Ripcord's 2002 Sport Ed. Version 2.0

[4-Ripcord]

|July 15-22, 2017|

Overlanding to FJ Summit 2017

A trip that had been in the works for months.. we wanted to start in Denver and overland our way to the FJ summit in Ouray over the course of a week. Total it would be about 500 miles of off road travel.

The trails we traveled are as follows in order:
Georgia pass
Mosquito pass (still blocked by snow)
Weston Pass
Hagerman Pass
Devil’s Punchbowl/schofield pass (still blocked by snow)
Engineer pass
mineral creek
Ophir pass
Black Bear pass
Imogene pass.

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Day 1:
The group all met up at 8am in conifer outside of Denver. The group consisted of [MENTION=129084]Flemster[/MENTION] , [MENTION=144428]RockyMtnPhoto[/MENTION] , a buddy with a red long travel first gen and myself. The first day was the longest. Started on hwy 285 and ran up Georgia pass to start things off. Crossed the continental divide for the first time of many on this trip. After Georgia pass, we were in the town of Breckenridge and we drove south a bit to Alma to attempt mosquito pass. I say attempt because we had heard this pass was still snowed in. Once we go up near the mill on the trail we confirmed this rumor and backtracked to the start of the trail. To finish off the day we headed to our alternate pass, Weston Pass, and camped there.




EPISODE 1 of the video

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Photo by [MENTION=129084]Flemster[/MENTION]


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Photo by [MENTION=129084]Flemster[/MENTION]


Also passed through the town of Fairplay, also known as the town of South Park!

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Photo by [MENTION=129084]Flemster[/MENTION]


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Photo by [MENTION=144428]RockyMtnPhoto[/MENTION]


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Photo by [MENTION=129084]Flemster[/MENTION]



The awning proved to be VERY useful as it rained almost every day on this trip

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Photo by [MENTION=129084]Flemster[/MENTION]



I was the only person without a roof top tent, so instead I used this pop up tent from Front Runner.

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Photo by [MENTION=129084]Flemster[/MENTION]



Camp night @1

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Photo by [MENTION=129084]Flemster[/MENTION]

 

[4-Ripcord]

Day 2:
We got a late start on Monday, making a killer breakfast. The plan for the day was very full. We did not have any time to spare for slowdowns. Upon descending the pass, drew (in the first gen) noticed he was losing brake pressure. We inspected and found a cracked brake line due to stupid people routing his hard line all the way up to his control arm… We limped him to the end of the trail to the road that leads to Leadville where Alex and I headed into town to get new brake lines while drew and will took the tire off in preparation for our return.

Leadville is a small town, and is the highest us city at 10,200ft, but luckily they still had a chain auto parts store. We were able to replace the hardline, but the whole situation had put us severely behind schedule. The good thing about a trip like is the schedule is very loose to begin with. With the remaining time we had in the day, we traveled west out of Leadville across the turquoise reservoir and up to Hagerman pass.
When we neared the summit, the views were so spectacular we just had to stop and enjoy them. We decided to have lunch also as we cowered under a rainstorm that was become the normal weather for this trip. Before we left, a passerby told us of a double rainbow that was visible from a nearby hilltop. Many group members ran to see it before we set off to descend the pass. As dusk approached we still needed to find a campsite, we descended deeper into the valley to find camp.

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Photo by [MENTION=129084]Flemster[/MENTION]


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Photo by [MENTION=129084]Flemster[/MENTION]


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Photo by [MENTION=129084]Flemster[/MENTION]


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Photo by [MENTION=129084]Flemster[/MENTION]

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Day 3:
We got an early start on, we needed to catch up! The plan was a bit different today though, we were going to head for the devil’s punchbowl cliff jumps outside of aspen Colorado. The daredevils among us headed straight for the high jump. We expected the water to be very cold, but I don’t think any of us were prepared for how strong the current of such a small body of water could be! After conquering the fear of the jump you had to immediately shift your focus to finding your way to the exit or risk being washed down a rocky waterslide. We did see one other poor guy go down it, he did not look like he enjoyed it. Once we all got our showers, which would turn out to be the last one we would get all week, we headed back out on the road we drove in on.

