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Braced the fame pretty heavily forward of the cuts to prevent any movement or warping Cut at a 45 degree angle and cleaned up Welded, will be plated later also And here's a tire mock-up, much shorter, which we like :)

OK....Many thanks to TrailReady that loaned out this mockup wheel so I could really dial in the backspacing. It’s cracked clean through from racing KOH but it did the trick Definitely assisted with finding the right backspacing. But.... unfortunately it's going to require some serious...

Pic of the frame notch needed for the threaded nutsert Nutsert welded to link bracket Cycling the suspension. It's works, and should work quite well

Working on the front upper links here. Two large “nutserts” are frenched into the frame and welded to the bracket. Custom made and tapped to 5/8-18 they have about 1” of thread engagement and allows the bracket to suck all the way up against the frame maximizing tire to link clearance The...

Got the rear link tubing and then tacked things together. No more PVC test links! Here's a shot of test fitting the front fender. The frame of the truck is set to represent 2" of total lift over stock. I'm hoping for no more, but maybe less than this.

Here's the upper panhard bar mount. Probably not in it's final location front and back but close. Probably. Panhard around the front differential. It'll need a little bend in it for sure in order to clear. Definitely will need a short pitman arm in the long run too And here is less...

Playing around with the front tires and steering angles/clearance. Trying to figure out what wheel backspacing to use. Wheels will eventually be TrailReady beadlocks Dirty passenger side axle tube... Clean tube, ready for links The passenger side link also incorporates the panhard...

Completed axle and frame brackets.... Coil over shock mount is nested in next to the main link mount Upper links are 2" 1/4" wall and lowers are 2.25" 3/8" wall DOM. The idea is that the lowers won't bend being 3/8" 1.25" shank Johnny Joints all around

Few more CAD drawings of the front link brackets... All nested together before being plasma cut And then my buddy doing the plasma work broke his collar bone literally on the finish line of a dirt bike race

Checking the rear axle articulation. This is way further than it will actually go, just wanting to make sure there is no bind. It'll work

The entire rear factory crossmember right behind the cab needed to be fully gusseted and strengthened in order to handle the stress of the rear links. Slowly did a lot of boxing and welding on this before test fitting the link brackets from Barnes4WD Adding the 2" square tubing for the...

This is my final design for the 4 link triangulated rear. The links will sit VERY flat and the anti-squat can be adjusted from about 70%-130% It should climb very well

Went ahead and rebuilt/assembled an SM465 for this. Used the best internals from 4 different SM465's and also added the short output shaft from ORD. Pressing on a bearing I fully tore down and replaced all the wear parts in the top shifter cover also. Media blasted it and tapped NPT...

Here is the crossmember which I fabbed for the ORD Magnum. The 3/8" drilled plate comes with the Magnum, I indexed it into 1/4" wall, 2" square tubing to make it ultra strong. Poly bushings and frame plates for easy isolation and mounting. One of my personal goals for this build was to...

Finally finished cleaning the frame of any unnecessary brackets, crossbars or mounts. What a mess I also slung the Dana 70HD under the rear along with an Artec truss. The truss is for a Dana 60 but with a little trimming it fits great. This axle ultimately ended up being TOO WIDE for the...

I only use this grinder for really "extreme" jobs, like cleaning up the frame from all the old hangers Slowing boxing in all the firewall cuts. The goal is to have the cab look as clean as possible, not all hacked up and beat to hell

Lots of work to remove all the factory leaf spring hangers and do it cleanly. Plus I don't love using a torch. This shows the factory body mount also. That'll be eventually removed as the new front suspension frame mount will incorporate the body mount also

Still taking some of the body apart. Pulled the vent cover and found a very old desiccated nest and a bunch of blast media I also managed to get the M16 rifle rack removed from just behind the driver side seat. The floor is fairly rusty here and will need to be replaced

This is how much of the poor body looks. With only 40K miles on the clock, I'm guessing much of it was just pounding off-road. Tons of cracks that need to be slowly filled back in and welded together Gently filling it back in with the TIG on low heat

Cad drawings for the front suspension which was created by my buddy Ethan. Radius arm w/panhard, essentially a 5 link. The below pic shows the arc angles or "how to avoid suspension binding" basically This is the upper frame bracket and axle bracket