SAS 720 Build Thread.

[MetalFab]

I'm posting up a build thread for those of us who want more out of their 720's. I'll be starting from scratch, that is, from the frame up.

Cleaned up the front of the frame, cutting away all the ifs nonsense and leaving the steering brace that the previous owner had already fabbed up.


Flipped the frame upside down and added 2x2 square tubing to the front of the frame and then added the 2x4 below it(above in the pic) to drop my hangers from.




Traded for a set of 6 inch BDS lift springs out of a full sized blazer Thanks Dan.


Had some 4x4 tubing lying around that works perfectly for the full width springs.




About how it's going to look.


More to come.

[PEZi]

This should be awesome to watch! Good luck man.

[Nathyne]

Nice good progress I should be starting one soon aswell! A couple weeks yet though. A little behind because I rear ended someone in my GTR had to dump some money into a new hood rad support, rad and fan for it (didn't damage the bumper or intercooler somehow!). Will be watching your thread closely that's for sure.

Edit: Also what thickness of metal are you using and are you just using a 120v mig? Thanks

[MetalFab]

Thanks guys, I've also cut out two of the cross members, leaving the middle one for structural support for the moment, lopped off the rear shackle mounts to use for the front as I'll be going with a really flexy leaf and a half setup for the rear end.

The 2x2 and 4x4 is 1/4 inch, the 2x4 is only 1/8 inch(it's what I had lying around) I'll be plating the front end to tie it all together to hopefully withstand the v8 that will be going in shortly.

The welder is a 240v miller. I wouldn't trust a 120v mig to do the job and I'd suggest sticking to 1/4" material as much as possible, but if I had to use a light mig I'd invest in a torch of some kind, bevel all your edges or groove butt connections with a grinder and preheat the material where you plan to weld. You might try testing this out on some scrap metal then do a destructive test (a BFH is my fav) to see how far your mig penetrates using those techniques. Better safe than coming apart on the highway somewhere.

[datsuntruggy]

I bought my 720 two weeks ago tring to soak in as much knowledge. As possiable be before I start my sas!!! What front axle r u useing???

[MetalFab]

I was going to use a toyota solid axle of unknown year but with drum brakes yet things are still up in the air as to what exactly I will use. I found a lightly used axle out of an 85 yota in the local junk yard yesterday and I'm hoping it'll still be there tomorrow when I can afford to buy it. It's the best year yota axle you can get and I can't let it pass me up. If that doesn't happen my buddy has a pair of axles under a 79 that he's willing to trade me so either way I'll have an axle set up with rotors up front and it only costs $37 including shipping to pick up a rear disc brake conversion bracket for the rear off ebay which use rotors and calipers off the front of a v6 toyota.

I have been busy with other projects but I've finally gotten to the suspension again. Made up offset shackles out of 2"x3/8" flat stock.



The axle I was going to use, and still might end up using as worst case scenario.


And the drivetrain that will go in it. My buddies are weakening my defenses for the time being for wanting an automatic in a crawler. I'll give it a try for now until I can find the right trans and transfercase setup that I want to keep. Most likely a turbo 400 203/205 doubler if I do end up digging the v8 with an auto in this ride.


Going to mock it up and see what it looks like on 34's in the next few days.

[Rev_D21]

This thread delivers! Looking great so far!

[MetalFab]

6 inch shackles, 4 inches bolt to bolt. I'm already lifting the truck 10 inches so I don't see the need to go any higher with extended shackles. I'm not worried about axle angles for now as those will be corrected with new perch mounts. On the shackles I should have drilled the spring end holes alittle lower so the bushing was almost flush with the end of the shackles, it would have been cleaner but I'll live with it.

[datsuntruggy]

Awesome step by step this will help me a lot in my build keep it going!!! !

[datsuntruggy]

What's the I.d on that 4x4 square tubing your using!!

[MetalFab]

3.5 inches, which just happened to be the outside diameter of the bushings in the 6" chevy lift springs. I was lucky and just went with it, else I'd have just made 2 pairs of brackets out of 1/4" flat stock.

I'm currently playing musical chairs with axles and trying to keep my tow rig operable. More to come as soon as I can get a pair of axles under this rig and find out my rear elevation.

[datsuntruggy]

When yall put that 350 in visios Satsuma I seen where he cut the firewall and trans tunnel. I have a 3 inch body lift on my truck do u think I would still have to cut all that out like he did???

[datsuntruggy]

When yall put that 350 in visios datsun I seen where he cut the firewall and trans tunnel. I have a 3 inch body lift on my truck do u think I would still have to cut all that out like he did???

[datsuntruggy]

On the 4inch tubing what's the measurement on how u cut it? I see the 2" over hang but how tall is it where the leaf spring eye goes in

[datsuntruggy]

I found a set of axles front and rear complete for free!! There out of a 1992 Jeep wrangler there d30 front and d35 rear! Problem is there driver side drop! I read some where that I can clock my devorsed t case to driver side is this true??

[MetalFab]

Many companies make kits to clock t-cases to certain degrees, IMO it would be best to find a divorced T-case with a left hand drop. The issues I see with clocking a case 180 degrees are possible linkage issues depending on the type of case you use. You'll run into issues with oil inlet and drain which can be solved with drilling and tapping the case in other locations but you will have to ask a specialist or t-case rebuilder to know for sure what levels of oil you need to keep the proper gears lubricated upside down.. It really opens up a can of worms. A quick google search for driver side drop tcase shows that ford makes a divorced drivers side drop np205. The 205's are the way to go imo as they are gear drive and virtually bulletproof.

