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New Navajo Truggy build


jaschlum

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City, State
Kenmore , WA
Year, Model & Trim Level
1992 Explorer XLT
Light bar is sweet! Post some beam pics if you have a chance.
 


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Trckmagik

Ole Bag
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City, State
Celina, Texas
Year, Model & Trim Level
1996








crazyflights

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St. Joseph, MO
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97 1 ton Jeep
Just read entire thread!!! Wow. Looks great
 




broncobra22

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Oklahoma
Year, Model & Trim Level
1985 Bronco 2
Tube work

Build looks great, cage and light bar looks right...can't wait to see how your going to tie the rear shocks back into the tube work.
 




Elgatoprerunner

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February 6, 2011
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City, State
La Habra, CA
Year, Model & Trim Level
1992 Mazda Navajo Truggy
More light bar work

I had a few hours tonight to work on the Navajo.

IMG_1410.jpg



IMG_1411.jpg



IMG_1412.jpg
 




Skitchy33

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City, State
OR
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'91 XLT 4X4
That thing is looking sweet! I wish I had your skills and wallet!!
 




Elgatoprerunner

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City, State
La Habra, CA
Year, Model & Trim Level
1992 Mazda Navajo Truggy
14" Bilstein Coil Overs part 1

Trying to get this thing done in time for a Thanksgiving trip to the desert. I really didn't want to take it any where with the front suspension being so soft. I bought a set of used 14" Bilstein coil overs and had them rebuilt. The suspension cycles out exactly at 14".


Started with the radius arms. I torched off the lower coil retainer

IMG_1414.jpg


I wanted a little of adjustability so I am installing 2 mounts. I'm thinking if the coil overs are too stiff I can play around with the position of the C/O.
IMG_1419.jpg



IMG_1421.jpg


Boxing everything in.
IMG_1422-1.jpg



IMG_1423-1.jpg


Sneak peak at the coil hoop.
IMG_1425-1.jpg
 




MountainMonkey

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City, State
canada
Year, Model & Trim Level
93 xlt
i had a dream last night that this truck was mine... then i died a little inside when i woke up.
 




Elgatoprerunner

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City, State
La Habra, CA
Year, Model & Trim Level
1992 Mazda Navajo Truggy
Coil over shocks finished

This is the passenger side. What a pain in the ass this side was. I had to move P.S hoses, please ignore the shitty brake tubing job.
IMG_1426.jpg


Cut pieces to fit contour of the frame.
IMG_1427-1.jpg


I havent figured out what to do with the HUGE reservoir
IMG_1428-1.jpg


It sits about 2 or 3 inches higher that I wanted. The coil adjuster is all the way loose. After I drive it I will know what needs to be done. I'm sure it will need softer springs.
IMG_1431.jpg


I think the heavier spring is 400 lb.
IMG_1432.jpg


The passenger side was much easier. I was able to land the tubing right on top of the frame. The best thing about the whole coil over conversion is that i was able to use the shock hoops I had previously made.
IMG_1436.jpg



IMG_1438.jpg
 




Elgatoprerunner

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City, State
La Habra, CA
Year, Model & Trim Level
1992 Mazda Navajo Truggy
Front Air Bump Cans

I couldnt resist flexing it out with the new coil over's
IMG_1439.jpg


Started making a landing area for the bump stops
IMG_1444.jpg



IMG_1445.jpg


I called Radflo and got the dimension for their 4" air bumps. I'm using these poly bump stops for the time being.
IMG_1446.jpg


The problem with radius arms at full bump is the track bar swing. The axle is quite a bit over to the passanger side. This would make the passanger side bump stop sit outboard of the frame sugnifigantly more than the driver side.
I compensated for this by making the bump contact the outside edge of the landing area on the drivers side and the inside landing area on the passanger side. It somewhat evens out the mounting of the bumps.
IMG_1447.jpg



IMG_1448.jpg
 




GRNMACHINE

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City, State
IL
Year, Model & Trim Level
95 Sport 4x4
INsane! Your work is beyond real.
 








