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  #1  
Old 23rd November 2016, 03:15 AM
Jeremiahs22 Jeremiahs22 is offline
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Default Project Baja Foz!

Hey everyone, this is the new build for The Wandering Foz, continuing where the old thread left off: The Great Alaskan Tundra Humper

IMG_3756 by jeremiah stewart, on Flickr

Goal:
I have wanted to race the Baja 1000 since I was a little kid, but a few years ago I came across the Mexican 1000 which is a little more grassroots and easier for a normal guy like me to race in. So that's the goal! I wanted to race in their "Rally Raid AWD" class using my Hotbits coilovers as they were at the max travel for that class, but most years there is nobody in that class. Might as well try to be competitive if i'm entering a race right? So the class I'm shooting for is Score Class 7 or BITD 7200. In the Mexican 1k it'll either be "Heavy Metal Class" or "Pre-run Truck".

For now I will only be focusing on suspension so I can stay on track to be able to take the foz on a roadtrip planned for May 2017. A roll cage and a bunch of safety items will need to be built after the roadtrip unless I have the time to do the rollcage this winter. Shooting to make the race in the spring of 2018, but if the foz is ready sooner than then, then I will enter a domestic race to get my feet wet.

Plan:
  • Dual A-arm front suspension cycling 18-22" of travel
  • Dual A-arm rear suspension with toe link (will make sense later - similar to the PPI 015 Toyota) cycling 20-24" of travel
  • 32" tires on factory offset wheels to allow for longer arms and more travel while keeping it under the BITD max width of 85"
  • Either King or Fox internal bypass coilovers all around
  • High compression EG33 unless the length is more than I want to build around, then it'll be an EZ30
  • Extended length axles (+8") probably from DSS

Follow on Instagram:@thewanderingfoz
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  #2  
Old 23rd November 2016, 03:15 AM
Jeremiahs22 Jeremiahs22 is offline
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Disassembly:

Pulled all of the old suspension, and the whole interior.. wow:

DSC00125 by jeremiah stewart, on Flickr

DSC00244 by jeremiah stewart, on Flickr

DSC00246 by jeremiah stewart, on Flickr

DSC00325 by jeremiah stewart, on Flickr


Measured for the EG, which is about 7" longer than the EJ25, hmm..


DSC00126 by jeremiah stewart, on Flickr
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  #3  
Old 23rd November 2016, 03:16 AM
Jeremiahs22 Jeremiahs22 is offline
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Got all of my heim joints in, as well as all of the pieces that I drew on CAD and got from Anderson Design and Fab

DSC00408 by jeremiah stewart, on Flickr

DSC00411 by jeremiah stewart, on Flickr

DSC00423 by jeremiah stewart, on Flickr


Started on the front subframe, using the old subframe as a jig:


DSC00421 by jeremiah stewart, on Flickr

DSC00419 by jeremiah stewart, on Flickr

Need to start boxing it in and reinforcing it, then get it under the car to tie it into my other mounts.

Below is my crazy ball joint replacement idea, let's hope it works out. The big hole is to hold a uniball joint, which I am still waiting on. I may need to just fab a whole knuckle for more strength though, we'll see.


DSC00414 by jeremiah stewart, on Flickr

DSC00415 by jeremiah stewart, on Flickr


The upper and lower joints will be 1" uniball joints, probably overkill.
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  #4  
Old 23rd November 2016, 04:15 AM
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Kevin Kevin is online now
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This will be a fantastic build!
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  #5  
Old 23rd November 2016, 07:58 AM
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carljwnc carljwnc is offline
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I'm not on here too much anymore...but I'm grabbin' a big 'ol box of popcorn for this one!!!
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  #6  
Old 23rd November 2016, 08:22 AM
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jf1sf5 jf1sf5 is offline
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Big box of popcorn for me too
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  #7  
Old 26th November 2016, 04:02 PM
casperfromholland casperfromholland is offline
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You'r doing something where i'm dreaming of!

have you seen bajaburu on facebook? That is a guy who builded and raced a wicked long travel suspension impreza in the the baja 1000.

Keep us informed!
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  #8  
Old 4th December 2016, 02:42 PM
Jeremiahs22 Jeremiahs22 is offline
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I'm glad you guy guys are excited, keeps me motivated when I feel lazy :D

I made some good progress yesterday, but got cut short by having to go pickup an engine block for mockup.
So I started off by bolting the subframe in to mockup the knuckle and make sure everything was gonna work before I started boxing it in:

DSC00499 by jeremiah stewart, on Flickr

DSC00500 by jeremiah stewart, on Flickr

Measured the track width from the center of the subframe, 42.5" then moved the tire inward 2 inches to 40.5" to give me room in the future for 32x11.5 tires with an inch for wheel offset differences. This will be the stance with stock fenders:

DSC00533 by jeremiah stewart, on Flickr

Bolted the knuckle into a wheel as well:

DSC00544 by jeremiah stewart, on Flickr

DSC00545 by jeremiah stewart, on Flickr

There's about 1/2" clearance all around in a 15" wheel, pretty good. Most likely going to be running 16's anyway.

Mocked up the steering rack location:

DSC00534 by jeremiah stewart, on Flickr

Looks like the inner heims are going to stick out just past the LCA pivot after the clevis is bolted on, so I may see some bump steer, but it looks like if I play my cards right, I can mount the LCA down one hole (UP in the pic) and then the inner tie rod heim would be in-line with the LCA and UCA pivots. So either way, we should have very minimal bump steer:

DSC00535 by jeremiah stewart, on Flickr

So I cut the original mounts out of the old subframe to save time, and welded them in the new subframe, and plated them a bit:

DSC00537 by jeremiah stewart, on Flickr

DSC00538 by jeremiah stewart, on Flickr

Mounted:

DSC00539 by jeremiah stewart, on Flickr

Fits like factory (the true test will be to see if the steering shaft fits right up like it did...)

DSC00541 by jeremiah stewart, on Flickr

View from wheel well:

DSC00543 by jeremiah stewart, on Flickr

And lastly, I just need to add these gussets:

Changes by jeremiah stewart, on Flickr

I made the shape the way it is to give clearance for the exhaust and the cylinder heads, but made way more than is necessary which would cause this thing to fold up the first time i landed a jump off-kilter. So anyways, that's the progress so far! My uniball's finally shipped out, so next weekend I may have some control arms mocked up! That's the exciting bit :D
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  #9  
Old 6th December 2016, 04:44 AM
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jf1sf5 jf1sf5 is offline
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Very nice !

From what I see, you will have 2 upper arms and 1 lower arm, right ?
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  #10  
Old 10th December 2016, 11:35 AM
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daniel glavin daniel glavin is offline
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Dude. This is insane. Super awesome man keep it coming.
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