Total Chaos Weld-on Spindle Gusset Install

[mtbtim]

Dudes, I've been practicing some welding and finally decided I was getting decent enough to do some welding on my rigs. I'm by no means trying to pass myself off as an expert welder now. There is still room for lots of improvement so don't bash me too hard if you're an experienced welder and you think my welds look like crap.

This is a video explaining how to weld on Total Chaos Spindle Gussets onto 3rd Gen 4runner steering spindles. They would also work for 1st Gen Tacomas because they have the same spindles as 3rd Gen 4runners.

Here's the video and Enjoy the Show!

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[Dezert4Runner]

Dudes, I've been practicing some welding and finally decided I was getting decent enough to do some welding on my rigs. I'm by no means trying to pass myself off as an expert welder now. There is still room for lots of improvement so don't bash me too hard if you're an experienced welder and you think my welds look like crap.

This is a video explaining how to weld on Total Chaos Spindle Gussets onto 3rd Gen 4runner steering spindles. They would also work for 1st Gen Tacomas because they have the same spindles as 3rd Gen 4runners.

Here's the video and Enjoy the Show!

<iframe width="560" height="315" src="https://www.youtube.com/embed/e954O0UAl5I" frameborder="0" allow="accelerometer; autoplay; clipboard-write; encrypted-media; gyroscope; picture-in-picture" allowfullscreen></iframe>

Your welds look great for being fairly new to welding. I would probably make an edit on the video around 4:25 when you mention brake cleaner. That stuff is a big no-no when welding because it creates a poisonous gas. I forget the chemical in it that causes it, but just thought I’d throw that out there.

 

[JZiggy]

Your welds look great for being fairly new to welding. I would probably make an edit on the video around 4:25 when you mention brake cleaner. That stuff is a big no-no when welding because it creates a poisonous gas. I forget the chemical in it that causes it, but just thought I’d throw that out there.

Good catch. Pretty sure that’s for chlorinated brake cleaner only (which Tim wouldn’t even be able to get in CA) since it can make HCl gas if it burns. But it’s a good thing to be aware of for sure.

 

[JZiggy]

Good catch. Pretty sure that’s for chlorinated brake cleaner only (which Tim wouldn’t even be able to get in CA) since it can make HCl gas if it burns. But it’s a good thing to be aware of for sure.

Actually it looks like phosgene is the main concern but HCl is in there too:

Safety Alert! Brake Cleaner = Phosgene Gas - BREW Bikes LLC

 

[jkeith.w]

Your welds look great for being fairly new to welding. I would probably make an edit on the video around 4:25 when you mention brake cleaner. That stuff is a big no-no when welding because it creates a poisonous gas. I forget the chemical in it that causes it, but just thought I’d throw that out there.

yeah, also get a good helmet that brings air in from the back side - no need for anyone else to have the chronic cough I have. (Plus Mustard Gas just plain sucks - it's no joke)

 

[shadow247]

yeah, also get a good helmet that brings air in from the back side - no need for anyone else to have the chronic cough I have. (Plus Mustard Gas just plain sucks - it's no joke)

This is a constant concern for welders that do it full time! I would suggest anyone get a fresh air hood or use a respirator that's rated for Organic Vapors at a minimum. Even a few hours of heavy exposure to the gas created from welding can cause chronic issues. I spent the past 20 years watching guys weld with little to no protection at the body shop, and it pains me to think what kinds of problems those guys will have when they get older.

Tim, you did a great job on the welding. I have seen worse welds pass the test to certify for Body Shop welding on frames, so feel good about what you are doing. With a bit of practice, you could be as good as anybody. You certainly have the right attitude. Slow and steady seems to be the name of the game.

 

[Dezert4Runner]

yeah, also get a good helmet that brings air in from the back side - no need for anyone else to have the chronic cough I have. (Plus Mustard Gas just plain sucks - it's no joke)

Or better yet, use a respirator behind the mask. I miss the fume extractors that they had at the local college when I took my welding classes. It was one less thing to worry about when learning how to lay a proper bead.

 

[mtbtim]

Your welds look great for being fairly new to welding. I would probably make an edit on the video around 4:25 when you mention brake cleaner. That stuff is a big no-no when welding because it creates a poisonous gas. I forget the chemical in it that causes it, but just thought I’d throw that out there.

I have heard non-chlorinated brake cleaner was an appropriate prepping cleaner for welding. Like Jordan mentioned, we can't even get the chlorinated brake cleaner in California. But, I will add a note in the video description advising people against using chlorinated brake cleaner as a metal prep.

**Update - I just read the link Jordan provided and I'll just stop using brake cleaner altogether. It appears it's just a concern when you actually have a puddle of chlorinated brake cleaner left in a pitted surface of the metal. I've welded quite a few parts I've cleaned with brake cleaner and no reaction like the guy had in that article. I'll edit the video taking out the mention of brake cleaner and re-upload it because I'd hate to hurt anyone's health if they ended up using chlorinated brake cleaner as a metal prep.

