This is what I tried to do as well. It sounds good in theory, but you may find out as I did that it is hard to drill an acurrate .25" hole through an angled piece of frame, then through some internal webbing, and out the other side of the frame. And then go over to the other side of the truck, and repeat the process so that both sets of holes are colinear.

The method that I ended up using was closer to what Bill did. Due to pilot hole missalignment, I had to enlarge my holesaw holes to align the tubing.

C

I see how you can get through one rail of the frame but go to the other side too? I got all kinds of stuff blocking it..like transmission for example...

Yep, you are right. I think you missunderstood what I was tryin to say. You have to drill the right and left frame rails seperately. This is one of the reasons this is the hardest part of the sas. There is talk over on pirate of sharing an all pro frame rail jig, so if you can get ahold of one of these, it would make life easier. However if I was going to do this procedure again, I would carefully measure the inside of the frame, and drill a pilot hole, and then measure the outside of the frame and drill a pilot hole. then go through with the hole saw. Then repeat on the other side of the truck. If you do a good job on this step, your shackle bushings will last along time.

C

ahh..that makes sense now....thanks.

don't want to be a moron but what is SAS?

Solid Axle Swap.......also know as a live axle.....most of the time a 1984-5 front toyota axle is what people use to replace the IFS ( indepenant front suspenion)

Now that you mention it the reason my holes lined up off center to each other is that the All Pro frame drill template was not welded straight. So one of those is not necessarily the end all to this PIA.

The front cross member was welded crooked as well. Unfortunately in the other direction to what the drill jig was. I understand their quality control is better now than 3 years ago when I did mine.

spent about 15 min. bending it back and forth with no give....gonna try drimmel tool tomorrow...got a few metal cutting disc.

I've just finish drilling both holes ( one on each side of the frame)

The first pic shows how far I could drill with the frame gusset hitting the bottom of the hole saw.


Next pic shows what's left after I use drimmil tool with the metal cutting disc to cut. ( I used about 1 1/2 disc per side. )



Last is pic of the gusset piece that came out after drilling through the frame.



I've discovered that after you have attached the spring hanger in the front, you can attached the springs to the hanger( I used 4" AllPro springs ), with the shackle attached, to kind of line up the hole so it's parallel. I used a jack to support the springs. The interesting thing is the spring never touch the lower IFS A-arm.

I didn't think of taking the pics of it while it's up...sorry.

i dont see why the hell people dont just weld the tube under the frame,,(works in the ass end from the factory),,,,hello, it would not only make bigger tires track a little better( caster angle), but would also be much easyier,,,,,but yes on the downside,it throws off the pinion angle,,,,,,,never mind me or the beer in my hand ,or the man behind the screen.....toto were not in kansas anymore..... <img src="/forums/images/graemlins/cheers.gif" alt="" /> <img src="/forums/images/graemlins/sleeping.gif" alt="" />