Our next destination was marble Colorado and the famous crystal mill. The trail leading up to the crystal mill was called devils punchbowl, not to be confused with the cliff jumps we had just come from bearing the same name. The ascent up the trail was one of the most spectacular drives of the trip. The way the rain fell through the sunbeams literally looked like it was raining glitter. We got to see the aftermath of an avalanche before we finally arrived at the mill itself. It was definitely worth the trip to it. The whole area was breathtaking. The student architects among us could not stop taking photos. Our plan from here was to assess the condition of the pass and hopefully make it across to paradise valley to make camp near the ski town crested butte. However some other enthusiasts we met on the trail informed us the pass was still unpassable. We expected this though, and our backup plan was to take some dirt roads around the long way to crested butte. But first we had to stop at the best bbq place any of us had been to. The journey to paradise valley through the dirt roads took us deep into the night, we arrived in camp after midnight. Mostly everyone promptly setup tents and went to sleep.



In Basalt

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Photo by [MENTION=129084]Flemster[/MENTION]



Will’s truck had been rear ended the night before our big trip. The truck was definitely going to be totaled, but that didn’t stop us from sending Milton off without a bang!

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Photo by [MENTION=129084]Flemster[/MENTION]



The cliff Jumps

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Photo by [MENTION=129084]Flemster[/MENTION]


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Somewhere on the road to Marble, CO
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Photo by [MENTION=129084]Flemster[/MENTION]



Heading up

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Photo by [MENTION=129084]Flemster[/MENTION]



At the Famous Crystal Mill

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Photo by [MENTION=129084]Flemster[/MENTION]


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From here on out through the evening, we were driving at night taking the long way around to crested butte.

 

[4-Ripcord]

Day 4:
We awoke to a breathtakingly beautiful valley. While we were tearing down and preparing to leave, a stunt plane came ripping through the valley. It sounded like a gang of Harleys. We were not fast enough to get any photos or videos of it, so you will just have to imagine it. The plan for the day was to travel into crested butte for a little then head south to lake city and run engineer pass.


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Not a bad place to live at all..

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Engineer pass was without a doubt the most scenic part of the trip.

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Photo by [MENTION=144428]RockyMtnPhoto[/MENTION]


Some remaining snow on the way up

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The group at the top of Engineer pass:

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Late night camping spot hunting on Mineral Creek trail

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Photo by [MENTION=129084]Flemster[/MENTION]

 

[4-Ripcord]

Day 5:

Day 5 was pretty relaxing. The camp spot we had at the top of the mineral creek trail was spectacular. The guided trail runs for the FJ summit event were in full swing so we saw plenty of convoys go by too. We went south through the animas forks ghost town and into the town of Silverton. The only trail we really ran was Ophir pass before camping near Alta lakes.



Waking up at camp on mineral creek:

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Ophir pass

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Day 6:

Day 6 we ran Ophir pass backwards to get to the top of Black bear pass then ran that.

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Photo by [MENTION=129084]Flemster[/MENTION]




It had been raining off and on all day. Before we descended, a group of bikes had to descend the “shelves”. Already a very exposed and steep section of the trail, only made harder now that the shale rock was slippery. The bikers hand walked each bike down.


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Day 7:

For the final trail day of the event, we ran Imogene pass. After that was done we hung around a bit in Ouray to check out the event itself.

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Photo by [MENTION=129084]Flemster[/MENTION]


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You can see the Black Bear pass switchbacks from Imogene

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Heading up to the top

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Photo by [MENTION=129084]Flemster[/MENTION]


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Photo by [MENTION=129084]Flemster[/MENTION]

<a data-flickr-embed="true" href="https://www.flickr.com/photos/149794382@N06/35819079760/in/album-72157684131836074/" title="20170722-IMG_5628"><img src="https://farm5.staticflickr.com/4323/35819079760_e8249da252_b.jpg" width="1024" height="640" alt="20170722-IMG_5628"></a><script async src="//embedr.flickr.com/assets/client-code.js" charset="utf-8"></script>


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Photo by [MENTION=144428]RockyMtnPhoto[/MENTION]

 

[4-Ripcord]

|August 19, 2017|

It was time to swap out the ICON suspension for some KING shocks, perks of the job and all

What/Why:
The main reason for this swap was that I wanted to get 12” travel shocks in the back, which involved custom brackets on the frame and on the axle housing. I got a clean axle housing to replace my rusty one. I have mentioned in the past how I was never satisfied with how I mounted the 10” ICONS. I also swapped in some SPC control arms in place of the all pro uniballs, the reason for this was that the uniball was starting to squeak and I didn’t want to deal with it. I also wanted some more caster adjustability.

