(Edits throughout so read everything if you are looking to copy any of this...and always measure yourself.. don't blindly trust a guy on the web with Louisiana skewling
Well, been working on this project for a couple months. Get a little done here and there. Did all the work with a 4.5" Harbor Freight grinder, a tape measure, and a carpenters triangle. (borrowed a friends welder to tack it together since I have ZERO welding skills and then had my buddies dad do the final burn with his 220) Pretty much just copied the Clayton system using pics I found on the web
Used Currie JJs (2.5"x1.25"-12 for the lowers) with the threaded shanks and RE rubber joints for the opposite ends. Got some nuts to match from mcmaster.com, picked up some 2.5x2.5x.25" tube for the truss and 2x2x.25 for the lowers. Uppers are 1.5" square tube .125". Used the smaller shanked JJ for the uppers (2.5" x1"-14 I believe). The RE Joint and the JJ take a 9/16" bolt (4" length is perfect)... grade 8 can be had at Lowe's if you don't order them from McMaster. So, you'll need to dig out that 9/16" drill bit if you have one already. If not, you'll need one...
4"x2" box tube will be helpful making your brackets if you don't order them from somewhere. I also had some 1/4" plate I got from the scrapyard for misc. tabs and such. Then it was just just cut for a couple hours every so often when I had time.
I got the front installed last night. I'm very pleased so far.
Put the passenger side on first, bolted it all up, then went to the driver side and did that side. I waited to make the final cut on my radius arms when I had the lower on that side on as to get it the right length.... I don't have that much faith in my old geometry skillz
Ran out of time to get the rear lowers on and the triangulated uppers go on with the F150/Explorer 8.8 (centered pinion and I got the F150 axle for free so I said why not make a centered pinion 8.8 with stock parts from my explorer axle and F150 axle).
Now onto gettin' the rear done
Total project cost including cutting wheels and paint is 649... Stress relief from flying sparks is PRICELESS!!
Bunch of Measurements - Page 2 post #19
Front end installed weak test flex shots - Page 4 post #59
Rear mock up shot - Page 5 post #62
Rear mock up with adj. Truss end brackets - Page 8 post #117
Finished Install Pics - Page 9 post #126
Poser Flex SHots - Page 9 post #131
Offroading Pics - Page 10 post #136
Video - Coming soon