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  • #61
    Rears done today. It is a bit of a bugger doing it all by yourself but quite possible. Old stuff came out fairly easily but getting the new springs in was a bit of a task. You really need a few assorted small jacks and a trolley jack. With the back up on blocks and the old shocks and springs out and the sway bar disconnected I found to get the lhs spring in, jack up the rhs of the axle . To help further I used a small scissor jack between the axle and the bump stop on the lhs the get the last few mm. I needed to get the bugger in. Same procedure for the rhs. The shock too are fiddly because it is hard to get enough thread through the top mounting to get the nut on. I ended up putting the nut on a few threads without the top set of washers and rubber and poking it up through the hole just enough the get a spanner under the nut. This was then used to get enough purchase to pull the rest of the thread up enough to fit all of the bits. Te sway bar links were easy but I wish I knew of the 46 mm shortening. I think that is where I ended up anyway by adding 30mm to the old one's length.
    I have only driven about 3 km just too see if anything fell off [ it didn't] BUT it seems great- no pitch, no squat, no nose diving and no sway. The ride from the back is firm but not harsh. It feels better than my old 120 did with OME [ ie Kings] mediums and air bags. More to come after the height settles.
    How long should I leave it to get the wheel alignment.... time/ distance?.
    404pug
    Avid PP Poster!
    Last edited by 404pug; 12-07-2017, 08:00 PM. Reason: correction

    Comment


    • #62
      Originally posted by 404pug View Post
      How long should I leave it to get the wheel alignment.... time/ distance?.
      Hey,

      If you are just driving locally and not doing too many kilometres, I'd drive it for at least a few days to get the front ride height settled in a bit. That way when you get your alignment done it isn't sitting up too high which would cause you to lose some caster.

      If you are planning a big trip right after your install, get the alignment done before you go, and check it again when you get back!

      Best

      Mark
      2006 GXL petrol auto. ARB deluxe bar x3 HID IPF's, ARB alloy roofrack, ARB awning, BFG A/T, Safari snorkel, Piranha breathers, Pacemaker extractors, custom Ironman 45710FE 436-569mm with Dobinsons 350, custom Ironman 45682FE 383-618mm with Dobinsons 487, Firestone kevlar 60psi airbags, 30mm extended Roadsafe links, AMTS bashplate and recovery points, ABR Flyer with Powersonic AGM.

      Comment


      • #63
        Hey all,

        Another installation tip;

        If you are still running the OEM upper control arms on the front, please check your coil-arm clearance at full droop. If your arm is contacting the coil, then you can rotate the coil so that the arm either clears or sneaks in between coil windings.

        If you are running around a 40-50mm lift on the front, you should end up with some decent caster on the OEM arms, around 1.5-2.0deg depending on your vehicle model.

        Best

        Mark
        2006 GXL petrol auto. ARB deluxe bar x3 HID IPF's, ARB alloy roofrack, ARB awning, BFG A/T, Safari snorkel, Piranha breathers, Pacemaker extractors, custom Ironman 45710FE 436-569mm with Dobinsons 350, custom Ironman 45682FE 383-618mm with Dobinsons 487, Firestone kevlar 60psi airbags, 30mm extended Roadsafe links, AMTS bashplate and recovery points, ABR Flyer with Powersonic AGM.

        Comment


        • #64
          Hey all,

          Another installation tip for the rear shocks;

          There are two versions of the rear shocks, 45682FE and 45682FEC. The FE and FEC are geometrically identical, the only difference is the Ironman valving, FE is 80 series spec, FEC is Prado/FJ. The FE shocks come with a different bush kit compared to the FEC. The FEC has two different chassis mount locating washers, one for a 120 (smaller hole size), the other for 150/FJ (larger hole size).

          In both cases, the correct sequence for the bush stack on the rear shocks is;

          (bottom washer)-(bottom bush)-(locating washer)-[chassis]-(top bush)-(top washer)-(nut)

          The locating washer which sits underneath the chassis plate hole is easily identified by the protruding cylindrical section which locates into the chassis hole.

          Please note that when you are doing up the top nut, you must use a small spanner to hold the flat section to stop the shaft spinning. A 7mm spanner is slightly too large for the flat, but it will be the closest match.