Parts/Cost:
$1250 – King 2.5 coilovers (extended travel)
$1000 – (2x) King 2.0 12” shocks w/remote resi, compression adj, finned resi
$400 – SPC upper control arms
$100 – Used axle housing

Tools:
Basically all the tools..

Time:
The front was 5-ish hours because I ran into some slowdowns getting the all pro arms off. The rear was a lot of custom time over the course of a few weeks…

Procedure:

Lets start with the front..

SPC compared to the old All Pro arms..

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Fancy new parts:

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All in, sorry I didn’t take a whole lot of progress pics but we have all seen my truck taken apart enough

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*NOTE: the coilovers are adjusted WAY too tall in this pic. I reduced the preload by a lot after this was taken*

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I set the SPC to the E setting. This brought the front axle forward from the neutral setting, which should help with the tire rubbing near the pinch weld.

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==========================================================================

Now on to the rear…

This was my design for the rear upper shock mounts.

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All the pieces cut out:

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Starting with the mounting plates

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Didn’t take any pics between that and the fully welded units..

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Painted the back sides BEFORE welding them on, there’s no way to get to it after..

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Picked up a few reservoir saddles..

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Here is the new rear axle I mentioned. It will be so nice to get rid of my rusty one!!!

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Stock shock mounts cut off

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For the Axle shock mounts you need to cut off the factory lower shock mounts. To position the new lower mounts, I used the published lengths of King 2.0 12” shocks: 19.585” compressed and 31.585” extended (bolt center to bolt center).

Now measure from the upper mount 24.585” with the axle at ride height position. This will be the length of the shock at ride height, 5” of uptravel and 7” of downtravel.

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Swapped the axle seals for new ones

<a data-flickr-embed="true" href="https://www.flickr.com/photos/149794382@N06/36490459952/in/album-72157682681808563/" title="20170810_125243"><img src="https://farm5.staticflickr.com/4333/36490459952_365a238c52_b.jpg" width="1024" height="576" alt="20170810_125243"></a><script async src="//embedr.flickr.com/assets/client-code.js" charset="utf-8"></script>


Cutting the old upper mounts off

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Welded on new ones and the reservoir saddles:
I did have to pound the wheel well to make some clearance for the mount, but this isn’t necessary. I could have just moved both mounts down a bit.

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[4-Ripcord]

Now for the install!!


Here are the shiny new parts

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Taking the rear axle out, look at that rusty hunk of junk!

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Whole axle out

<a data-flickr-embed="true" href="https://www.flickr.com/photos/149794382@N06/35846008064/in/album-72157682681808563/" title="IMG_2959"><img src="https://farm5.staticflickr.com/4435/35846008064_9a5a570e90_b.jpg" width="1024" height="683" alt="IMG_2959"></a><script async src="//embedr.flickr.com/assets/client-code.js" charset="utf-8"></script>


Side by side with its replacement

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Comparing shock mounts

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All cleaned up

<a data-flickr-embed="true" href="https://www.flickr.com/photos/149794382@N06/36680897955/in/album-72157682681808563/" title="IMG_2967"><img src="https://farm5.staticflickr.com/4404/36680897955_4d31a49542_b.jpg" width="1024" height="683" alt="IMG_2967"></a><script async src="//embedr.flickr.com/assets/client-code.js" charset="utf-8"></script>


The diff is still looking good!

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Shocks in! (this is at full droop, they sit very even with the mount at ride height)

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Compression adjuster and finned reservoirs, gone full bling on this one!

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AHHHHHHHH so much better!!

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At ride height
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*note: you will need wheel spacers in the rear to clear the shocks when flexing. The above images are before that spacer was added.*

 

[JWaldz]

Awesome work Jim! Almost looks too clean. Time to go get it all dirty lol.

 

[Scramble]

Nice work! 2 things, your old axle housing was not rusty! And those new lower shock mounts look low. Be careful not to drag them on anything.

Here's what I'm working on now, E-locker swap. This is my old rusty axle housing. Still thick & solid in all areas. My new housing is almost perfect but I'm still painting it with a rust converter & top coat before I put it back on my truck.

 

[derpiful]

Looks awesome! Glad to see you finally got them in. Those things are looooong, excited to see them at droop on the trail!

 

[Black798]

About damn time lol! Ive been looking forward to seeing your trip report and those rear shocks for a long time. I really like the upper mount design. How do you like the ride with king vs the icon stuff or is there much difference? Also what kind of driveshaft contact issue are you having with that much articulation in the back? I ask because I have probably 3 inches less travel and with the stock skid was shearing zerks off on every trip.