I'll throw a tape on my buckets to see what the exact height is, 3-4 inches. All you really need is a pair of tabs long enough to give you clearance for the spring eyes and another 1/4 inch or more for bushing flex. You may not want to build your truck as tall as mine.. Heck I may regret going this tall. But it's only metal.. I'll just do it again.

Going to pick and pull tomorrow to see if that 85 toyota axle is still there, I doubt it is but I gotta try anyway.

[datsuntruggy]

Thanks Bro!!!! Your a life saver!!! You make thangs a lot waxier just ask u instead of a lot of searching cause when I searched the t case problem everyone was saying do this do that then smothered Guy would say smothered thing totally diff

[MetalFab]

That 85 yota axle was gone the day I walked away from it.. I knew I should have tore it loose and paid for it somehow.. Talked to one of the forklift drivers and he said the next day they cleared out that section and restacked 3 of them.. two went to the scrappers, sure enough that yota was picked clean and gone. It's alright though, I'll make due with a 79 axle and build my own trusses =)

Motto? Don't ever walk away from a good deal.

[datsuntruggy]

Sorry to hear that!! I read on pirate4x4 somewhere about that I can use my stock devorced t case and build a new cross member to reclock it to driver side drop. But I can't find it anywhere now.

[MetalFab]

I thought I saw somewhere that you were going v8/auto? while you're fabbing up your newly clocked nissan transfercase think about whats going to happen when you least want it to.. one good goose with bigger tires and a v8 and that case is going to scatter =P Just a thought.

[datsuntruggy]

What t case would u use what a Chevy 305 mild cam th350 d30 front d35 rear on 33 or maybe one day 35's?

[MetalFab]

Finally got back to the chassis after finishing several other projects that popped up. Having very few materials and no cash to buy flatstock I ended up digging into what little I have left of the 4x4 square tubing. I might as well match it up some and use it everywhere to keep the "theme" the same. I'm building so the rear of the vehicle sits an inch or two lower than the front to make up for the sag I'll get with the V8 up front and for stability off road. I doubt it'll be enough to give it any pre-runner look. Anyway, here's a few pics.





Just threw it on the frame for now until I can find my 9/16 drill bit or buy a new one. It'll sit under the frame butted up to the old spring hanger which I'll definitely cut off soon. The new location plus the length of the chevy springs should stretch my wheelbase about 6 inches+ and give me enough room to run a mated np205 transfercase with a divorced np205 behind it ^_~

Still have to plate the frame up front and make new spring perches on the front axle before I can mock up the engine/trans/cases. I hope to have it rolling by this weekend.

[MetalFab]

Rear spring brackets are almost finished. They're taking foreeever because I nit-pick everything. I had to cut a half inch strip out of the middle of the bracket to narrow it from 3-5/8"id to a snug 3-1/16". Once I plate the 45 degree angle I'll weld em on and get this show on the road.

[MetalFab]

Stayed up til after 2am lastnight in the garage on a few projects and finished these up.. Starting to get the hang of my buddies mig but I still can't seem to weld in a straight line maybe someday when I grow up I'll be able to actually weld in a process which supposedly monkeys can be trained to do but at least I'm good with a grinder!

[MetalFab]

I should have cleaned up the frame better, and will while I grind these welds down and throw some plating on the frame to reinforce this section as the frame is rather thin.

Heading to the coast for a few days and still trying to come up with some tubing and plate.. or the funding for it.

[Bloodman324]

Looking good so far haha are you gonna keep the 720 body style when your all finished? or is it gonna look like somethin else haha just wonderin

[MetalFab]

Just got back from the coast, I reaaaallly wanted to take my tow rig out on the ohv dunes but I didn't want to chance getting it stuck lol, next time I'll have to trailer my nissan out there and make sure I have some proper extraction tools on hand.

I picked up a few feet of tubing at gerlingers to make bushing brackets for the rear of the chassis. I also scored on about 4' of semi bent up 3/16x4" strap that I can get several projects out of the way with, all for about 15 bux, way cheaper than I expected (honestly I didn't know what to expect so I just imagined an arm and leg) They didn't have any 1/8th sheet handy but they get new scrap daily from their fab shop next door.

I want to stick really close to the stock nissan look, I don't want to modify the grille or hood like visio did to make the radiator and aircleaner fit but I do plan to cut up the fenders some, I want to keep the round look while maybe making bushwhacker flares for another application fit.. Fenders will be cut horizontally flush with the bottom of the headlights/grille and the bumper I have in mind will tuck in to give me a decent approach angle. I don't plan to dovetail the front end at this point although I have thought of glassing some prerunner fenders to help cover the beefy tires.

[synack7350]

you're sick metalfab

[MetalFab]

Plated the inside of the frame and bolted on the front axle. Starting to believe the axle is older datsun, I read somewhere that they come with kingpin axles up to 78.

Had to widen the spring perches on the axle, did this by taking a piece of that 4" square tube and cutting one side flat and the other with a U shape to fit the axle and placed it over the existing perch. It might not stay that way if I decide to change the caster. I also had to make a new top plate to mount the spring to the axle as the ones I had kicking around didn't match the 2.5" spring width.

Moving back to the rear tonight.

[MetalFab]

No progress, but I did pick up some tires. 35 12.5 r17.









Going up!! Only down side is 17" 6 lug wheels are $100 bux a pop, and thats for the cheap ones.