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Offline Flyin6

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Tundra SAS conversion
« on: September 26, 2014, 12:46:40 PM »
Years ago I discovered the TRD off road package I had on my Ivan Steward edition Tundra meant it was capable of pulling off the road onto a parking lot or driveway. the truck had 4WD in the event the driveway was gravel, and even low range in the event you had groceries in the back seat.

I was so disappointed with the off-highway capability of that truck that one day I decided to commit to a solid front axle.

I thought I'd show that commitment by simply putting it on jack stands, then using a plasma torch to get the stock junk on the ground!
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Offline Flyin6

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Re: Tundra SAS conversion
« Reply #1 on: September 26, 2014, 12:50:08 PM »
I sourced a high pinion Dana44 from an ancient Ford F250

Yea, what I was thinking...Dana 44 in an F250.

Oh well, I bought it!
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Offline Flyin6

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Re: Tundra SAS conversion
« Reply #2 on: September 26, 2014, 12:52:20 PM »
Then I slid it under the frame rails using plumb bobs to accurately locate it
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Offline Flyin6

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Re: Tundra SAS conversion
« Reply #3 on: September 26, 2014, 12:55:24 PM »
PVC really increases accuracy!

Well, maybe it doesn't, but I was believing my way through it!

I ended up deciding to do a coil-over 4-link mostly because everyone else was doing leaf springs

I had to build the arms myself from DOM tubing and a 3/4" threaded insert and home-made studded jonny joints
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Offline Flyin6

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Re: Tundra SAS conversion
« Reply #4 on: September 26, 2014, 12:56:02 PM »
Had a cool garage floor before I started too!
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Offline Flyin6

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Re: Tundra SAS conversion
« Reply #5 on: September 26, 2014, 12:57:43 PM »
I made the studded joints by welding a 3/4" bolt to a jonny joint. The threaded stuff and all the gee-whiz stuff was not on the market yet at that time, so I had to get more inventive
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Offline Flyin6

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Re: Tundra SAS conversion
« Reply #6 on: September 26, 2014, 01:03:03 PM »
Then out of sheet steel, I drew and cut out the tabs, then welded them in place
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Offline Flyin6

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Re: Tundra SAS conversion
« Reply #7 on: September 26, 2014, 01:03:46 PM »
A little crude looking, but OK for 2003
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Offline Flyin6

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Re: Tundra SAS conversion
« Reply #8 on: September 26, 2014, 01:05:12 PM »
Then I fabbed up a new cross member. I did so because I was going to use that for the top arm mounts.
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Offline Flyin6

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Re: Tundra SAS conversion
« Reply #9 on: September 26, 2014, 01:07:34 PM »
That second pic, last post is the modified skid plate

I selected King to build me up some dandy 12" stroke coil-overs with two different rate springs
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Offline Flyin6

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Re: Tundra SAS conversion
« Reply #10 on: September 26, 2014, 01:12:32 PM »
I fabbed up a couple three legged shock hoops, bending up some 2" tubing on my model 300 bender
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Offline Flyin6

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Re: Tundra SAS conversion
« Reply #11 on: September 26, 2014, 01:13:11 PM »
And after plating the front frame with 1/4" steel, welded them in place
« Last Edit: September 26, 2014, 01:14:19 PM by Flyin6 »
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Offline Flyin6

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Re: Tundra SAS conversion
« Reply #12 on: September 26, 2014, 01:20:32 PM »
The upper and lower control arm mounts came next:
« Last Edit: September 26, 2014, 01:24:10 PM by Flyin6 »
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Offline Flyin6

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Re: Tundra SAS conversion
« Reply #13 on: September 26, 2014, 01:23:30 PM »
Sort of snuck ahead there with the pics.

Next I built the panhard bar
« Last Edit: September 26, 2014, 01:45:40 PM by Flyin6 »
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Offline Flyin6

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Re: Tundra SAS conversion
« Reply #14 on: September 26, 2014, 01:38:29 PM »
The steering box was built by PSC and featured a pressure takeoff for a lower ram assist
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Offline Flyin6

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Re: Tundra SAS conversion
« Reply #15 on: September 26, 2014, 01:43:36 PM »
That box was actually from an earlier IFS toy truck which had been given the full treatment

So next the steering linkages
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Offline Flyin6

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Re: Tundra SAS conversion
« Reply #16 on: September 26, 2014, 01:46:59 PM »
Then I had my brain removed and decided to paint things awful colors
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Offline Flyin6

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Re: Tundra SAS conversion
« Reply #17 on: September 26, 2014, 01:51:05 PM »
Then the shocks went on and I started running the lines for the ram assist
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Offline Flyin6

