Pickuptrucker
Well-known member
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Legends Class 4800 Build - "Tinkerita"
- Thread starter FSU Off-Road
- Start date
With the long list of things to do, I've been doing my best to gather the needed parts to get Tinkerita ready for KOH24. After a few last-minute buys, I was able to get everything loaded up and took everything to the shop to start getting this thing put back together. To say the least, the truck was full both inside and out.
With limited time, our team has put together a timeline of everything to do to get it ready. First on the list was get the new crossover tube installed so we can start assembling things. Prior to burning it in completely, we triple checked everything to make sure it would all align. With a few minor adjustments, we were able to get it completely welded in as well as all of our tube clamps for the supports and skid plates. After we let it cool down, we got it all painted and ready for everything else to be installed.
During the process of welding, cooling, cleaning and painting, our team also worked on getting the transmission all cleaned up to install the new pan. During the frantic rush at Crandon, we did have some issues with our hardware on the trans pan, so while everything was a part, we also took the time to chase all the treads and get new bolts. Unfortunately, the pan gasket went missing during the late night, so we have to get another one prior to installing the transmission. This will take place this week.
While working on the TH400, we were also working on our new NP205 upgrade. As some of you are aware, Midnight Metalworks tanked, and Behemoth Drivetrain has taken most of that business. Therefore, lead times have been a little longer, however Dylan at Behemoth worked directly with me on getting me a case in time. I'm very grateful for this and was able to do a shop tour. If you are ever in the market for a D300 or NP205 case, I highly recommend them. Everything is 100% manufactured in KY and they have future plans to expand their portfolio. I won't go into great detail; however, they are working on more economic cases, manufacturing USA made gears, and more!!! With that said, we started our disassembly of our donor case in order to get us our Colossus NP205 case built. I also partnered with JB Conversions on the 3:1 gearing as well for additional options in the future and SPARES! I'm looking forward to getting this installed, it's a beefy case and I highly doubt we'll have any further issues.
Once we get the new NP205 case together, we sourced a new mount from TMR Customs to replace the D300 mount. Once we get the t-case all assembled and installed, we'll be able to make short work of the mount. Then our goal is to make it a roller again and move it that way we can start on the suspension while establishing the new belly pan height. Lots of work to do still, but small progress is better than no progress. Thankfully I have a great support system and team that is helping get this thing ready without me having to be there. Luckily, I'll have some time off to be able to focus on dialing everything in before the New Years!
With limited time, our team has put together a timeline of everything to do to get it ready. First on the list was get the new crossover tube installed so we can start assembling things. Prior to burning it in completely, we triple checked everything to make sure it would all align. With a few minor adjustments, we were able to get it completely welded in as well as all of our tube clamps for the supports and skid plates. After we let it cool down, we got it all painted and ready for everything else to be installed.
During the process of welding, cooling, cleaning and painting, our team also worked on getting the transmission all cleaned up to install the new pan. During the frantic rush at Crandon, we did have some issues with our hardware on the trans pan, so while everything was a part, we also took the time to chase all the treads and get new bolts. Unfortunately, the pan gasket went missing during the late night, so we have to get another one prior to installing the transmission. This will take place this week.
While working on the TH400, we were also working on our new NP205 upgrade. As some of you are aware, Midnight Metalworks tanked, and Behemoth Drivetrain has taken most of that business. Therefore, lead times have been a little longer, however Dylan at Behemoth worked directly with me on getting me a case in time. I'm very grateful for this and was able to do a shop tour. If you are ever in the market for a D300 or NP205 case, I highly recommend them. Everything is 100% manufactured in KY and they have future plans to expand their portfolio. I won't go into great detail; however, they are working on more economic cases, manufacturing USA made gears, and more!!! With that said, we started our disassembly of our donor case in order to get us our Colossus NP205 case built. I also partnered with JB Conversions on the 3:1 gearing as well for additional options in the future and SPARES! I'm looking forward to getting this installed, it's a beefy case and I highly doubt we'll have any further issues.