 

[4-Ripcord]

Awesome work Jim! Almost looks too clean. Time to go get it all dirty lol.

Thanks bud, in due time!

Nice work! 2 things, your old axle housing was not rusty! And those new lower shock mounts look low. Be careful not to drag them on anything.

Here's what I'm working on now, E-locker swap. This is my old rusty axle housing. Still thick & solid in all areas. My new housing is almost perfect but I'm still painting it with a rust converter & top coat before I put it back on my truck.

The lower mounts are pretty perfectly positioned in terms of shock length. I got the upper mount as high as I could. They are also about 2 inches higher up than the stock lower mounts, for reference..

Looks awesome! Glad to see you finally got them in. Those things are looooong, excited to see them at droop on the trail!

Thanks Hayden! It should be a good setup. It was great to see you in Colorado last month.

About damn time lol! Ive been looking forward to seeing your trip report and those rear shocks for a long time. I really like the upper mount design. How do you like the ride with king vs the icon stuff or is there much difference? Also what kind of driveshaft contact issue are you having with that much articulation in the back? I ask because I have probably 3 inches less travel and with the stock skid was shearing zerks off on every trip.

I have been without that zerk fitting for a long time haha. The main improvement has been the rear, the icons were land cruiser shocks so they were a bit firm. I specifically tuned these shocks for the 4runner's weight so they are perfectly matched. Both a very good shocks, I would say the kings have less damping on low velocity high amplitude inputs so it is more comfy but can have more float to it.

 

[puttster]

Holy smokes man.. just keeps getting cleaner and cleaner! Gotta get mine driving again...

 

[theesotericone]

Great trip and great suspension. I need to get a job where I have perks. lol

 

[BoarderDave]

Damn.. that's some tasty suspension work. :yo: Great job.

 

[trailbikerider]

An update finally! What a great end to my day!

 

[rickashay]

Wow [MENTION=57546]4-Ripcord[/MENTION]! Some deadly photos and updates. Certainly worth the stop in this thread. Props for those fancy mounts allowing 12" shock to fit in there. Surprised the tire doesn't come close to the shock at full bump on one side?

Must have missed it, where are you working now? Switching to the pretty blue King stuff I see!

Cheers.

 

[Tyler James Inc]

New long shocks, and no flexy pics?! What a letdown!
Looks good though [emoji1360]

 

[AssBurns]

Wow I need to catch up on that trip report. Didn’t have time read it all yet but looked awesome. Those shocks look amazing! Are those 7/8” shafts on those things? They are huge! Looks great dude! Looking forward to seeing some action shots. Hows the clearance looking between the tire and frame?


Edit: Went through the trip report. That looked like a phenomenal trip. I’d love to someday to a trip like that!

 

[4-Ripcord]

see next page for the tragic conclusion to this build...

 

[4-Ripcord]

Holy smokes man.. just keeps getting cleaner and cleaner! Gotta get mine driving again...

As you will see in the next post, we are actually in the same sh*tty boat.

Damn.. that's some tasty suspension work. :yo: Great job.

Thanks, it was a long time coming.

Great trip and great suspension. I need to get a job where I have perks. lol

Its pretty sweet haha, thanks!

An update finally! What a great end to my day!

Glad to help

Wow 4-Ripcord! Some deadly photos and updates. Certainly worth the stop in this thread. Props for those fancy mounts allowing 12" shock to fit in there. Surprised the tire doesn't come close to the shock at full bump on one side?

Must have missed it, where are you working now? Switching to the pretty blue King stuff I see!

Cheers.

Thanks Addison! Yours is getting pretty sick lately too! Thanks for stopping by. I work at King Shocks now since you asked.

New long shocks, and no flexy pics?! What a letdown!
Looks good though [emoji1360]

Well I had them in for a total of 4 days before the truck was totaled, so...

Wow I need to catch up on that trip report. Didn’t have time read it all yet but looked awesome. Those shocks look amazing! Are those 7/8” shafts on those things? They are huge! Looks great dude! Looking forward to seeing some action shots. Hows the clearance looking between the tire and frame?


Edit: Went through the trip report. That looked like a phenomenal trip. I’d love to someday to a trip like that!

The frame clearance was a bit tight when articulating. If I did it again I would move the lower mount out about an inch and get a small wheel spacer. 3/4" shafts.

The trip was amazing, thanks. I highly recommend trips like that.