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Once a Postal 67 800 Build

LScout800

LS Powered Tractor
Joined
Jun 10, 2020
Member Number
1937
Messages
141
Loc
CA
Spent time tonight building the doubler box. Took the np241 i had cut up and welded some scrap aluminum to it as a cap.
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I also welded some tabs to bolt down the adapter plate to. I also built the adapter plate out of 1/4 inch aluminum, but am going to probably scrap it and make a steel one. The aluminum one will be too flimsy and bent/crack under the load of a transfer case bolted to it. Feel free to critique the aluminum welds, I did them with a spoolgun after a quick preheat with the torch. Came out ok for my first time welding aluminum.
 

LScout800

LS Powered Tractor
Joined
Jun 10, 2020
Member Number
1937
Messages
141
Loc
CA
I also have some plans for putting trailing arms in the rear to keep the shocks away from the tires, and to get rid of the radius arms for a parallel four link in the front. I am drawing it up in CAD currently and will upload a picture when it is done.
I also blew up a powersteering line, and an o2 sensor went out. Everything is backordered until next year which is annoying. Semester ended so I have more time, but I am waiting on parts which is a tad bit annoying.
 

LScout800

LS Powered Tractor
Joined
Jun 10, 2020
Member Number
1937
Messages
141
Loc
CA
Made up some trailing arms. I took the rear links (2" OD by 1/4 wall DOM) and cut them about a quarter of the way to the back. I took some 1.5" 1/4 wall DOM that was left over from the steering and panhard, and bent two pieces in the good old harbor freight pipe kinker. I pounded the bigger tube over the smaller tube to give it a bend and cut some 1/4" plates for the shock mounts and to reinforce the trailing arms. The shock mount sits at about an inch below the centerline between the suspension joint bolts. I also replaced the rear johnny joint with a forged poly bushing from barnes.
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Will add a plate to the bottom to act as a skid. Going to relocate the shock mounts on the frame to where the old gas tanks were and it should all go together pretty easily.
 

LScout800

LS Powered Tractor
Joined
Jun 10, 2020
Member Number
1937
Messages
141
Loc
CA
Was out of town for a few weeks so not much has been done. Found some time to install the trailing arms.
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Cut out the flat plate the gas tanks used to sit on and started figuring out shock placement.
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It looks like the shocks will fit great. Much better than before with mounting the shocks on the axle. This setup allows for about 22 inches of travel. But I will probably have to strap it at less because of the driveshaft binding. I wish I had some 10 or 12 inch coilovers instead of 14's for the rear since it would have been even easier to package and the travel would have been easier to manage.

I also got in contact with NWF and they said they can ship me one of their shafts for the ecobox for a few hundred bucks. It should fit perfect in the case that I built. Was hoping to have this thing ready for KOH this year but oh well, it will have to stay home again this year. I got school starting up again but my new job will give me more time so I will be able to work on this more than 1-2 days a week.
 

LScout800

LS Powered Tractor
Joined
Jun 10, 2020
Member Number
1937
Messages
141
Loc
CA
Made some shock mounts out of the old ones. And got them tacked on the frame.
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Flexed out the axle to see how everything cleared. It all looked good so Welded them up. Then its paint and final assembely. Currently have the shock limited at 11 inches of stroke, with 15 inches of wheel travel. I will have to get new straps for more travel, but the driveshaft seems to hit its limit at 17-19 inches of travel, and it will only get worse once the doubler goes in. I have some heavy 16 inch and 14 inch springs laying arpund i will probably use. They are quite a bit heavier than the old springs, so we will see how they work.
 

LScout800

LS Powered Tractor
Joined
Jun 10, 2020
Member Number
1937
Messages
141
Loc
CA
Painted up the rear and got they shocks on. Fixed the powersteering and took it for a drive. I have 200lb 14 inch springs as uppers and 250lb 16 inch springs as lowers. It gave me the ride height I wanted without any preload.
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I Can push the back bumper down easily and almost hit the bumpstops. (Currently at 6 inches of bump.) The back compresses to the bumps when I back down my driveway, (it is pretty steep) and backing up the driveway the suspension extends in the rear until it tightens up the limit straps.
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The tire is only a foot above the ground, but the back end fully flexed out right away, and the front passenger did not move at all, only the front driver, which is on the strap. One of the radius arm uppers is dissconected. Instead of flexing like it did before, the body just wants to spill over. I definetely need to actually tune the shocks properly, the rear needs way more aggressive valving to help with the rear being so easy to move, and I also need to buy a rear swaybar once my paycheck comes in.
 
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