Started working on stripping the truck down for the SAS..

It took me a couple hours (by myself) to remove the front driveline (halfshafts, front diff and front driveline)

Yesterday I took out the upper and lower control arms. Here is the result.



I will post more pics over the coming days as the truck comes together.

So far there the teardown has not been difficult and anyone with basic tools can do it.

Some things you will need to make life easier are :
Good 3 ton floor jack and matching stands
Pry bar
5# Hammer
Angle Grinder (with both cutting wheel and grinder)
Sawzall (I am using a DeWalt)
Good weather (truck wont fit in the garage)

See ya in Moab!

What needs to be cut off? I thought it was a full bolt on deal?

I had my truck looking like that in about an hour when we did mine. That part was actually kinda fun.

Wow, a bit close to Moab for that kind of work isnt it? Little time for testing and tweaking.

You have to cut out the mount for the lower control arm. No need for it and it gets in the way.

That’s a deceit start air tools make quick work of all the bolts. Really not that hard just tedious, but wait until the cutting/grinding then the fun really starts

Might be interesting/tricky with just a sawzall & grinder, especially on the passenger’s side with the motor mount. Glad I used the plasma cutter, some thick stuff/tricky spots.

DR in-line is what you have to cut/grind, last one is the upper shock mount gone.

Good luck man, mine should be rolling tomorrow
Brian

That'll definitely void your warranty

It's awesome to see some real hardcore mods going on. Keep up the good pics.!

-hutch

Ya, I remember cutting all that crap off mine....I thought it stayed with the Calmini kit.

Have fun Carlton. Hope you don't encounter any bugs along the way.

looking at those pics put that stupid intro in my head...."monster....monster garage"

Damn you Brian!!!!!! You were supposed to call me when you didi this. I wanted to help.

Jason

That first picture is awesome... funky lookin but awesome.

A driveway SAS install, NICE!

Carlton/Brian take lots of pics, can't wait to install my first kit on someone's X.

I bet you guys can't wait to get to Moab and test them out.

It will look better in a few days :-)

Yea.. I was afraid it would not make it out of the garage after the swap :-) Praying for nice days!

Those pics are from the Calmini "how to" book.. those are not Brians.. Run quick and you can still help I bet!

Awesome!!

Good deal and good luck..

Looking good guys. I't looks like there will be 4 of us with the Calmini SAS. (Brian, Carlton, Me, Calmini).
BTW, my braking system is working great. Modding the Chevy MC is the way to go.

-Doug

A couple update pics.

I got my front diff guard installed and both of the shock hoops are in place.

Diff protection


Passenger side shock hoop.


Both hoops went in with little effort. There was one hole on the passenger side that I smoothed out so the threads were not hitting it.

The most difficult thing thus far has been the removal of the front LCA mount. Pain In The Ass.

If you have access to a cutting torch get it. I did the entire removal with a grinding wheel, cutting wheel and a Sawzall. With those it took me two days on and off to get the damn mount off.

I will keep the updates coming.

7 days to Moab.

So you've gotten everything but the good weather huh?

Looks like this is your only chance cause its gonna start raining again. I'd love to come down, but I'm on call this weekend and have to stay by home.

Keep the pics coming though. Maybe you can start an album somewhere.

Wow,

Looks like a lot of work but fun though!!! Looking forward to hearing what everyone thinks.
What size tires/gears/and locker did you use?

Tim

Plasma cutter - even better.

From earlier today.

I have all the new cross members in place and have the axle under the truck.





I should have the long arms in place by tomorrow as well as the coilover and other junk.

At this point I don't have any doubt that I will have the truck ready for Moab.

CM,

Yeah now another monster garage build, in < week put my X members on this weekend, went in like butter.

The bolts for the middle X member where a bit fun on top with the tight space, getting a wrench in took some positioning & smaller fingers.