Once we get the new NP205 case together, we sourced a new mount from TMR Customs to replace the D300 mount. Once we get the t-case all assembled and installed, we'll be able to make short work of the mount. Then our goal is to make it a roller again and move it that way we can start on the suspension while establishing the new belly pan height. Lots of work to do still, but small progress is better than no progress. Thankfully I have a great support system and team that is helping get this thing ready without me having to be there. Luckily, I'll have some time off to be able to focus on dialing everything in before the New Years!
ridered3
Low Talent Wheelin
FSU Off-Road glad to see some updates! Didn't know that about Midnight Metalworks though, but I'm not in that market to keep tabs on things of that nature.
I hope everyone had a wonderful Christmas. While most were celebrating, I utilized most of my time off to tackle some of our "to do" list. Since the car isn't at the house, I'm having to do what I can to get parts ready to install, for when I do go to the shop. I decided to work on the new Behemoth Colossus NP05 case and get it ready to install. I'm still waiting on my JB Conversions parts to arrive (Saturday), however I put the case together as best as I could. When I install the new parts, I'll put on the new retainers as well. Just a side note, the gear differences between the D300 and NP205 are massive. I suspect zero failures with the transfer case now!
While I was away, some of the guys got the transmission all done and installed. The new pan is nice and beefy and with the new crossover tube, we should eliminate any transmission pan issues.
When I was at the shop, we ran into an issue with the NP205. Luckily, we have some good partners that have helped us get what we need. With the short 32 spline input, we don't have enough seal engagement with the Novak adapter. After a pathway forward, we went ahead and installed the new case for driveline measuremenst and verification. The last thing we still need to knock out is the mount. But I have an idea for that.
With progress finally moving forward, we wanted to move Tinkerita off the lift and into another bay to work on the suspension. In order to move it, we needed to install the lower links. We finally got to install something new and shiny without having to remove it again in the future. Unfortunately, we didn't get to install the uppers just yet. That'll come soon enough.
The last thing we got to work on was the new 3" IBP's. These things are massive and causing some fitment issues with the chassis. We've decided to notch out the front to get them to fit, double up the upper brackets, and build new brackets for the rear. By doing this, we should be able to add 2" to our belly height and keep everything relatively close. We're really looking forward to having these installed and feeling the difference.
Stay tuned, we officially leave in 4 weeks. There's so much left to do, but one bite at a time.
While I was away, some of the guys got the transmission all done and installed. The new pan is nice and beefy and with the new crossover tube, we should eliminate any transmission pan issues.
When I was at the shop, we ran into an issue with the NP205. Luckily, we have some good partners that have helped us get what we need. With the short 32 spline input, we don't have enough seal engagement with the Novak adapter. After a pathway forward, we went ahead and installed the new case for driveline measuremenst and verification. The last thing we still need to knock out is the mount. But I have an idea for that.
With progress finally moving forward, we wanted to move Tinkerita off the lift and into another bay to work on the suspension. In order to move it, we needed to install the lower links. We finally got to install something new and shiny without having to remove it again in the future. Unfortunately, we didn't get to install the uppers just yet. That'll come soon enough.
The last thing we got to work on was the new 3" IBP's. These things are massive and causing some fitment issues with the chassis. We've decided to notch out the front to get them to fit, double up the upper brackets, and build new brackets for the rear. By doing this, we should be able to add 2" to our belly height and keep everything relatively close. We're really looking forward to having these installed and feeling the difference.
Stay tuned, we officially leave in 4 weeks. There's so much left to do, but one bite at a time.
ridered3
Low Talent Wheelin
Progress is looking mighty good!
WiscoF100
Red Skull Member
You really should be running sheet metal pans. Cast breaks. KOH has rocks. Everything in that environment wants to kill your machine. You’re driving from the wrong coast. Crandon already ruined your investment once. You want to gamble on KOH?
You are correct my friend. Our new pan is metal, not aluminum. It's just shiny.
Happy New Years Everyone!
While most were recovering yesterday, I spent the day in the shop trying to make some progress on the race Jeep. It was a rollercoaster of a day to say the least. We moved Tinkerita in the upper room to set our new desired ride height and go from there. Once we got it moved and established, the fun began...
Once we came up with some ideas, we started getting some preliminary mounts in place for testing on the front IBP's. It was early on that I noticed we had rotated the upper coilover mount on the driver side. Even with the support, it wasn't enough to stop the rotation of the tube. I'm thankful we saw this as it allows us to strengthen this in the future. However, for now, I cut it on the back to rotate it down again.
