Four Link Rear Suspension Anyone?

With the project where it is,and with the addtion of the widened rear tubs... I quickly noticed that I would have some clearance issues with the existing leaf spring perches.  These likely wouldn't be able to work like stock.

So - go big(ger) or go home right?   I looked over a number of kits, most of them ran the links for the suspecnsion from the front leaf spring perch.  In my case, with the widened tubs, I needed something different.

I ran across Martz Chassis - they have a kit that installs on the inside of the frame rails to run the linkage to the rear end.  EXACTLY what I needed.   I threw off an email message to Martz and after some question/answer I decided to drop the hammer on the kit.  It arrived as seen below (with optional sway bar).

One of the centerpieces of the kit is this cross member - it has a driveshaft loop built in (nice feature) and it also includes cutouts that would accommodate the exhaust pipes.  After close examination of the cross member, it did look like there was a little too much metal ground down during the fab process of the cross member.  So - I got out the TIG to flow those cracks together, adding material where needed.

Next step was to epoxy prime the pieces to prep them for mock-in and installation. This rattle can Rustoleum epoxy primer actually held and has proved VERY resilient.  I'll buy more in the future.

Now for installation - I mocked in the cross member - to find that my rails were a little - (just under a quarter inch) wider than the cross member at the point it installs.  It also mounts even with the rear leaf spring perch holes - just uses them to bolt in on the inside of the frame.

So - it was time to make some plates that I could weld onto the inside of the frame rails to take up the slack equally on each side.  This came in the form of 1/16 inch plate.  I cut them out so they fit and interfaced with the subframe connectors and tried to 'fish'  one end for a little more weld coverage.

Got the area prepped - scrubbed off the epoxy primer for a nice welding surface.

Clamping in place the plate - note the hold in the plate - big enough to allow the bolt/fastening of the front rear end kit cross member.

Positioning the rear cross member between the frame rails proved to be rather tricky.  The first thing you need to do is cut the area just forward of where the gas tank is mounted.

To validate that this was where I needed to cut- I sent the Martz crew an email message with the above photograph.  I used my trusty Sharpie to indicate where I thought I needed to cut, but wasn't sure because the instructions didn't portray it the best.

On confirmation - I got to cutting.... (again)

The above two pictures show the cutting that i did and how I bent upwards the decline of the floor pan.  When you do it, you can really tell the amount of space you're creating for the rear cross member.

Now- to make a plate that will (eventually) be welded in to box the section. (honestly I've thought bout making this removable.... but I don't need to decide that until later)

Sheet metal shear made quick work of this - lots of straight lines.  Will likely fab up a nice plate for the top too - that way I can use a gauge thicker material and set it nice and flat.   This really won't matter in the end - it will be covered by carpet/bedliner ... but I'll feel better about it.