Project: SAS the FM

[Reserector [Veteran Member]]

I have owned what is now known as the Flaming Marshmallow for five years now. It has come a long way from being known as The Battleship.

Now it is finally time to "step my game up". I have decided to do a solid axle swap, or SAS for short. That is where the factory "a-arm" suspension is cut off of the frame, and a conventional "straight" front axle is adapted to the truck.
This is the type of axle you would find in many full-size pickups and almost all Jeeps. The center portion of the axle is similar to a straight rear axle, but with steerable ends.

It is a highly technical process, and a very critical, major modification. If not done correctly, it can render the vehicle unsafe to drive. Fortunately, I have many successful SAS write-ups to guide me, plus a couple of friends who do this sort of work that I can call at any time.

The first step is gathering the components and adaptor items that will be needed. I plan to refurbish used parts as much as possible, and fabricate the brackets and other components in order to save money. This will take longer than buying new parts, but I simply do not have a budget for this.

So far I have an axle housing and outers for a '79 Ford Bronco/Dana 44 High Pinion with 4.56:1 gears on a welded carrier. I believe that this is a close enough match to my existing 4.63:1 gearing, so I won't have to buy gears.

I am planning to narrow it to match my existing axles. I also plan to swap the 5-lug outers for 6-lug.

Here are some things I am looking for:
*Ford inner shafts
*Chevy or Waggoneer outer shafts, spindles, rotors, etc. I will gladly trade for my 5-lug parts.
a non-welded carrier. I prefer an LSD, actually.
*A tapered reamer or someone who can use theirs to ream my pitman arm to accept the larger tie rod ends that I will be using.

Here is the junk that I have so far:

[601cherokee [Veteran Member]]

Hell just froze over...

[oO_Rogue_Oo [Veteran Member]]

That’s a pretty ambitious project; should keep you occupied for a while.
I look forward to seeing it take shape. Oh and of course it goes without saying; Good Luck with it

[balage [Veteran Member]]

Nice project Res! Sorry you haven't got (much)Patrol there.

[zachcrosby [Veteran Member]]

Can't wait to see this. Once you get started if you need any help I have no useful mechanical knowhow for this but if you need a guy to tell "hold this here" "tighten this" I'm there

[MarkyB [Veteran Member]]

Narrowing the Ford D44 is an ambitious project.

Just curious, why not a Toyota front axle? or a Jeep D30?

[mike327 [Veteran Member]]

I am on dry land again so we can work up a trade. I am going to need the waggy inners and ford outers and I am swapping to 5 lug. I have some chevy 10 bolt outers that I think will work for you also.

[Reserector [Veteran Member]]

I only have one outer stub, and it is of questionable quality. When can I come visit? Tomorrow evening maybe?

[601cherokee [Veteran Member]]

Narrowing the Ford D44 is an ambitious project.

Just curious, why not a Toyota front axle? or a Jeep D30?

I'm guessing so he can re-use the coil buckets on the 44 instead of fabbing some on a Toyota axle. And the D30 wouldn't hold up to enough abuse. (Plus Mark swears to never drive anything Jeep)

[mike327 [Veteran Member]]

I only have one outer stub, and it is of questionable quality. When can I come visit? Tomorrow evening maybe?

That works for me, I should be home all afternoon. What time did you have in mind?