After fixing the upper mount, we worked on mocking up lower mounts onto the axle. After spitting some ideas around, we had a solution to plate and double plate some stuff with what we had laying around. Unfortunately, the 3" IBP's are a bit larger than the 2.5" and we ran into all kinds of clearance issues. To say the least, in my frustrations I decided to leave it for now and come back to it with a clear mindset.
Instead of wasting time on the front, I decided to double check the rear. I was able to utilize the old mount, just on the outside. After a few measurements, flex test, and more measurements, I was happy with there the rear was sitting. In our crunch for KOH, this is going to have to do for now. I'll plate all of this in for support and we should be good to go on the rear IBP's.
After a long and hard-fought day at the shop, I knew I had to bring this thing home so I can have more time to work on it. We spent the next couple of hours getting this and all the parts loaded so I could head back home. It was a bittersweet day as we made some progress, just not enough to give me the warm and fuzzies.
This week I plan on finishing the rear mounts so I can completely finish the rear suspension setup. This includes the bumps and limits. After that, it's just one thing at a time. As I look over the car, try to plan ahead, and order what parts are needed, it feels as if the list is growing.
Will definitely be a down to the wire KOH prep for sure.
While most were recovering yesterday, I spent the day in the shop trying to make some progress on the race Jeep. It was a rollercoaster of a day to say the least. We moved Tinkerita in the upper room to set our new desired ride height and go from there. Once we got it moved and established, the fun began...
Once we came up with some ideas, we started getting some preliminary mounts in place for testing on the front IBP's. It was early on that I noticed we had rotated the upper coilover mount on the driver side. Even with the support, it wasn't enough to stop the rotation of the tube. I'm thankful we saw this as it allows us to strengthen this in the future. However, for now, I cut it on the back to rotate it down again.
After fixing the upper mount, we worked on mocking up lower mounts onto the axle. After spitting some ideas around, we had a solution to plate and double plate some stuff with what we had laying around. Unfortunately, the 3" IBP's are a bit larger than the 2.5" and we ran into all kinds of clearance issues. To say the least, in my frustrations I decided to leave it for now and come back to it with a clear mindset.
Instead of wasting time on the front, I decided to double check the rear. I was able to utilize the old mount, just on the outside. After a few measurements, flex test, and more measurements, I was happy with there the rear was sitting. In our crunch for KOH, this is going to have to do for now. I'll plate all of this in for support and we should be good to go on the rear IBP's.
After a long and hard-fought day at the shop, I knew I had to bring this thing home so I can have more time to work on it. We spent the next couple of hours getting this and all the parts loaded so I could head back home. It was a bittersweet day as we made some progress, just not enough to give me the warm and fuzzies.
This week I plan on finishing the rear mounts so I can completely finish the rear suspension setup. This includes the bumps and limits. After that, it's just one thing at a time. As I look over the car, try to plan ahead, and order what parts are needed, it feels as if the list is growing.
Will definitely be a down to the wire KOH prep for sure.
cdemart2
Well-known member
- Joined
- Nov 4, 2021
- Member Number
- 4528
- Messages
- 105
you really need to get springs on those shocks in order to mock them up properly. as huge as these shocks are compared to a 2.5, the springs make them even bigger. looking at that turned/flex picture you're going to have a lot of clearance issues with those upper mounts in front.
I always joke about how my rig looks like an R/C car with these 3.0 shocks on it.
I always joke about how my rig looks like an R/C car with these 3.0 shocks on it.
Yea, that's my plan when I get back to working on the front. Going to have to cut and refigure a few things out. They are definitely bigger!!!
- Product Brand: Fox
- Product Body Diameter: 3
- Product Piston Rod Diameter: 1.0"
- Product Series: Internal Bypass
- Product Adjuster: DSC - Dual Speed Compression
- Product Collapsed Length: 23.4
- Product Extended Length: 37.49
- Product Travel: 14"
- Product Mounting Size: 1/2 x 1.50
- Product Bearing Size: COM-12T
- Product Piston Rod Material: 17-4 H900 Stainless Steel
- Product Reservoir Size: 2.5 X 14.1
- Product Wiper Material: Urethane
- Product Main Seal Material: Viton
- Product Piston: High Flow Aluminum
- Product Finish: FOX Grey Cerakote
outside looking in your are biting off a lot with very little time. youre going to be better off getting a race under your belt prepared without the added stress of dealing with rebuilding the car to get 3.0s to work. put the 2.5s back on the front, repair the chassis, get the 3.0s to work on the back and get back to prepping the car.