**I confirmed that the brake cleaner I buy in California is non-chlorinated. The main ingredient in the California compliant brake cleaner is Acetone which is an accepted metal prep for welding. The other chemical ingredients are C02 and Heptanes.

 

[mtbtim]

I uploaded a new version of the video that doesn't mention using brake cleaner as a metal prep for welding.

 

[theesotericone]

Here's what happens when you don't weld the TC gussets to your spare spindles because your in a hurry to get wheeling again.

 

[HiluxSurf SSR-G]

may i know if that's due to the induced loads associated with the way you wheel, amount of lift, and the tire size or is that due to fatigue?

Here's what happens when you don't weld the TC gussets to your spare spindles because your in a hurry to get wheeling again.

 

[mtbtim]

Here's what happens when you don't weld the TC gussets to your spare spindles because your in a hurry to get wheeling again.

Bummer.

 

[TonyB66]

Here's what happens when you don't weld the TC gussets to your spare spindles because your in a hurry to get wheeling again.

I see the Kings, so this was some time back, not recent? Either way, that sucks...

 

[theesotericone]

may i know if that's due to the induced loads associated with the way you wheel, amount of lift, and the tire size or is that due to fatigue?

All of the above. It failed while I was on my way to do a snow recovery of a stuck Tacoma. I was only about 100 yards in on the trail when it snapped.

Bummer.

Not really. I had a spare spindle in the rig and was rolling again 45 minutes later. It did take out my brake hard line so I had to crimp that off until I could make a new one.

I see the Kings, so this was some time back, not recent? Either way, that sucks...

This was 2 weeks ago. lol

 

[mtbtim]

All of the above. It failed while I was on my way to do a snow recovery of a stuck Tacoma. I was only about 100 yards in on the trail when it snapped.




Not really. I had a spare spindle in the rig and was rolling again 45 minutes later. It did take out my brake hard line so I had to crimp that off until I could make a new one.




This was 2 weeks ago. lol

Do you normally wheel with a set of spare spindles?

 

[theesotericone]

Do you normally wheel with a set of spare spindles?

Yep. The spindles have an SPC UBJ slugs in them and new LBJ's attached to them. They get stored behind the drivers seat along with 2 spare ITR's and L/R OTR's. I also carry a starter rebuild and alt rebuild kit in the glove box. The only thing that would make my rig a long term trail plug is motor or trans failure.

 

[mtbtim]

Yep. The spindles have an SPC UBJ slugs in them and new LBJ's attached to them. They get stored behind the drivers seat along with 2 spare ITR's and L/R OTR's. I also carry a starter rebuild and alt rebuild kit in the glove box. The only thing that would make my rig a long term trail plug is motor or trans failure.

I've thought it would be smart to carry a set of extra spindles but they are quite bulky and heavy to cart around on a trip. But, I carry lots of tools and other crap so what's a couple more big bulky things to throw in the back.

 

[TonyB66]

This was 2 weeks ago. lol

I somehow wrongly thought you parted ways with the Kings after that fiasco a year or two back...

Yep. The spindles have an SPC UBJ slugs in them and new LBJ's attached to them. They get stored behind the drivers seat along with 2 spare ITR's and L/R OTR's. I also carry a starter rebuild and alt rebuild kit in the glove box. The only thing that would make my rig a long term trail plug is motor or trans failure.

Sounds like since you got the RCV axles you no longer carry spares?

 

[jkeith.w]

Has anyone tried Heavy Friction Works' spindle gussets? Wondering how they fit.

HFW • Instagram

also, when I went to SPC UCAs, I welded the UBJ insert to the spindle to help reinforce the top (along with the TC gusset)

 

[theesotericone]

I somehow wrongly thought you parted ways with the Kings after that fiasco a year or two back...

Sounds like since you got the RCV axles you no longer carry spares?

Nope. I still run the Kings. They are a great shock. Their customer service and warranty on the other hand are some of the worse in the industry. Filthy Motorsports ended up giving me the shaft and rebuild kit at cost to offset the dimension of pissed off I was in. Huge thumbs up for Ben at Filthy and huge thumbs down for King supporting their product.

I do not carry spare CV's since I went to RCV's. If one goes I'll just drive out on the other one in 3wd. It's pretty much the same as a non-locked front. lol

Has anyone tried Heavy Friction Works' spindle gussets? Wondering how they fit.

HFW • Instagram

also, when I went to SPC UCAs, I welded the UBJ insert to the spindle to help reinforce the top (along with the TC gusset)

I haven't even heard of them. Assburns is pretty close to them. I wonder if he's heard of them.

Welding the SPC slug in would have most likely prevented the failure I had. Or at least given me time to notice it before it went catastrophic. As soon as my breaks went to the floor I knew something bad had happened on the passenger side. lol