          Also bear in mind there is some side load, so you must push the shaft and bottom bush/locating washer tightly into the chassis hole, and make sure it does not slip out while you do up the top nut.

          The clearance to get the 7mm spanner is quite small on the 120, so be patient and take your time!

          Best

          Mark
          2006 GXL petrol auto. ARB deluxe bar x3 HID IPF's, ARB alloy roofrack, ARB awning, BFG A/T, Safari snorkel, Piranha breathers, Pacemaker extractors, custom Ironman 45710FE 436-569mm with Dobinsons 350, custom Ironman 45682FE 383-618mm with Dobinsons 487, Firestone kevlar 60psi airbags, 30mm extended Roadsafe links, AMTS bashplate and recovery points, ABR Flyer with Powersonic AGM.

          Comment


          • #65
            Whitey's Ironman kit arrived today.

            Started just before lunchtime, fitting the front shocks first. Took me a while but got them in and torqued up the bolts to the specs. Bounced the front around the block before torquing up the front lower shock mount bolts. Fitted the bolts with the nuts to the front - they have been the other way since the billies were in from 2009, makes it easier to torque them up if they face the front. Had some other family jobs between work on the shocks, but worked my way through the rears tonight.

            Made a couple of errors which had to fix along the way:
            -- The rubber bushes and washers for the rears came with 4 washers each side, and I installed all 4. Whitey corrected me and had to remove the extra 150 washer from my 120 - only install 3 washers each side.
            -- On the last rear shock install, I didn't notice that the lower ring is actually offset, and I installed it wrong, so had to remove it and turn it the other way. I did notice the shock was touching the axle/bracket when it was incorrectly installed. eeek!

            All done now, and looks good. Have a big job tomorrow so will probably not be able to give it a run tomorrow, hopefully Sunday.

            My Dobinsons MRR shocks are now off the Prado. Not going back on. One of the front MRR's had a total failure on our outback trip. Also one of the rubber boots on the rear is shot to bits. They will all go into Dobinsons for repair and will offer them on PradoPoint first for a good price if anyone is interested.

            Thanks Whitey for all your help and getting this Ironman group buy and the valving sorted.. Great job!
            2008 D4D M6 GXL [MT ATZ-P3][Whitey's Ironman 45710FE/45682FE+KTFR101H/Dob487][extended Roadsafe links][Polyairs][DBA T3/T2][amts diffdrop & recovery points][Tin175's stone guards][Bushskins BashPlate][ARB Sahara][IPF 900s][Snorkel][WindCheetah][MaxTrax][IC-440][Parrot Asteroid][ARB Fridge][Lifestyle 2nd Row Fridge Mount][ARB Compressor][Thumper][SandGrabbers][Cargo Barrier][Tigerz Awning][MCC Rear Bar]

            Comment


            • #66
              Hi Mark, just sent you a PM regarding an installation question. Thanks
              [B]Steve[/B]

              2010 Silver GXL Prado 150, D4D Auto, with a few non standard bits

              Comment


              • #67
                Originally posted by krypto View Post
                Hi Mark, just sent you a PM regarding an installation question. Thanks
                Hey Steve,

                All sorted!

                Best

                Mark
                2006 GXL petrol auto. ARB deluxe bar x3 HID IPF's, ARB alloy roofrack, ARB awning, BFG A/T, Safari snorkel, Piranha breathers, Pacemaker extractors, custom Ironman 45710FE 436-569mm with Dobinsons 350, custom Ironman 45682FE 383-618mm with Dobinsons 487, Firestone kevlar 60psi airbags, 30mm extended Roadsafe links, AMTS bashplate and recovery points, ABR Flyer with Powersonic AGM.

                Comment


                • #68
                  Hey all,

                  An update for 11-15 on the list, I'll hopefully be getting new stock in tomorrow or Tuesday!