ChrisRWG
Build & Film
When I saw the picture of the tire turned into the shock body I couldn't help but agree with this statement. Save the 3.0s for future upgrades and get this thing in its best current form for KOH
Opiebennett
XJ_Ranger
Or order some king 2.5 IBP's and get a small part of the bypass features you were looking for, in a 2.5 shock, with the springs you already have. accutune or filthy moto sports should be able to get you close valving and a pair in a box on its way to you.
Install current 2.5's for now, swap to kings if time, keep fox 3.0's for later.
Then sell the used kings for 80% what you paid. "never abused, only used one week, only raced once. "
Install current 2.5's for now, swap to kings if time, keep fox 3.0's for later.
Then sell the used kings for 80% what you paid. "never abused, only used one week, only raced once. "
As time permits, I'll do my best to keep things up to date. As you all know, Last week I loaded up the Jeep and brought it back to its beginnings... my little house garage. I was in high spirits to get this thing unloaded and knocked out, however unloading everything I tweaked my back leaving me in a lot of discomfort... making the next few days' progression slow. As if we aren't already on a crunch, it's these things that we all neglect to think about that cause more delays. Regardless, this past weekend I worked both day and night to push through KOH prep to get TInkerita ready. After establishing our new belly height at the house on Friday night, I went right back to the rear to finish it up on Saturday. Unfortunately, after a few additional measurements, there were some changes that needed to happen to get our travel numbers. The original 2.5 coilovers were 16" in length, therefore we lost 2" in stroke with the new IBP's. With a few moved mounting locations, we were left with the same travel as before. With the increased belly height, I also had to add some bump extensions. After a quick spray of paint and bolt install, I completed the rear suspension.
Although a long Saturday, I spent most of Sunday afternoon and night working on a new tire carrier. Most people would work on the front suspension but I'm still working on some final details on the front. To eliminate any delays, the tire carrier is second on the importance list to finish. I liked the overall appearance of the last carrier, it just wasn't supported enough. With that said, I kept a similar appearance on the chassis just changing the lengths up and mounting locations to add rigidity. Also, while working on the carrier, I proactively configured the spare drive shaft location, jack, tool/spare parts box, etc. All of which will be contained in the rear for weight distribution. Should work out well.
My plan is to finish the last few supporting tubes tonight, rear tire bar, and install the strap tie downs for the y-strap. After the tire carrier is all finished up (tonight/tomorrow), I'll focus on getting everything ready for the front suspension. My goal is to have the suspension completed this weekend and finalize the NP-205 output mount, leaving me with 1 final week to finish the small insignificant items on the list. Regardless, we're making progress!
Although a long Saturday, I spent most of Sunday afternoon and night working on a new tire carrier. Most people would work on the front suspension but I'm still working on some final details on the front. To eliminate any delays, the tire carrier is second on the importance list to finish. I liked the overall appearance of the last carrier, it just wasn't supported enough. With that said, I kept a similar appearance on the chassis just changing the lengths up and mounting locations to add rigidity. Also, while working on the carrier, I proactively configured the spare drive shaft location, jack, tool/spare parts box, etc. All of which will be contained in the rear for weight distribution. Should work out well.
