I have to agree with Mike here, as when I was looking at SAS'ing my kick, the price of doing that would've been far greater than doing the steel GV housing that I plan on doing.
Just out of curiosity, does anyone know the cost of Heather and Nate's rig? Could give a nice comparison of the cost of SAS and GV front. :-/
Here is a quick run down of our estimated costs.
Front:
Misc steel for cross members, t-case brackets, spring/shackle hangers, shackles, etc = ~200
Dual t-case setup 600 (OTT kicker 3) + ~200 (stock sammy case )= ~800
Calmini rock crawler gears = 1000 (kicker case)
Custom drive line w/long slip + high clearance joints = ~400
Custom front housing = ~250 Sky manufacturing
Custom front axle shafts = ~300
Double tough Birfields = ~200
Jeep Wrangler YJ 2" lift leafs = ~300
ubolts, spring plates, spring perches = ~100
long travel shocks = ~100
rear 3rd member Sidekick = ~200
lengthened break lines = ~50
Sammy sway bar and brackets = ~50
Welding wire, gas, paint, bolts other misc shop materials = ~150
2 Sammy tie rods modified for stearing = ~100
Mercedes stearing arms modified = ~50
Total ~4200 for the front leaf sprung over.
For Rear;
YJ 4" lift springs = ~300
ubolts, spring plagtes, spring perches =~100
long travel shocks = ~100
Custom drive line w/long slip + high clearance joints = ~400
lengthened break line =~25
So probably add ~1000 for doing the rear leaf sprung over
Grand total ~5200 for keeping it 'in the family' Suzuki products.
We have lots of travel, (unmeasured at the tire at this time, but 16 inches of travel at the shocks.)
Lots of clearence. (23 inches at the lowest part of the frame)
Lots of power with the reduction in high due to the sammy case.
Lots of low range due to the rock cralwer gears.
Easily room for 36 inch tires.
20 forward gears, 4 reverse gears.
Bearly fits inside the garage (~2 inches to spare)
It could be done a little cheaper to just have a Sammy front end widened ~6 inches and 1 custom axle shaft made.
You'd still need to address strength in the front axles and birfields. And you'd need to address the slip in the drive lines as the stock slip yokes on the stock case is probably going to be way too short to handle all of the extra travel. (I'd ask Eric B about how he addressed his).
You could also do without all of the extra gearing options we chose to go with. (the Sammy case solved the fixed flange issue at the t-case)
But overall I would say that this is a quick and accurate estimate of our costs.
Please note that a SAS suspension is VERY different from an IFS setup with regards to ride and capability.
Both with Pros and Cons.
~Nate
