4 linking the Trail Rig

[bggrnchvy]

A couple of years back I noticed I wasn't getting the performance out of the front suspension I wanted with leaf springs. I used low spring rate, high unloaded arch Alcan leafs with an offset pin and had a front anti-wrap to keep my driveshaft intact and it flexed great. Sadly though there was a lot of sway and it just wasn't fun at high speed.

To fix that I spent the better part of a year picking up parts here there to remedy the problem with a triangulated 4 link (I went to full hydraulic steering at the same time).

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I also bought a ton of tabs and brackets to make the fabrication move along faster as nothing sucks worse than trying to save $4 here and there and wasting hours as a result.

First things first, I ripped the front suspension and axle out of the truck.

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The next phase was to remove all the IFS bracketry I had left over as it was now in the way. OBS shock mounts are a bear to remove even with a plasma, grinders and a sawzall.

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Weld washers were added around bolt holes for years of beating without oblong holes.

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Due to the size of the joints on the frame side (Ballistic 3.0 REV1) I had to bore the hole diameter and turn down a nut and weld it in place to prevent interference with the frame rail.

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With a clean axle housing I began make the truss and tacking link mounts on as per my layout.

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Plates were cut from 12ga to box in the truss.

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Holes were made and dimples added.

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Down tubes to the ram truss were added.

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Coilovers were assembled.

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Plates and added tube were fully welded, including the nodular housing.

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Frame side lower mounts were contructed using Ruffstuff lower mounts, bent tubes, cut and dimpled plates and straight tubes.

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[bggrnchvy]

The frame rails were cleaned and smoothed out and coilover hoop mounting plates and boxes were created.

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Flange mounts were added for diff cover removal.

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The inner side of the frame was plated and boxed back further.

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Axle side lower link tabes and gussets were burned on.

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Frame side link mounts were modified and welded in place.

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Joints and hardware were assembled.

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JMX16t compred to a 1/2" rod end.

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Mockup links were made from 1-1/2" .120w 1018 HREW and some butt tack welds.

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Factory LCA crossmember was found to be an issue so welded in a peice of 2x3 .120 wall furhter forward and then removed it.

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Final links were made using fillet and rosette welds. Upper link material is a 2" .250w 1020 DOM and lowers are 2-1/4" .375w 1020 DOM. Even with short links they ended up being pretty heavy.

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A sway bar was added along with end links made from 1" DOM and 1/2" rod ends.

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[bggrnchvy]

I modified the axhaust to clear the new link mounts as well.

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To provide for slowing the axles upwards acceleration at speed I added pneumatic bumpstops as well in some gusseted cans following dissambly and destroking to work with my suspension.

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The spacer turned on the lathe.

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Showing the change in stroke.

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A last gusset was added to the truss as well as limit strap mounting points and the unit was painted.

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The axle and links were slung under the truck and everything was attached including the limit straps.

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The frame was also primed and painted.

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With that the suspension was completed.

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[Mike]

Thanks for bringing this over here! Don't forget to start a build thread for your truck so you can keep a journal of all your work

 

[Greg]

awesome build thread man. Such attention to detail.

 

[88GMC]

Awesome work as always Kyle. What spring rates did you end up going with on the coilovers? Your truck is the inspiration for mine. Keep us posted.

 

[bggrnchvy]

Thanks for bringing this over here! Don't forget to start a build thread for your truck so you can keep a journal of all your work

I will, I'll work on getting a few more tech articles condensed here and then I'll start it and put them there as an all in one.

 

[bggrnchvy]

Awesome work as always Kyle. What spring rates did you end up going with on the coilovers? Your truck is the inspiration for mine. Keep us posted.

12" 300in/lb spring over a 16" 450in/lb spring.

 

[CodyB]

So what company did you design that setup for?

Thats some insane fab skills you have there sir, Very nice. This is how GM should have done it the first time haha.

 

[The big beast!]

WOW that looks good! nice work! do you want to do my suburban next? haha