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With the CreeperBox and t-case in place it was time to get busy on the 4-link rear suspension. This installation was our Prototype so you’re going to see some things that aren’t apart of the kit these days. Sure all the measurements are the same, but we’ve cleaned up the parts a bit. Making them more eye and installation friendly.
The 4-link starts with the usual welding of the links. Custom machined weld-in threaded bungs (inserts) go into high strength DOM. These inserts are the first style we had, where there’s a flare that creates a groove for easy welding (just fill in the groove). Today we use ones without the flare, this allows us to double-weld the inserts into the tube.
While we were welding up the links, Chris (our old partner) started fitting up the truss.
Next we started gusseting the stock Scout II frame where the link attachments were to be welded. To do this we used 1/4″ steel plate (4″ high) and just started welding. We went all the way around the frame (except for the top of course) to insure the maximum amount of strength. Today we use specially modified box tube to sleeve the frame (as seen in Project 2). This allows us to build the link brackets without even installing it on a frame.
Then we assembled the link mounts and fitted the new links into the frame mounts and let the links hang while we wheeled the axle into place. You’ll note the “axle dolly” we’ve got under the front and rear axles, these are necessary when dealing with heavy axles, instead of dragging them across the floor to get them into position, we simply push them into place and they go willingly!
Next it was time to start putting on the axle mounts, where the links go to the axle. So we jacked the axle up and placed it on jack stands. This allows us to set the pinion angle at ride-height. Since our 4-link is designed to keep the pinion perfectly lined up with the t-case at all points in its travel, this should be the only time we need to worry about pinion angle, no matter how much lift P3 ends up with.
Since this was the prototype we only used weld-on tabs. Although these are more than strong enough for P3, we changed the design on our current kits (as seen in Project 2) to make them a little more beefy and eye-catching.
Once everything was in place, we test flexed the rear suspension to make sure all our CAD work wasn’t wasted.
Everything checked out! It was time to remove the rear axle, fully weld everything in place, add a few gussets (for good measure) and paint it.
Now that looks good!
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