                  Best

                  Mark
                  2006 GXL petrol auto. ARB deluxe bar x3 HID IPF's, ARB alloy roofrack, ARB awning, BFG A/T, Safari snorkel, Piranha breathers, Pacemaker extractors, custom Ironman 45710FE 436-569mm with Dobinsons 350, custom Ironman 45682FE 383-618mm with Dobinsons 487, Firestone kevlar 60psi airbags, 30mm extended Roadsafe links, AMTS bashplate and recovery points, ABR Flyer with Powersonic AGM.

                  Comment


                  • #69
                    Hi Mark,

                    Wow, haven't been on here for a while and then poke my head in and see this amazing work going on. I am in awe of the work and knowledge you have put into this.

                    What are your plans once you finish the current list? Are you going to keep doing this in small batches of close the group buy? I am interested in this and don't want to miss out but wasn't planning on spending the coin until after Christmas. If you are going to finish this then I'll get a set now otherwise I'll wait.

                    Also another question. Seeing as the front struts are fully adjustable and we can set the ride height independently of spring length, is a longer or shorter spring better given the same spring rate? Or am I overthinking this?

                    Cheers,
                    Nova

                    Comment


                    • #70
                      All in today and super happy with the result. A minor hitch, I've got 40mm (790mm) lift in the front and 50mm (840mm) lift in the back which hopefully will settle to 40mm (830mm)?

                      Was expecting a much rougher ride, but rides beautifully. Couldn't resist the speed bump test, we have a couple of doozies on our road, and it's gone from bucking and wallowing to just a smooth ride. Can't wait to use these on the corrugations up north, fully loaded up with a camper used to be all over the place, should be sweet now.

                      Thanks again Mark for your knowledge and generosity in pulling this together.
                      [B]Steve[/B]

                      2010 Silver GXL Prado 150, D4D Auto, with a few non standard bits

                      Comment


                      • #71
                        Originally posted by krypto View Post
                        All in today and super happy with the result. A minor hitch, I've got 40mm (790mm) lift in the front and 50mm (840mm) lift in the back which hopefully will settle to 40mm (830mm)?
                        Which Springs did you use?

                        Cheers,
                        Nova

                        Comment


                        • #72
                          Originally posted by Nova View Post
                          Which Springs did you use?

                          Cheers,
                          Nova
                          They are the C59 327. They dropped a bit when I filled up the tank so pretty hopeful that they'll settle at 830 after a bit of use, which is exactly what Mark predicted looking back through his info.

                          I also got the KTFR-101H up front because I don't run a bullbar.
                          krypto
                          Avid PP Poster!
                          Last edited by krypto; 17-07-2017, 10:05 PM.
                          [B]Steve[/B]

                          2010 Silver GXL Prado 150, D4D Auto, with a few non standard bits

                          Comment


                          • #73
                            Mine too has the C59-327 rear springs but it is a GX so no rear seats. After about 100km and 4 days it is sitting closer to 850 ! I am hoping that it drops 15-20 mm fairly soon. To hopefully accelerate this process today I have had it sitting in the garage with a heap of weight added to the rear - trailer- 80kg, 40 l of water, and another 30-40 kg of assorted crap. All up about 150 kg [plus full tanks]. This has it sitting at 830 mm. The question is how much are springs likely to sag and over what time period? Does added weight help the process? At the moment it is above the legal 50 mm lift at the rear when empty.
                            The fronts with C59-352 are sitting at between 800 and 805 after 6 days- close to ideal and 45 mm above where it was when new.
                            As to handling....sensational- no more pitch, sway, squat, and greatly reduced roll. Ride is firm but not harsh. A particular speed hump near me has apparently been stolen!

                            Comment


                            • #74
                              Prado 120 with front and rear Whitey modded ironman shocks now installed with Kings KTFR101H springs at the front and Dobinsons 487’s at the rear.

                              Awesome. The ride is firm, but not harsh. Better control over bumps than any of the suspension previously had on the Prado! The valving brings the Prado very compliant, and the previous dive under brakes is gone, and control around corners has the Prado running very flat. Ran the Prado along a dirt track in the hills which had some deep drains across the track and the suspension just soaked it up. This will be an awesome outback setup now. They look, they measure, and I bet, they are stronger than any shock I have had previously.