4pullingGM

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Princeton, Illinois
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Stand on it!
All the time invested will be worthwhile the first time you take your creation out and use it for its intended purpose :thumbsup:
 




Elgatoprerunner

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City, State
La Habra, CA
Year, Model & Trim Level
1992 Mazda Navajo Truggy
Hand operated light bar (Adjustable)

I wanted to make the light bar adjustable on the fly.

Being that both the ends were attached with heims I needed a way to provide friction so the lights would not move unless I moved them.

I started by machining out some steel pipe to accommodate a piece of copper tube. I cut a slit in both to allow the squeeze and welded some smaller tubing for bolts. The copper acts like a bushing.
IMG_1455.jpg


Mounted this piece to the middle of the light bar tubing
IMG_1456.jpg


I welded on some pieces of tubing on either end for hand grips. Both passenger and driver can operate by reaching outside the window.
IMG_1458.jpg


I stole some grips off my daughters scooter. She wont mind.
IMG_1461.jpg
 




GRNMACHINE

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IL
Year, Model & Trim Level
95 Sport 4x4
Ingenious! Hate to see your daughters face when she sees her scooter without hand grips! Heh Heh
 




Elgatoprerunner

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City, State
La Habra, CA
Year, Model & Trim Level
1992 Mazda Navajo Truggy
Rear shock mounts

Finished the rear shock mounts today.


IMG_1467.jpg



IMG_1469.jpg



IMG_1470.jpg



IMG_1471.jpg



IMG_1472.jpg


Finally removed the cage and welded it up today.
IMG_1473.jpg


The unistrut is so the cage doesn't warp.
IMG_1474.jpg
 




baphomet666

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City, State
Bordeaux,FRANCE
Year, Model & Trim Level
Explorer.1994. 4WD
:notworthy:notworthyOMG it's a mammoth task, I can not explain what I feel when I see all you did fact, what mastery, and all these ideas, I am dreaming to such an achievement, Congratulations you are a genius Mr Elgatoprerunner:thumbsup::thumbsup:
-:exp::exp:
 


Join the Elite Explorers for $20 per year. Gets rid of the ads! New $5 per month "try out" option.

Explorer Forum has probably saved you that much already, and will continue to save you money as you learn how to diagnose fix problems yourself and learn which modifications work without having to experiment on your own. Elite Explorer members see no advertisements, no banner ads, no double underlined links, can add their own profile photo, upload photo attachments in all forums, and Media Gallery, create and save more private Conversations, and more. Join Today. Your support is greatly appreciated.




Elgatoprerunner

Active Member
Joined
February 6, 2011
Messages
224
Reaction score
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City, State
La Habra, CA
Year, Model & Trim Level
1992 Mazda Navajo Truggy
Almost finished

:notworthy:notworthyOMG it's a mammoth task, I can not explain what I feel when I see all you did fact, what mastery, and all these ideas, I am dreaming to such an achievement, Congratulations you are a genius Mr Elgatoprerunner:thumbsup::thumbsup:
-:exp::exp:

Wow. Your too kind. I hope my head will fit through the door now.






Before I welded the cage on I thought I should do something with the 1/2 a rear fender well I had left after the chop.


I cut the outer skin to the shape I was looking for being careful not to cut the inside fender well lip.
I made some relief cuts in the inner fender well and bent and hammered them to meet the outer skin. Then tacked them together.

IMG_1479.jpg



IMG_1480.jpg



The picture is bad but it turned out pretty good. A little bondo and it looks close to factory.


Almost finished painting
IMG_1477.jpg


IMG_1484.jpg


This is from the first trip out. I'm trying to put together a video from my Go Pro helmet cam I mounted all over to get some cool action shots. As soon as I figure it out I will post.
IMG_1491.jpg
 




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