of right now. I am going to put the transfer case back in and begin to tack brackets and cut tube for the 4 link tommarrow.

I finished up the transfer case then threw it back into the truck. After that I was able to see where to place the frameside bracket as I wanted it as far forward as possible without interfering with my transfer case. In order to do that the stock e-break crossmember mount had to go and I cleaned the frame a bit. I then tacked the mounts in from barnes. They are a combo bracket with adjustable uppers and look like they were designed to be there. Next was the axle mounts, I put the outer mounts as far over as possible in order to get as much triangulation as possible and still clear the nut on the brakes. The upper mounts had to mount over the pumpkin, so I used this link truss from barnes to clear it and give me a place to mount them. I also put the mounts themselves on it. I know it looks wierd as they are offset to the side of the truss, but that is actually the center of the axle. I put some Johnny joints in the brackets and measured for tube, but did not get that cut as it was getting late. I will do that today and maybe get to flex the rear end a bit.

I also threw a slightly less worn out 35 on it just to see what it will end up sitting like. I like the stance of it.

I cut the links and threw them on the truck in order to start having fun and flexing the rear axle.
The upper links hit the rear crossmember at full compression, but this does not seem like a huge deal to me as the suspension will not flex this much without major body modifications. I threw a tire on to get a real world idea of how much flex I would get. This gave me 6 inches of uptravel and 8 of down before the tire wanted to custom clearance the fender.
A 35 fits quite nicely. It has enough room to clear the fender at full bump. If I ever wanted to run a bigger tire, like a 37 or 38 I could leave the suspension alone I would just have to widen up the fender openings a bit. Which I might do, but put in the extra effort to keep the fender opening looking stock much like they did on the ultimate adventure scout 80 in 4wor.