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Subframe extension to spring shackle using 2"x2" box tubing
Posted: Sat Feb 28, 2015 1:22 pm
by Astrophysics
Hi Everyone,
I have fabricated a sub frame extension on my 2003 AWD Astro which has the 2 inch body lift from Overland.
I thought of getting the $350 shackle bar kit from overland and having the bar welded to subframe, but decided to make my own using a 70 inch long piece of 2"x2" steel box tubing that connects the rear hanger to the front subframe.
For a bolt on, no weld installation I am using various Uni strut heavy plates and channel fittings.
The 2"x2" box tube has 1/8" wall thickness and weighs about 2.5 lb per foot.
I will post photos.
AP
Re: Subframe extension to spring shackle using 2"x2" box tub
Posted: Sat Feb 28, 2015 1:27 pm
by Astrophysics
Uni strut flat plates hang from OEM shackle bolts.
2x2 box bolts to uni strut plates with 1/2" hex bolts.
Re: Subframe extension to spring shackle using 2"x2" box tub
Posted: Sat Feb 28, 2015 1:30 pm
by Astrophysics
Detail of rear uni strut plates at oem shackle bolts
Re: Subframe extension to spring shackle using 2"x2" box tub
Posted: Sat Feb 28, 2015 1:31 pm
by Astrophysics
Whoops photo sideways.
Re: Subframe extension to spring shackle using 2"x2" box tub
Posted: Sat Feb 28, 2015 1:34 pm
by Astrophysics
Uni strut U shaped 3 hole and corner braces bolted to subframe forward OEM oval bolt hole
Re: Subframe extension to spring shackle using 2"x2" box tub
Posted: Sat Feb 28, 2015 1:36 pm
by Astrophysics
Subframe and its existing oem holes to attach 1/2 " bolt to uni strut
Re: Subframe extension to spring shackle using 2"x2" box tub
Posted: Sat Feb 28, 2015 1:38 pm
by Astrophysics
More images forward bolt to secure 2x2 box
Re: Subframe extension to spring shackle using 2"x2" box tub
Posted: Sat Feb 28, 2015 1:42 pm
by Astrophysics
More images fporward subframe oem holes
Re: Subframe extension to spring shackle using 2"x2" box tub
Posted: Sat Feb 28, 2015 1:45 pm
by Astrophysics
Use geavy washer or uni strut 3 hole backing plate inside subframe this image is rear oem hole in subframe
Re: Subframe extension to spring shackle using 2"x2" box tub
Posted: Sat Feb 28, 2015 1:48 pm
by Astrophysics
Rear oem hanger bolts are 9/16" diameter, just un do hex nuts and attach uni strut 5 hole plates, then Loc tite nuts and retorque.
Re: Subframe extension to spring shackle using 2"x2" box tub
Posted: Sat Feb 28, 2015 1:50 pm
by Astrophysics
Frame extension
Re: Subframe extension to spring shackle using 2"x2" box tub
Posted: Sat Feb 28, 2015 1:54 pm
by Astrophysics
Use steel spacers inside tube to keep wall from bending when torque bolts
Re: Subframe extension to spring shackle using 2"x2" box tub
Posted: Sat Feb 28, 2015 4:15 pm
by Astrophysics
Once all parts are torqued and double checked, i plan to paint on "torque stripe" with blue lacquer on the hex nuts, etc.
Then if a fastener loosens after time due to vibration, the straight line of the stripe will be disturbed and it will give a visual clue to re torque fasteners.
AP
Re: Subframe extension to spring shackle using 2"x2" box tub
Posted: Sat Feb 28, 2015 4:18 pm
by Astrophysics
Once frame extender is finished, i plan to bolt on Manik 4x4 brand nerf bars using the awesome Unistrut wing fitting which has welded gusset. See mock up image
Re: Subframe extension to spring shackle using 2"x2" box tub
Posted: Sat Feb 28, 2015 4:20 pm
by Astrophysics
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