My plan is to finish the last few supporting tubes tonight, rear tire bar, and install the strap tie downs for the y-strap. After the tire carrier is all finished up (tonight/tomorrow), I'll focus on getting everything ready for the front suspension. My goal is to have the suspension completed this weekend and finalize the NP-205 output mount, leaving me with 1 final week to finish the small insignificant items on the list. Regardless, we're making progress!
chaplinfj60
Well-known member
when do you have hit the road to KOH?As time permits, I'll do my best to keep things up to date. As you all know, Last week I loaded up the Jeep and brought it back to its beginnings... my little house garage. I was in high spirits to get this thing unloaded and knocked out, however unloading everything I tweaked my back leaving me in a lot of discomfort... making the next few days' progression slow. As if we aren't already on a crunch, it's these things that we all neglect to think about that cause more delays. Regardless, this past weekend I worked both day and night to push through KOH prep to get TInkerita ready. After establishing our new belly height at the house on Friday night, I went right back to the rear to finish it up on Saturday. Unfortunately, after a few additional measurements, there were some changes that needed to happen to get our travel numbers. The original 2.5 coilovers were 16" in length, therefore we lost 2" in stroke with the new IBP's. With a few moved mounting locations, we were left with the same travel as before. With the increased belly height, I also had to add some bump extensions. After a quick spray of paint and bolt install, I completed the rear suspension.
Although a long Saturday, I spent most of Sunday afternoon and night working on a new tire carrier. Most people would work on the front suspension but I'm still working on some final details on the front. To eliminate any delays, the tire carrier is second on the importance list to finish. I liked the overall appearance of the last carrier, it just wasn't supported enough. With that said, I kept a similar appearance on the chassis just changing the lengths up and mounting locations to add rigidity. Also, while working on the carrier, I proactively configured the spare drive shaft location, jack, tool/spare parts box, etc. All of which will be contained in the rear for weight distribution. Should work out well.
My plan is to finish the last few supporting tubes tonight, rear tire bar, and install the strap tie downs for the y-strap. After the tire carrier is all finished up (tonight/tomorrow), I'll focus on getting everything ready for the front suspension. My goal is to have the suspension completed this weekend and finalize the NP-205 output mount, leaving me with 1 final week to finish the small insignificant items on the list. Regardless, we're making progress!
Car leaves Jan 24th - Afternoon/Night sometime
chaplinfj60
Well-known member
you are taking up time posting here for sure. cant wait to see it out there.
ridered3
Low Talent Wheelin
He's allowed 2-two minute breaks a day to keep us updatedyou are taking up time posting here for sure. cant wait to see it out there.
chaplinfj60
Well-known member
yes but.... dont check on anything else. 2 minutes... update back to work....He's allowed 2-two minute breaks a day to keep us updated
ridered3
Low Talent Wheelin
Gotta use them wiselyyes but.... dont check on anything else. 2 minutes... update back to work....
Well, it's been a couple of weeks since I updated the progress on Tinkerita. To say the least, it's been a long two weeks with many late nights and absolutely no sleep it feels. Last I left off, I was finishing up the tire carrier as I awaited some brackets and miscellaneous other parts. Once I had the overall design, I knew I wanted to add a retainer bar on the back to support the tire since I was removing the unit bearing design, but I did however utilize some of the tubes from the old carrier. Also added hook points for the y-strap, a pivot mount for the jack, and custom brackets to hold the spare driveshaft. Was able to finish that up last week before the weekend hit.
... now to last weekend. Luckily, I have some great friends that will sacrifice just as much time as I do for race prep. Last weekend was no different as I was going to attempt to tackle the front suspension yet again. After I ran into clearance issues with the original design, I knew I had to cut off the chassis mounts and the bump mounts. Since I had already cut the axle mounts off, I knew there really wasn't any going back to the 2.5" coilovers. However, I do appreciate the input and concerns with time restraints (I was concerned too). Since we decided there was no going back, I didn't have a choice but to figure out a way for them to work. After many hours of mocking up, flexing, cutting, and fitting brackets in different configurations, we were able to squeeze new 3" IBP's onto the front. With literally no room to spare, they FIT! Got everything burned in, then had to figure out the bump location.
Unfortunately, we had to notch the chassis to get the bumps to fit with the new coilover package. Not a big deal but took a lot of extra time. Due to the tight packaging, we also had to add bump pad extensions. At 2am after burning in the new can location and gussets for support, extensions, we were able to install the springs and get Tinkerita under her own weight again.
With over 30 hours invested last weekend, I was able to go to sleep knowing it was at least under its own suspension. We'll have to set ride height and mount the reservoirs, etc. but we're one step closer. There was a ton left to do, but thankfully the list was manageable at this point.
