After pizza and a movie I was pretty stoked about all the work we got done today, and I was still in a work mode when everyone else went to bed. So I ambled back out to the shop to try my hand at creating a bastard pack. The axle was removed earlier and was sitting on the shop floor. I didn't show how to remove the springs from the axle. If you're a Noob, and you need this kind of help, just ask.
I took one of the XJ packs to the table and began to break it down. Here are the pics...
Clamped up and getting ready to disassemble it.
Center bolt removed. I used a pair of vice grips and 13mm wrench.
Getting ready to remove the spring clamps. I used a hammer and chisel to bend down the tab, then slightly bend the clamp for removal.
XJ pack spread out on the floor. What does the little helper spring do??
This is a comparison of the XJ spring pack (top) and the S10 pack (bottom). Pretty significant difference in arch.
This is the S10 pack on the table. I'm preparing to remove the clamps holding the springs. I'm not sure this is a good idea!? But I'm a first-timer, and I'm ignorant!
Ground down the head of the rivet.
Popped clamp off with a chisel.
Notice the center holes don't line up. I'm not looking forward to drilling the new holes!
Figuring out how I want to position the S10 main against the XJ main. Again, notice the differences in the arch.
After determining where I want to cut the S10 main, I marked it with chalk so I would remember the orientation.
Marked it and clamped it in the vice.
A cut off wheel makes quick work. Take your time.
Ground the edges slightly to remove burrs and snags.
Figuring out which leaves to use and how they should fall upon each other. Remembering what everyone else has said about alternating S10 and XJ leaves, ride quality (stiffness), finished lift, etc, I really don't know how this is going to finish up. I ended up using all the S10 leaves with the idea it would keep its arch longer than the XJ leaves. I did NOT use the S10 helper spring, but I guess I could before I am done. Do I need a helper spring???
Clamped together. When clamping the leaves together you sort of need to push with your hands to make the ends extend/compress evenly at both ends.
This is a comparison of the other XJ pack and the new bastard pack I made. The BP is tilted due to the C-clamps. There is more arch than what is evident in the picture.
We'll do the other one tomorrow. We'll also attempt to make our own shackle relocation brackets. Have welder, will travel!