Homemade Long Travel (the build thread)

[Deviant_Illusion]

This thread is going to follow my long travel build for my Teryx. I have few reasons for sharing this build. First while this type of fabrication in home garages is some what common for sand cars off road buggies desert trucks their doesn't seem to be much of it on the web for the UTV guys building their own suspension. Next I want to show that while it is possible for most people with some fabricating skills to build their own suspension it just may not be the way to go unless you have access to a fair amount of tools help etc.. And last but not least I want to show that it can be done on a small budget. My wife and I have been trying to start a family for a few years now and over the last 6 months have turned to the medical professionals for help. This type of help come with a huge price tag so my fun money is slim at best.

Comment all you would like. Good bad I don't care I just ask that we try to keep this thread in the general area of long travel.


Ok so tonight I started step #1 the jig. The jig is all that matters with this type of stuff. Good jig = good arms. My jig will be mostly built from 2" .120 wall square tube. My friend Andrew machined all the stuff I need to hold the ball joints and bushings in. He did a great job. Everything is super tight and will make for some super tight arms.

My jig will be adjustable. From stock all the way up to 8 over. I am however not making the wheelbase adjustable. I don't think I will be building many arms on this jig and I want to keep stock wheelbase so the extra work doesn't seem worth it.

This is a shot of one of the ball joint fixtures I will be using in the jig. They are two pieces the top bolting to the bottom to create a tight fit.



This is a shot of the two pieces apart. You can also see the holes drilled and taped in the tube below. This will also be part of my jig.



Rear bushing area.



Rear bushing apart.



This just shows the top arm will be using the same type of system.




So that's all for tonight. I hope to have some more updates by the end of the weekend.

[sean]

i have another set of stock arms if you need them

[az_amsoil]

Should be a cool thread...post up often.

[bigmo450]

Originally Posted by az_amsoil

Should be a cool thread...post up often.

x2

[perks offroad]

I'm in keep it coming

[sleepy23]

Interesting to see how it turns out. Last time I mentioned building it, there were companies complaining left and right trying to justify their prices.

[Deviant_Illusion]

Originally Posted by sleepy23

Interesting to see how it turns out. Last time I mentioned building it, there were companies complaining left and right trying to justify their prices.

If you price out axles and shocks most companies are charging $1000 to $1500 for their arms. With material and shop rate around $75/hr its about what it takes for arms.

I picket up a full set of four air shocks last winter for $100 thats total not each.



so thats about a $900 savings already.

[DM310]

Good stuff. Nice to see another person doing this. I am in the process of doing the samething. What size tubing are you planning on using?

[Deviant_Illusion]

Originally Posted by sean

i have another set of stock arms if you need them

How much $?

Originally Posted by DM310

Good stuff. Nice to see another person doing this. I am in the process of doing the samething. What size tubing are you planning on using?

I will be using 1.25" for most of it. I would love to see some pics of your jig and or arms. Please post them up in this thread so we can make this a really good reference for people.

[DM310]

Sounds good. I was going to use 1.25" DOM .120 wall. I am going to chop up some stock arms and use the balljoint sections. Are you going to do 5+ or 6+?

[Freeezen]

I love build threads.

[the scottsman]

i am interested too. have access to a shop to build my own. I am not paying more for a long travel kit for the rex than i did for a truck.

[POWERTRIP]

Deviant,
Are you planning on having this done for Wendover 300?

I live in N Utah also, and my brother and Dad are both building Rhinos for the BOR races this year. I am so jealous that you have the skills and tools to do something like this. My Teryx spanks my the rhinos in speed, but the lack of a long travel is the only reason i have stayed away from Desert racing. I am afraid i would go to fast for the suspension and wreck.

If you get this worked out and want to do another set, please let me know. I would like to even help build them and learn something in the process.

Thanks,
Bill

[Deviant_Illusion]

Originally Posted by POWERTRIP

Deviant,
Are you planning on having this done for Wendover 300?

I live in N Utah also, and my brother and Dad are both building Rhinos for the BOR races this year. I am so jealous that you have the skills and tools to do something like this. My Teryx spanks my the rhinos in speed, but the lack of a long travel is the only reason i have stayed away from Desert racing. I am afraid i would go to fast for the suspension and wreck.

If you get this worked out and want to do another set, please let me know. I would like to even help build them and learn something in the process.

Thanks,
Bill

Yes it will be done for the Wendover 300. You really don't need long travel to race just prerun with a gps and mark the spots to slowdown. But that being said I really want to do a set of +3 arms. I want to do it with someone somewhat local because is what I'm looking to do is find a spot do a video shoot with stock suspension. Then do video in the same spot with totally stock base shocks maybe some sport shocks and if possible nicer aftermarket shocks. While +3 arms in a four seater just wouldn't work with stock shocks I think alot people would really be happy with the performance. Its been drilled in our heads how it wont work but I did it on my rhino and it was no LSR with fox but for the money it was great.

Im very serious about this get 4 or 5 people with nothing to gain to drive it before and after and give honest opinions. If they all say it sucked with stock shocks then we can put it to bed. So if your down to buy some +3 axles I will build you some arms. Just know if it does totally suck on stock shocks you will need to buy new shocks or sell the kit.

TONIGHT'S UPDATED
I'm so lucky that my wife bought us tickets to go see "When In Rome" tonight I only had about an hour to work on the jig after work.

You should be able to see how it will adjust forward and back and will clamp down and hold it from turning on the jig rail. The rear will be bolted down with the same pattern so I can flip it for left and right.

[roadiestar]

How about designing something closer to stock with more wheel travel? If it's possible that would be sweet for use guy's in the East.