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Trackota YJ - SAS Project Pictures

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Offline Shredder

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Trackota YJ - SAS Project Pictures
« on: September 01, 2008, 02:49:02 PM »
My brother calls it a Trackota Wrangler because of the parts used. I am just glad to see it fanally coming together. It has been collecting dust in the garage for 2 years. I guess I just had to finally commit to doing it.

All in all it is coming along good. I would have been done by now if I just welded up what I needed to get the spring mounts on but I wanted it to be able to be duplicated and bolt on. I used CAD for all the parts I designed and made. Although you do need to cut off the old IFS brackets and crossmember and drill a few holes the rest is bolt on (with the option to weld for added strength). I took it apart to clean everything up but when I put it all back together I will shoot some pictures.

It is a Gen. 1 SWB with Toyota pickup axles and YJ springs front and rear. It will be interesting to see just how fast it can be installed when I put it all back together. I am going to clean the axles up and shoot some paint on them. Then I will put it all back together. I have a busy week ahead with the fire station but should be putting it back together next weekend. Here are the parts. I might have edit this as I remember more.

Parts List (I made):
2 Front spring hangers (bolt on)
2 Front spring shackle mounts (bolt on)
2 Rear spring hangers (bolt on)
2 Rear spring shackle mounts (bolt on)
4 Shackles (bolt on of course)
2 Front shock upper mounts (bolt on)
2 Front shock lower mounts (bolt on)

Other parts:
2 Toyota pickup axles F/R
4 YJ front springs (4 leaf), (YJ rears, 5 leaf, recommended for SPOA)
2 front shocks
2 rear shocks
3 weld on axle/spring perches for spring under aplication
4 New brake lines
« Last Edit: September 11, 2008, 11:40:49 PM by Shredder »
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'96 Astro Van 2wd, +10 Overland, 32s, Tow Rig
'96 Tracker LWB 4x4, +4.5 Calmini/Boondox, +3 Boondox BL, 31x10.50 (wife rolled)
'93 Sidekick LWB 2x4, 235s, +3 Boondox Suspension kit, 4wd swap 2b
'91 Tracker SWB, Toy axles, YJ Springs, Boondox Swap Kit, 31x10.50
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Offline Shredder

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Re: Trackota YJ - SAS Project nears completion (Pictures)
« Reply #1 on: September 11, 2008, 11:40:00 PM »
Well I got the chance to start work on the Trackota Wrangler. Here is a shot of it after cutting off the IFS and removing the rear suspension and axle. The YJ springs are also in this shot.


The Toyota axles waiting to be cleaned up.


Here are most the 1/4" pieces cut and bent before welding up to make the "kit".


This shot shows most the parts ready to be bolted onto the Tracker frame.


This is a few hours later. The "kit" installed surprisingly fast. I had all the brackets on and the springs hanging in about 4 hours. Then I had to decide between spring over or spring under. Spring over was easy. I just rolled the axles under and bolted them up. It was too tall for the wimpy 31" tires I currently have on the Toyota rims so I decided on spring under. This shot shows it with the rear spring over while the front is spring under. Spring under did require the welding on of spring perches on the axle.



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'96 Astro Van 2wd, +10 Overland, 32s, Tow Rig
'96 Tracker LWB 4x4, +4.5 Calmini/Boondox, +3 Boondox BL, 31x10.50 (wife rolled)
'93 Sidekick LWB 2x4, 235s, +3 Boondox Suspension kit, 4wd swap 2b
'91 Tracker SWB, Toy axles, YJ Springs, Boondox Swap Kit, 31x10.50
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Offline j2custom

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Re: Trackota YJ - SAS Project Pictures
« Reply #2 on: September 12, 2008, 09:20:38 AM »
That is really cool.  I like the "bolt on" idea, is that something you are going to produce?  It may sell...
Nice job  8)
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95sidekick

Re: Trackota YJ - SAS Project Pictures
« Reply #3 on: September 12, 2008, 06:23:42 PM »
that is awesome, i want it..lol if you ever decide to make one to sell , lots of us would love that kit...well i no i would!
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Offline Shredder

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Re: Trackota YJ - SAS Project Pictures
« Reply #4 on: September 14, 2008, 09:51:50 AM »
Here is a picture of it with the spring under option. It sit's pretty much how I hoped it would. It measures about 38" at the fenders on 31" tires. It has 16" under the frame rails and 18" at the rockers. About the same as a 6.5" suspension lift would be. No body lift.

This was done with new 4-leaf YJ springs F/R. I think 2-3" lift YJ springs would be nicer. I also tried with the springs over the axle which gave it about 21" under the frame rails but it looked silly with the 31" tires.

Overall I liked the "kit" however I am making a few simple changes to make it even better for the next one.

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'96 Astro Van 2wd, +10 Overland, 32s, Tow Rig
'96 Tracker LWB 4x4, +4.5 Calmini/Boondox, +3 Boondox BL, 31x10.50 (wife rolled)
'93 Sidekick LWB 2x4, 235s, +3 Boondox Suspension kit, 4wd swap 2b
'91 Tracker SWB, Toy axles, YJ Springs, Boondox Swap Kit, 31x10.50
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Offline Amilla

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Re: Trackota YJ - SAS Project Pictures
« Reply #5 on: September 14, 2008, 12:00:43 PM »
Looking good! 
Have you thought about adding a piece to your spring hangers to act as a skid point.  The way they are sitting now looks like you could have some snag points while sliding over obstacles.

