Project Green Hornet '01 Sport SAS

[OffTrac]

I'm just silently watching since you're doing exactly what I want to do.

Edit: disregard pm part.

If you have a parts list, I'd walk to Tennessee for it.

 

[1-MEAN-X]

As far as a parts list, here is a run down. I don't have any part numbers, but they are pretty easy to find/figure out. If you trouble figuring something out just ask.

Front:
Front leaf spring hangers - ruffstuffspecialties.com
rear shackle hangers - ruffstuffspecialties.com
boomerang shackles - eBay
Rancho leaf springs - amazon
2x3 rectangle stock for front cross bar for mounting front hangers
Stock 1978 f250 Dana 44hp 8 lug machined for high steer
high steer arms - skymanufacturing.com
3/4" shank 5/8" eye heim joints - eBay
9' of 1-1/4x.120" wall dom tubing for steering
Safety washers for heim joints - ballisticfabrication.com
F250 upper shock towers - eBay
lower shock mounts - ballisticfabrication.com
outriggers for shackle mount - homemade
steering gear box from Chevy astro van (forgot year check earlier posts) tapped for hydro-assist later
Steer box brackets - homemade

Rear:
Pro comp add a leaf - done several years ago
leaf spring perch - ruffstuffspecialties.com
Brake caliper brackets - cutthroatoffroad.com
brake calipers for 1980 k20 - eBay
brake rotors for 1980 k20 - eBay
F250 upper shock tower - eBay
lower shock mounts - ballisticfabrication.com
Stock rear Dana 60 from 1978 f250

I'm probably forgetting some stuff but that is the run down. Alot of the eBay parts actually came from barnes4wd.com. I think that's their actual website. They have alot of great stuff and were really easy to work with.

Hope this helps.

 

[1-MEAN-X]

Just a side note, my wife told me yesterday that I HAVE the have this thing finished by mid October. Why you may ask? Because she wants me to take her to wheeling in the country in summertown tn which is near where she grew up for our 1 year anniversary weekend of fun. How cool is that? I thin she's a keeper.

 

[OffTrac]

Thanks. That'll help a lot with getting started.

 

[1-MEAN-X]

Update: I had to make a new battery box top for the new battery that was given to me after my optima red top died. I didn't want to waste the ballistic box that I had so I just made a new top for it.

Here is the concept with the actual pictures of box after paint.

 

[1-MEAN-X]

I'm headed to the pull-a-part in Nashville this weekend to get a set of roller wheels/tires since all I have are 5 lug. While I'm there it got me thinking about checking out some other parts. What are your thoughts about a divorced t-case since my transmission is 2wd right now? Or should I just snag a 4wd 5r55e and a 1354 manual t-case and go that route?

 

[1-MEAN-X]

Well I was able to finish getting the tone ring taken care of and mounting the ABS/VSS sensor on the housing. I also installed the new 44 under the front and got some tweaking done. I still need tires (obviously), but it gives you guys an idea of how wide it will be when it gets done. I think it is going to look good. Not too wide, but gives it an aggressive edge.

 

[1-MEAN-X]

.

 

[exploder01sport]

I have an 01 sport as and this is the first true SAS thread I've seen, I've been wheeling for a while, but this is the first time I've thought about an SAS on my truck, can anyone give me some pointers as to which is better/cheaper, leafs or coils in the front? Also is it okay to keep the stock 8.8 in the rear? And How did you obtain the lift with the leafs or did you get brand new leafs? Also what is the time/average cost of this project?

Thanks a lot!

 

[1-MEAN-X]

Personally, I think leafs are cheaper and easier to use for a SAS. I don't have much experience with the coils, but to me it seemed like a lot more brackets etc. for trac bar and all that. Some of you other guys that have done a SAS with coils may want to weigh in.

The stock 8.8 is very capable and frankly would make the project a lot smoother. I originally intended to use the 8.8 and a EB front 44, but came across the full width 44/60 combo on a trade.

For the rear lift I did a SOA. There are a lot of threads about how to do this so just do a quick search and they will be able to help out. Once I get around to installing the rear 60 I will have more pictures of the brackets and brakes etc.

As far as how much time/money it takes, it varies widely based on how much time you have devoted and how readily you have parts and tools. Money is another story. It all depends on what route you go. There really is no answer for that other than if you are on a tight budget, maybe just do a spindle lift and a SOA and call it a day. There is a lot of time and a good chunk of money in most SAS.

 

[4pullingGM]

First I've seen of your project, good job, it's looking good!

 

[1-MEAN-X]

Thanks. Hopefully I can get it wrapped up this month. That would be sweet.

 

[4pullingGM]

And yes, sounds like your wife is a keeper, you better get the truck done so she stays happy!

 

[1-MEAN-X]

Well, I picked up some wheels a couple weeks ago for cheap. Unfortunately they are from a old CUCV military GMC truck so the wheel opening is too small for the back axle. So I made a jig to use a 5" metal hole saw to cut out the center since the wheels are lug-centric. I drilled 2 holes for the bolts to go through and used lug nuts to center the wheel. I drilled another hole in the middle for the hole saw pilot. Finally, I milled out a couple reliefs for the hole saw so it could drill through and not bite and break the teeth. There are several holes already drilled that are not necessary, it was a piece of scrap I got from work.

 

[1-MEAN-X]

Here is what it looks like on the back axle. Fits like a glove.

 

[ranger-93]

There is a lot of time and a good chunk of money in most SAS.

You can say that again. I'm slowly working on my SAS and I've spent an easy 800 dollars. All I've bought so far is FW dana 44, gears, spool, and install kit. Plus the small stuff from parts store like brake cleaner and what have you.

First I've seen of your build and its looking good. Maybe its just me but I'm glad you find the 3/4 tons rather than using the dana 30. I feel like the dana 30 is almost a step backwards in regards to strength.

 

[1-MEAN-X]

I definitely agree about the 30. It was never my intention to stay with it but it was something to get me going on the sas.

 

[exploder01sport]

Do you think that doing a SAS to this truck with leaves is easier or cheaper with leafs rather than coils in the front?

 

[1-MEAN-X]

Personally, I think leafs are cheaper and easier to use for a SAS. I don't have much experience with the coils, but to me it seemed like a lot more brackets etc. for trac bar and all that. Some of you other guys that have done a SAS with coils may want to weigh in.

 

[ranger-93]

Do you think that doing a SAS to this truck with leaves is easier or cheaper with leafs rather than coils in the front?

The search button is very helpful. Just a pet peeve of mine but I'm not a fan of seeing good threads get filled with questions that have been answered many many times throughout this forum. Also it seems like you didn't take the time to read 1-MEAN-X's first response to your question as you asked what he answered in his first sentence.