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  #281  
Old June 22nd, 2015, 09:24 PM
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Charles Galpin
'94 D90 ST, '63 SeriesIIA
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Rear skid plate

I painted and mounted the rear battery box support/skid plate and trailer hitch and wiring.

Prepping for paint
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Installed
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Battery box in place
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  #282  
Old June 22nd, 2015, 09:28 PM
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Charles Galpin
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zinc plating

I have started doing some zinc plating. Ed was over for a congugal visit with his plasma cutter and helped me get started, but I left some parts in the solution while waiting for my zinc anodes to come and they started rusting so I started over.

So far I have had mixed success. Some things are not taking the zinc and I'm not sure why. It could be prep (like needing blasting) or my solution is off. I need to get something to check the PH.

Anyway, here is an action shot and a example of the results.

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  #283  
Old June 22nd, 2015, 09:46 PM
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Charles Galpin
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air springs

Xmas came early! In the spirit of getting this damn thing done, I was going to just stick regular springs in for phase 1, but while trying to figure out what springs would meet my needs I was talked into going for the end game - air springs. Andy_Andy here gave me a smoking deal on some air bags and adapters to make them fit a rover. All I have to do is make an adapter for the larger rear spring seats and pretty much everything else is there (I'm going to use an RRC EAS system for the rest.

Here is what I got. The rings on the right are templates to drill holes in the rear spring perches for a 90. He included a bunch of T's and fittings and 6mm tubing too!
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The bottoms just bolt into the stock holes in the axle housings
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The kit includes adapters that mount to the spring perches. The front fit perfectly. I have to reproduce these for the rear
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This shows the "normal" position and the extra 4+" of droop/travel they offer if needed. I doubt I'll ever take advantage of this but pretty cool!
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I modeled the rear adapters, and printed up a slice to verify my dimensions (but took my slice too high so the center hole isn't the one I wanted to test). I have ordered some delrin to make the real deal out of.
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A shot of the fronts installed. I ordered some schrader valves so I can put some air in them before doing some min/max height tests.
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  #284  
Old June 22nd, 2015, 09:46 PM
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thanks!
Quote:
Originally Posted by JSBriggs View Post
The weight points toward the rear of the vehicle near the tie rod mounts.

-Jeff
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  #285  
Old June 22nd, 2015, 10:14 PM
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Don Bunnell
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Those air springs are sweet! Looks like it was factory.
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  #286  
Old June 22nd, 2015, 10:32 PM
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Bill Adams
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So do you have the holes in the chassis for the front EAS shock mounts? I assume you have an EAS front axle there.
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  #287  
Old June 22nd, 2015, 10:39 PM
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I must admit, I was advocating for going springs only, but after seeing the photos, the airbags look pretty sweet! Sorry for being a doubter!

I'll think about why those other fasteners are not plating I haven't had anything not plate on me yet, but as with all things there must be a reason...
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  #288  
Old June 22nd, 2015, 10:41 PM
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John B.
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Is someone selling those air spring adapters? If so, who? I would love that for the rear.
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  #289  
Old June 23rd, 2015, 04:49 PM
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Charles Galpin
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Quote:
Originally Posted by o2batsea View Post
So do you have the holes in the chassis for the front EAS shock mounts? I assume you have an EAS front axle there.
Yes (you can see them in the last picture) and yes I have the axles and suspension (and soon the EAS setup other than bags) from the 93 RRC you gave me.

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Originally Posted by Red90 View Post
Is someone selling those air spring adapters? If so, who? I would love that for the rear.
You can check with Landy_Andy to be sure but I believe these are prototypes and he never made them available for sale (or will be).
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  #290  
Old June 23rd, 2015, 05:08 PM
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Quote:
Originally Posted by cgalpin View Post
You can check with Landy_Andy to be sure but I believe these are prototypes and he never made them available for sale (or will be).
Bummer. I've always wondered why nobody sold an air spring conversion kit. I would think it would sell well. 110 rears on their own would sell a ton.
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  #291  
Old June 24th, 2015, 06:28 PM
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I think the reason is the expense
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  #292  
Old June 24th, 2015, 06:32 PM
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Quote:
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I think the reason is the expense
It should not be crazy. Air springs are about the same price as coils springs. Just the adapters to make. If done in decent quantities, the adapters would be pretty cheap.
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  #293  
Old June 24th, 2015, 07:07 PM
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Possibly. I'm paying $130 for enough delrin to make 2 pucs, which is what you'd need per corner, but I guess you could get that done in volume. Then you have to make the post part which requires a laser/waterjet cut disk and tube welded to it with a nut welded in the top. I haven't seen the bags cheaper than around $230. Then there are fittings, screws, nuts and bolts, lines. I am not even talking labor to machine, cut, weld, a chromate finish on the steel parts, or making a profit. Seems like a fairly expensive end product if you are starting at a cost of $400+ per corner for parts/materials alone.
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  #294  
Old June 24th, 2015, 08:34 PM
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We could send you to China to open a sweat shop.
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  #295  
Old June 24th, 2015, 08:45 PM
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You can get air springs in the $100 to $150 range with enough travel that you do not need to retain or worry about disconnecting parts. Just a simple adapter. Plain aluminum would be cheap and work fine. Lots of guys have done there own in Australia at low cost.

This for replacing 6" springs
http://www.truckspring.com/products/...-358-9901.aspx

And these for 7" springs
http://www.truckspring.com/products/...-358-5712.aspx

Most people would just want to do the rears to allow for being empty one day and loaded to max the next.
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  #296  
Old June 24th, 2015, 09:59 PM
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Charles Galpin
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Yeah I'm not sure what's different about mine (W01-358-9310) that makes them expensive - maybe an older model? But yes I guess with a simple adapter out of aluminum to retain them you'd keep it simpler and the costs down. Still not the cheapest setup but if you think they would sell, you should make some! Keep in mind most people will then want some sort of management system to adjust the height etc too.
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  #297  
Old June 24th, 2015, 11:10 PM
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Quote:
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Keep in mind most people will then want some sort of management system to adjust the height etc too.
THAT is the expensive part. You are $1000+ for anything decent.
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  #298  
Old June 25th, 2015, 10:02 PM
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Let's see how mine goes. I'm either going to have a success story with a sweet cheap refurbed RRC EAS setup, or I'll be eating crow. Time will tell
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  #299  
Old July 1st, 2015, 11:26 PM
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My delrin arrived Monday, and Tuesday happened to be a good day to go down to TechShop and make the rear adapters after work.

Here is what I started with.

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Milling. I forgot to take pictures working the back side
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The end product, and compared to the front

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Fitted

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I had to redo the model in different software in order to use the TorMach mill and accidentally entered the diameter of the inner hole as the radius and started cutting before I realized the mistake. So I have a cosmetic blemish on one

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I was also (intentionally) more generous on the groove for the ring, and I fear it's going to be a dirt trap. The front's are quite thin and clearly Andy gave this plenty of thought. I also made the center hole slightly larger than I'd like, so I'm considering re-making them. It took me a whole day (8 hours) to make these two, but the second one only took an hour, lol. Anyway, other than a bit pricey for a prototype, it wouldn't be the end of the world.
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  #300  
Old July 1st, 2015, 11:31 PM
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I also got a few more bits bolted onto the frame this weekend before running out of hardware.

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I installed the rivets for the ride height sensors

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