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Re: Tundra SAS conversion
« Reply #18 on: September 26, 2014, 01:55:29 PM »
You might have noticed the ring and pinion.
I have been a long time customer of Randy's Ring and pinion. I ordered a complete rear 4.56 set up carrier, and all the stuff along with an eaton locker front

I actually set those gears up myself
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Offline Flyin6

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Re: Tundra SAS conversion
« Reply #19 on: September 26, 2014, 01:59:28 PM »
Then new drive shafts including this Tom Woods unit with some strange offset U-joint

It never worked well, and was only good for 5mph. The truck needed a double cardan unit on the transfercase end to be sure
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Offline Flyin6

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Re: Tundra SAS conversion
« Reply #20 on: September 26, 2014, 02:02:59 PM »
Assembly continued

along with some way small 33" tires and 8" wheels
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Offline Flyin6

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Re: Tundra SAS conversion
« Reply #21 on: September 26, 2014, 02:06:12 PM »
I had ended up flipping the shackles which gave me all the lift I needed for the read. That required some 14" Brillstein 5150's and some rewiring of the brake system
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Offline Flyin6

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Re: Tundra SAS conversion
« Reply #22 on: September 26, 2014, 02:08:32 PM »
Then just like that, it was time to test the flex
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Offline Flyin6

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Re: Tundra SAS conversion
« Reply #23 on: September 26, 2014, 02:12:42 PM »
Nothing historical, but a lot better, and as you will see in a moment, it gets a lot better in the dirt

I then added some 35" tires to cut down the gear to a proper hum and fill those wheel wells up some
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Offline Flyin6

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Re: Tundra SAS conversion
« Reply #24 on: September 26, 2014, 02:15:29 PM »
And in the dirt
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Offline BobbyB

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Re: Tundra SAS conversion
« Reply #25 on: September 26, 2014, 04:02:18 PM »
I did like that set up. I wanted to do that to mine... but I sold it.
So, Bobby...being the calculating trained warrior NCO that you are.  Take the appropriate action, Execute!
your standard grunt level CQB is just putting rounds and rounds on scary stuff till it stops scaring you!

Offline Flyin6

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Re: Tundra SAS conversion
« Reply #26 on: September 26, 2014, 05:15:40 PM »
Me too!
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Offline KensAuto

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Re: Tundra SAS conversion
« Reply #27 on: September 26, 2014, 05:22:32 PM »
I'm not in to tundras....but...that was an awesome setup, and I bet you enjoyed it!
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Offline Flyin6

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Re: Tundra SAS conversion
« Reply #28 on: September 26, 2014, 08:35:18 PM »
I did for over 10 years
It had 37's on and 4.88's that Tate helped me setup.
I added a supercharger and was building it when one day I took it out and floored it from a dead start.
It ripped half the teeth off the ring gear before snapping the pinion gear in half.
I guess it was making a bit more torque that I had suspected.
Later I did something interesting
Instead of selling or junking it, I took it apart and ebayed all the parts fetching near premium prices. I recall getting $3700 for the supercharger, $2800 for the Dana 44, $1200 for the trans and on and on.

What I had left was a pretty good looking body that I tried to give to our very own Bobby, then later Ashley, but with no takers, I sold it for $1500
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Offline KensAuto

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Re: Tundra SAS conversion
« Reply #29 on: September 26, 2014, 09:42:34 PM »
It sounds like you did alright!
Speaking of Ashley, I haven't seen him (here) yet. I miss conversing with him.
« Last Edit: September 26, 2014, 09:43:14 PM by KensAuto »
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Offline Bob Smith

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Re: Tundra SAS conversion
« Reply #30 on: September 26, 2014, 11:13:37 PM »
It sounds like you did alright!
Speaking of Ashley, I haven't seen him (here) yet. I miss conversing with him.
Ditto, I hope all is well with that young man

Offline Flyin6

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Re: Tundra SAS conversion
« Reply #31 on: October 11, 2014, 05:17:02 PM »
It sounds like you did alright!
Speaking of Ashley, I haven't seen him (here) yet. I miss conversing with him.
Ash is back, he just joined!
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Offline JR

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Re: Tundra SAS conversion
« Reply #32 on: October 13, 2014, 01:21:57 PM »
I remember when you were trying to get that "toy" out of the garage during your builds. At least you got some $$ back from it.

I am off to do 4 pallets of pavers next to the pool. Hopefully the burb can get some work done on it at night. retired and less time!
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Offline Flyin6

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Re: Tundra SAS conversion
« Reply #33 on: October 13, 2014, 05:16:55 PM »
retired and less time!

Good problem to have!
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