... now to last weekend. Luckily, I have some great friends that will sacrifice just as much time as I do for race prep. Last weekend was no different as I was going to attempt to tackle the front suspension yet again. After I ran into clearance issues with the original design, I knew I had to cut off the chassis mounts and the bump mounts. Since I had already cut the axle mounts off, I knew there really wasn't any going back to the 2.5" coilovers. However, I do appreciate the input and concerns with time restraints (I was concerned too). Since we decided there was no going back, I didn't have a choice but to figure out a way for them to work. After many hours of mocking up, flexing, cutting, and fitting brackets in different configurations, we were able to squeeze new 3" IBP's onto the front. With literally no room to spare, they FIT! Got everything burned in, then had to figure out the bump location.
Unfortunately, we had to notch the chassis to get the bumps to fit with the new coilover package. Not a big deal but took a lot of extra time. Due to the tight packaging, we also had to add bump pad extensions. At 2am after burning in the new can location and gussets for support, extensions, we were able to install the springs and get Tinkerita under her own weight again.
With over 30 hours invested last weekend, I was able to go to sleep knowing it was at least under its own suspension. We'll have to set ride height and mount the reservoirs, etc. but we're one step closer. There was a ton left to do, but thankfully the list was manageable at this point.
Now for the final countdown... This past week I had to travel to Texas for a couple of days, keeping my progress minimal. With a long list of things to do, I focused my time on the most important things first for this past weekend. First things first, get the NP205 all done. Huge thanks to Behemoth Drivetrain, JB Conversions, Novak, and NWF for all the parts to make this happen. Originally, we installed the stock gear set with the old bearings, seals, etc. After a complete disassembly, we were able to reassemble everything with the brand new 3:1 gear set (massive gears), new bearings, seals, and retainers. As for the input, I was able to utilize Novak's insert in my TH400 mount and Behemoths low profile retainer to have enough seal engagement on the input shaft. Due to the D300 mount, to keep everything simple, I utilized NWF output retainer and their output mount. Was able to make quick work of this mount and got everything installed.
With the suspension buttoned up (for the most part anyways), and the drivetrain all installed, it was time to focus on other important KOH related things like storage. I was able to source an aluminum box to practically fit under the tire carrier, by design of course. After a couple of brackets, I was able to get the storage box installed. Should be plenty of storage for parts and tools. Also knocked out a few tabs and small items as well.
As for yesterday, Sunday, it was my deadline to get the car loaded up and back to the race shop for tuning. Yesterday was frantic as I was pushing to get every little last-minute thing buttoned up and parts loaded. Took way too long to get loaded up and packed up, but at the end of the day, after fluid, battery charging, panel installs, I was able to load up Tinkerita for KOH24!
There are still a few things to go over and button up, but she's as ready as I could get her in the time that I had. Got her to the shop late last night and she's now off my hands for a week.
We still have to mount the new Atturo Tires, install the skid plates, take care of a few small items, and install a few electrical plugs and wires, but she's KOH bound as far as I'm concerned. I'll mark it as a victory!
With the suspension buttoned up (for the most part anyways), and the drivetrain all installed, it was time to focus on other important KOH related things like storage. I was able to source an aluminum box to practically fit under the tire carrier, by design of course. After a couple of brackets, I was able to get the storage box installed. Should be plenty of storage for parts and tools. Also knocked out a few tabs and small items as well.
As for yesterday, Sunday, it was my deadline to get the car loaded up and back to the race shop for tuning. Yesterday was frantic as I was pushing to get every little last-minute thing buttoned up and parts loaded. Took way too long to get loaded up and packed up, but at the end of the day, after fluid, battery charging, panel installs, I was able to load up Tinkerita for KOH24!
There are still a few things to go over and button up, but she's as ready as I could get her in the time that I had. Got her to the shop late last night and she's now off my hands for a week.
We still have to mount the new Atturo Tires, install the skid plates, take care of a few small items, and install a few electrical plugs and wires, but she's KOH bound as far as I'm concerned. I'll mark it as a victory!
ridered3
Low Talent Wheelin
FSU Off-Road glad to see some more progress on Tinkerita!
You may have covered it already, but I’m just curious, why the swap from 2.5’s to 3.0’s?
You may have covered it already, but I’m just curious, why the swap from 2.5’s to 3.0’s?
you can go faster with IBPs
