Unleashing the Baja Burban - Epic Off-Roading Adventure

Table of Contents

1. Introduction
2. Removing the Upper Ball Joint and Sway Bar Link
3. Upgrades for the Baja Bourbon
   • New Upper Ball Joint
   • Camera Batteries and Charger
   • New Camera Stand
4. Suspension Check and Troubleshooting
   • Reason for Replacing Only One Part
   • Issues with the Torsion Bar
   • Purchasing Four Shocks for Dual Setup
5. Progress Update and Preparation for Off-Roading
   • Removal of Front Clip and AC Components
   • Installation of Interior and Cleaning
   • Weighing the Vehicle
6. Ground Clearance Measurements
   • Comparing Stock Ride Height to Gutted Truck
   • Measuring Front and Back Differences
7. Cranking the Torsion Bars for Extra Lift
   • Purpose and Process of Torsion Bar Cranking
   • Effects on Alignment and Tire Angles
8. Mocking up Shock Mounting
   • Creating a Temporary Mock-up Plate
   • Designing a Cross Brace and Mounting Locations
9. Conclusion

Removing the Upper Ball Joint and Sway Bar Link

The first step in the project was to remove the upper ball joint and sway bar link. These components were identified as problematic during a suspension check before heading to the dunes. Removing them would allow for upgrades and enhancements to be made. In addition, a new upper ball joint was purchased, ensuring a smoother ride and better control.

Upgrades for the Baja Bourbon

Several upgrades were planned for the Baja Bourbon. First and foremost, new camera batteries and a charger were acquired to prevent any future battery-related issues during filming. A new and improved camera stand was also purchased to enhance the filming experience and provide better camera angles. These upgrades would make recording and documenting the project much easier and more enjoyable.

Suspension Check and Troubleshooting

Before proceeding with further modifications, a thorough suspension check was conducted. This check revealed that the front suspension was in poor condition, necessitating the replacement of multiple components. However, only one suspension part was found to be in need of immediate replacement. The torsion bar and sway bar link were also found to be problematic and would require Attention.

The decision was made to purchase four shocks to provide extra durability and protection for off-roading adventures. The plan was to run dual shocks in the front of the vehicle to handle the demanding terrains and potential impacts. This setup would ensure a smoother ride and minimize the risk of damage to the suspension system.

Progress Update and Preparation for Off-Roading

Significant progress was made on the Baja Bourbon, but some delay occurred due to unexpected circumstances. However, the ultimate goal was to have the vehicle up and running in time for a trip to the dunes the following week, weather permitting. Excitement was building, and preparations were underway to make the off-roading experience a success.

The front clip was partially removed to facilitate the installation of a new radiator and improve airflow. This involved removing the condenser for the AC system, providing better cooling performance. Additionally, the interior of the vehicle was cleaned and installed, including the dashboard and center console. These updates significantly improved the overall appearance and functionality of the Baja Bourbon.

Before hitting the road, the weight of the modifications and components needed to be determined. This involved weighing various parts and accessories separately to calculate the total added weight. The information gathered through this process would provide valuable insights into the vehicle's handling and performance.

Ground Clearance Measurements

Measuring ground clearance was a crucial step in evaluating the effectiveness of the modifications and upgrades. The stock ride height was compared to the modified height after removing excess weight and cranking the torsion bars. Measurements were taken from the center of the hub to the bottom of the fender to ensure accuracy.

Surprisingly, the gutted truck exhibited an increase in ground clearance. The difference between the stock and modified heights ranged from one and a quarter to two inches, depending on the location being measured. These findings were promising and indicated that the modifications were effective in providing the desired lift and increased clearance.

Cranking the Torsion Bars for Extra Lift

Cranking the torsion bars was an essential step in achieving additional lift and ground clearance. The torsion bars are responsible for twisting the lower control arm and act as a suspension mechanism. By adjusting the keyway and twisting the torsion bars, the front of the vehicle was lifted, providing the desired height increase.

It was important to note that cranking the torsion bars changed the alignment angles and tire geometry. This Altered the tire position and required a realignment to ensure proper tire wear and performance. While off-roading, precise alignment was not a significant concern, but for everyday driving, it would be necessary to correct these alignment angles.

Mocking up Shock Mounting

Designing the shock mounting system involved creating a temporary mock-up plate and planning for a cross brace. The mock-up plate allowed for a visual representation of the final shock mount location. This plate would be replaced with a more robust and permanent mounting bracket made from thick steel. A cross brace would also be constructed to connect the shock mounts and provide additional support.

To complete the shock mounting system, a bar would be mounted across the cross brace, allowing for the attachment of dual shocks. This setup would be replicated on the other side of the vehicle to ensure symmetry and balance. Once constructed and installed, the shock mounting system would provide the necessary strength and resilience for off-road adventures.

Conclusion

Despite some delays and unexpected challenges, progress was made on the Baja Bourbon project. The upper ball joint and sway bar link were successfully removed, opening the door for upgrades and enhancements. Various modifications and improvements were implemented, including the installation of new camera batteries, a camera stand, and the removal of excess weight in the front clip.

Suspension issues were addressed through the purchase of four shocks for a dual setup, ensuring a smoother and more controlled ride during off-roading activities. Ground clearance measurements were taken, confirming the effectiveness of the modifications. Cranking the torsion bars provided an additional lift and improved clearance.

The design and mock-up of the shock mounting system also progressed, with plans for a permanent mounting bracket and cross brace. The installation of this system would provide the necessary support and durability for off-road adventures.

Overall, the Baja Bourbon project was shaping up well, and the anticipation for the upcoming off-roading trip was palpable. The modifications and upgrades made to the vehicle would undoubtedly enhance its performance and reliability in challenging terrains.