Fine.
It's not *quite* a book. But here, free for all.
Thanks for the comments! It's been a cool project and a learning experience.
How far you want to take an SAS conversion really depends on how much $$$
you are willing to spend on it. It also depends on your fabrication
skills, or, the availability of someone WITH fabrication skills or at
least the tools to LEARN the fabrication skills.
We went through two phases of our SAS. We first started out with a Samurai
front axle, which we widened ourselves, and got custom axles as well as
double tough birfields for. The front axle in the end proved to be almost
bulletproof (we trussed it as well) but the rear axle did not. Sidekick
axle shafts are not known for their strength on anything above 31-33"
tires. Especially with a locker. Others might tell you different, if they
haven't broken anything "yet".
We then decided we wanted a stronger rear axle. Well, when you do the
research, you also want something that has the correct offset, and that is
strong. We then learned that a Toyota Landcruiser FJ80 contains the
correct offset axles, and, as a bonus, come with 30 splined shafts, full
floating, electric lockers, and 4 wheel disc brakes. They can be
expensive, however. Mine were. But, they are worth it.
We decided on a leaf spring setup, because like old technology is, it's
simpler, and easier to create. You could go with Coil, though. A lot of
people on the board have. We just didn't have the time, or the skill to
work on creating the links and control arms needed with coils, and then
decide on what kind of coils we wanted.
One of the biggest issues with SAS on a Track/Kick is the transfer case.
You will need to do something about slipyoke elimination. The slips in a
Track Kick transfercase are in the case itself, not in the driveshafts. So
this means your shaft could pull out or push in too far to the
transfercase when you flex.
There are ways to modify your own case for an SYE. It's been discussed on
the forum.
We went to OTT industries and got their Kicker 3 mod. They take your
transfercase, chop off the output shaft, and make an adapter to allow you
to bolt on a samurai transfercase to the back of your sidekick one. Since
a samurai case already IS SYE, then that's taken care of, plus, now, you
have two transfercases.
Other than OTT's mod, (they also created a high steer arm for us because
FJ80 axles are .. different) we did all of the work ourselves in our
garage. We had friends with welders and torches who would work together
with us for work on their rigs, or beer and pizza.
A suggestion to you to keep the SAS cheaper, would be to find a set of
Toyota minitruck axles (79-85), they can be had for about 200-300 bucks,
bolt them on with some Jeep wrangler leaf springs, some shocks, and then
purchase an OTT Kicker 3, or Kicker 2 (that mates a sidekick case to a
toyota case) get some drivelines, put some gears in the toy cases, get a
toyota high steer arm (can be bought at numerous online places) modify the
toyota truck drang link so it's toyota on one side and sidekick on the
other, and away you go.
Sounds simple. There is a lot of fabrication involved, particularly
welding. You'll need to weld on spring perches for the leaf springs,
create new crossmembers, as well as various other things.
I think this is why a lot of people just buy Samurais. Since they are
already SAS. But I like my amenities (I am a girl, anyways) I like A/C,
comfortable seats, and the more modern look.
If you plan on doing the SAS, you can always ask me questions, I'll be
glad to help.
You can also find me on IM during the day using GalvinLuv for AIM, and
hcgalvin on YIM.
Heather
I'll take those PayPal payments now. I'm trying to save up for a polka dot bikini that I can give to Bob next EJS.
EDIT: I SHOULD write a book about my experience with my sidekick. I wonder if it would sell...