                              Will let the suspension settle while waiting for the Ironman shock spanners, then adjust them and put it in for it's wheel alignment.
                              2008 D4D M6 GXL [MT ATZ-P3][Whitey's Ironman 45710FE/45682FE+KTFR101H/Dob487][extended Roadsafe links][Polyairs][DBA T3/T2][amts diffdrop & recovery points][Tin175's stone guards][Bushskins BashPlate][ARB Sahara][IPF 900s][Snorkel][WindCheetah][MaxTrax][IC-440][Parrot Asteroid][ARB Fridge][Lifestyle 2nd Row Fridge Mount][ARB Compressor][Thumper][SandGrabbers][Cargo Barrier][Tigerz Awning][MCC Rear Bar]

                              Comment


                              • #75
                                Originally posted by Nova View Post
                                Hi Mark,

                                Wow, haven't been on here for a while and then poke my head in and see this amazing work going on. I am in awe of the work and knowledge you have put into this.

                                What are your plans once you finish the current list? Are you going to keep doing this in small batches of close the group buy? I am interested in this and don't want to miss out but wasn't planning on spending the coin until after Christmas. If you are going to finish this then I'll get a set now otherwise I'll wait.

                                Also another question. Seeing as the front struts are fully adjustable and we can set the ride height independently of spring length, is a longer or shorter spring better given the same spring rate? Or am I overthinking this?

                                Cheers,
                                Nova
                                Hey Nova,

                                Cheers for the kind words!

                                Once the buy is complete I'm going fishing on Fraser! I'll prolly still do some revalving down the track, so you should be right for later on.

                                The free height of the front spring you choose will be dictated by the accessories you run. As an example, I have tested the C59-350 on my own 120, and I run it at quite a short coil seat length around 205mm to get my front ride height at around 790mm with just my ARB deluxe bar up front. Start adding more accessories, and I'd look at the longer C59-352. Put that same C59-350 on a 150 with an ARB deluxe bar, and you'll need to preload it more to combat the higher kerb weight, so the coil seat length will increase past 205mm.

                                Depending on your vehicle type and weight, FJ, 120 or 150 in order of increasing kerb weight, typically for lighter FJ's and 120's, I'll run the KTFR-101H. Heavier 150's I'll run the C59-352 in most cases as it gives you an extra 5mm of free height to play with. The coil seat length can be anywhere in between 205-220mm covering all vehicles and accessories.

                                There are already specific cases in this group buy where I use coils that are the opposite to the way I described above, eg., a 150 with no bullbar I can use the KTFR-101H, but a fully loaded heavy 120 with steel bar/second battery/winch+steel cable/underbody, I prefer to use the C59-352.

                                While the difference between a 660lb/in KTFR-101H and a 725lb/in C59-352 (710lb/in load deflection tested) seems like a lot, eg. 50lb/in difference, keep in mind this is at the strut position on the IFS, and once you scale inversely through by the square of the motion ratio and get the spring rate at the wheel position, ie, wheel rate, that 50lb/in difference is really only 50/(1.89x1.89) = 14lb/in difference at wheel position. It's like moving from say 260 up to 280lb/in coils in the rear. On the IFS, you can initially feel this difference on a lighter 120 or FJ, but once the higher rate coil settles in, it is actually almost as supple to drive on!

                                I've been driving on my C59-350 coils for almost a month now on my light 120, and I'm really enjoying them! So don't be surprised to see a mix and match of these coils across all three vehicle types. Also by a quirk of coil rate and free height, the C59-350 and KTFR-101H will give almost an identical lift. Keep in mind the most important aspect of choosing these coils is matching them up to the valving!

                                Hope this gives you an idea!

                                Best

                                Mark
                                2006 GXL petrol auto. ARB deluxe bar x3 HID IPF's, ARB alloy roofrack, ARB awning, BFG A/T, Safari snorkel, Piranha breathers, Pacemaker extractors, custom Ironman 45710FE 436-569mm with Dobinsons 350, custom Ironman 45682FE 383-618mm with Dobinsons 487, Firestone kevlar 60psi airbags, 30mm extended Roadsafe links, AMTS bashplate and recovery points, ABR Flyer with Powersonic AGM.

                                Comment

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