Something like this.


Just my 2 coins worth

Amilla
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Offline Shredder

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Re: Trackota YJ - SAS Project Pictures
« Reply #6 on: September 14, 2008, 04:13:43 PM »
That's a good point and observation. Just may have to do that. Thanks.
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'96 Astro Van 2wd, +10 Overland, 32s, Tow Rig
'96 Tracker LWB 4x4, +4.5 Calmini/Boondox, +3 Boondox BL, 31x10.50 (wife rolled)
'93 Sidekick LWB 2x4, 235s, +3 Boondox Suspension kit, 4wd swap 2b
'91 Tracker SWB, Toy axles, YJ Springs, Boondox Swap Kit, 31x10.50
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Offline 90LSI

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Re: Trackota YJ - SAS Project Pictures
« Reply #7 on: September 15, 2008, 07:20:17 PM »
Any plans to sell the kit and or possible drawings for all of the bracketry so that I can make my own  ;D ;
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Offline Shredder

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Re: Trackota YJ - SAS Project Pictures
« Reply #8 on: September 16, 2008, 07:59:43 AM »
It is being considered as a kit. I am making a few small changes in it to address any of the issues observed and to make it easier to manufacture. The prototype emptied my wallet (firefighters are underpaid). There is over $200 dollars in the 1/4" steel alone. Then there was the plasma cutting, bending, drilling 96 holes, welding, grinding and painting. There are a few machined parts in it also and over $75 in grade 8 and 10.9 hardware. Then I also had to build the jig to fit and hold the parts during welding.

Metal is expensive so I need to do a CAD layout for the laser cut so all the pieces nest for minimal scrap. The laser will also be able to "drill" the holes at the same time for less man-hours. Not to mention less drill bits. I'm working out price structure for it now. So you just might see an actual kit soon.  ;) It's hard to find time to do all this when you are a firefighter 24/7 but I have had alot of requests for this.

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'96 Astro Van 2wd, +10 Overland, 32s, Tow Rig
'96 Tracker LWB 4x4, +4.5 Calmini/Boondox, +3 Boondox BL, 31x10.50 (wife rolled)
'93 Sidekick LWB 2x4, 235s, +3 Boondox Suspension kit, 4wd swap 2b
'91 Tracker SWB, Toy axles, YJ Springs, Boondox Swap Kit, 31x10.50
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Offline 91zukisas

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Re: Trackota YJ - SAS Project Pictures
« Reply #9 on: September 16, 2008, 06:51:07 PM »
This kit will be great!
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Offline v-stone

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Re: Trackota YJ - SAS Project Pictures
« Reply #10 on: September 19, 2008, 10:09:28 PM »
Are you using the stock sidekick steering box? What did you do for steering?
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Offline Shredder

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Re: Trackota YJ - SAS Project Pictures
« Reply #11 on: September 20, 2008, 07:07:47 PM »
Yes the stock Tracker steering box was retained. The steering linkage used on the axle was stock toyota. For a temporary set-up we tried a driver side tierod on the passenger side with a shortened crossover. A custom draglink between that tierod's stabilizer mount and the pitman arm connected the two. This is going to be changed to an aftermarket hi steer setup to allow for spring over axle also. I'll post some pics of it once the change is completed.
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'96 Astro Van 2wd, +10 Overland, 32s, Tow Rig
'96 Tracker LWB 4x4, +4.5 Calmini/Boondox, +3 Boondox BL, 31x10.50 (wife rolled)
'93 Sidekick LWB 2x4, 235s, +3 Boondox Suspension kit, 4wd swap 2b
'91 Tracker SWB, Toy axles, YJ Springs, Boondox Swap Kit, 31x10.50
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Offline 96Kicker

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Re: Trackota YJ - SAS Project Pictures
« Reply #12 on: September 23, 2008, 07:43:03 AM »
Is this the Boondox kit that has been in developement?
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Offline Shredder

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Re: Trackota YJ - SAS Project Pictures
« Reply #13 on: September 25, 2008, 07:47:41 AM »
Quote from: 96Kicker on September 23, 2008, 07:43:03 AM
Is this the Boondox kit that has been in developement?

I guess you could call it that since I am the only one left at Boondox. I run it on the side (real job = fire fighter/first responder) from my garage/basement and do what I can to keep customers happy but it isn't easy with my schedule. Development of this kit stalled for over a year but I finally made some time to get to it.

Boondox will soon be moving to Denver where the new owner has some good plans to make things better. I'll still be connected with them in R&D work though which is cool.

BTW- Sorry I am so hard to get hold of to any of you reading this. It is hard to take a call when you are fighting a fire. :police:
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'96 Astro Van 2wd, +10 Overland, 32s, Tow Rig
'96 Tracker LWB 4x4, +4.5 Calmini/Boondox, +3 Boondox BL, 31x10.50 (wife rolled)
'93 Sidekick LWB 2x4, 235s, +3 Boondox Suspension kit, 4wd swap 2b
'91 Tracker SWB, Toy axles, YJ Springs, Boondox Swap Kit, 31x10.50
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Offline bashzuk

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Re: Trackota YJ - SAS Project Pictures
« Reply #14 on: September 25, 2008, 11:16:51 AM »
Shredder do you have an estimate of customer cost this is exactly what I would like to do to a tracker.
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