Just picked up the tie rod [ES2223R] to stock pitman arm and will be putting that on tonight. Kind of dark in the garage for pics but when I roll it out I'll snap a few during the day.

My shocks and coils came separate so I had to take the shock head apart and reassemble to get the coils on. The top rings adjusts the ride height; about ½ to 1" from the top is what I was told.

What are you doing for the rear?

BTW make sure to use a 10mm flare nut wrench on the hard brake line when removing the old & connecting the new longer lines.

Looks like it's coming together terrificly, Carlton. Have fun playing with that in Moab.

Man this kit is awesome and very easy to work with, rolled mine into the garage last Thursday and it will be done by tomorrow.

The engineering & design that went into this kit is nothing short of brilliant, everything goes together beautifully and I managed to put it on rather quickly considering I just spent a few hours here & there squeezed in between working 10hrs days and all the family things I have going on. Talk about beefy everything from the shock mounts, to the long arms and x members are super heavy duty/thick.

Brian

Here is the progress today:

one of the two long arms


close up of the shocks


with the front about all together


just need to connect the front driveline.. hook up the brakes.. align it and do the springs in the back and I am on the road.

I am amazed at how nice this has come together. Very well built kit. Calmini really hit the nail on the head with this.

Awwww....F*ck me....stop posting pics of this shit. The more I see....the closer the money is to creeping out of my wallet and finding its way to California.......

Seriously though.....looks great guys. It appears that Steve did a very good job on designing and building this kit. I hope it works well for you next week, and thereafter.

looks great. my housing is waiting patiently to be put together. what's the dillio on the brakes and master cylinder? is it recommended to install a proportioning valve or upgrade the master?

I am going to drive it with the stock brakes first before I think about switching.

Doug removed his ABS unit (which actually helps boost pressure) so that is why he really needed to swap masters.

Aw come on Brad, jump in. Get the kit and I'll come over during on a weekend and we'll get it put together.

This really tempting me....trust me. I already have a lead on the necessary axle (actually three of them)....have someone who would buy my lift and steering parts....oh damn! I am really just waiting to hear or read some in-depth, thorough reviews of its performance and the like, as well as a chance to see it in person. Also waiting to see what I might do with the Sami.....But I think an SAS on the X would be a good project, and build up the Zuk over time, and only as a very extreme plaything......hmmmmmmm.

Oh damn.....damn....damn....damn

I'm running essentially the same brake setup in my Pathfinder (stock master, stock rear, and Chevy D44 calipers), except for the rear disk brakes mine has. You will find that you will have a little more pedal travel overall, but will have absolutely no problem locking up the front wheels.

Yeah, let Carlton bang it around a bit. Then buy.

I wish I had waited for this kit... Looks very well thought out and almost too easy. Keep the pictures coming, I'll use it as motivation to go fix my own junk again...

And yeah, You need to buy this kit RedX, Burgy and I can drive over and help you install it all.

Not to be a pessimist cuz that kit looks great, but what do insurance companies think of changing the entire front end of the truck like that? Or are these trailered rigs?

Oh yeah! Beer, tools and new hardware. That'll be a great weekend!

Come on Brad, get movin!

More updates. SAS in under a week. After doing some rough math I would figure that I spent about 25 hours doing the swap

I installed the rear springs and other stuff today.

Brakes are up and working. All that is left to do is get it aligned and weld on the swaybar tabs.





A rainbow appeared just as I was finishing up.


I am a happy camper. Now to test it out in Moab for a week.

The NISMO 16s are HOT. Nicely done

Marvalous simply marvalous.

Take lots of action pics. What am I saying this is Carlton.
Just curious, I was checking out the Calmini site, did you get the whole kitten-kabootle? I know you got the leaf pack, shocks and of course the SAS kit but did you go with the CV shaft as well?

Awsome Awsome Awsome.

I cannot wait to hear the write ups after moab.

More pics please, that is one bad ass truck!

you have a nice lawn.

Yeah, I don't know how he finds time to mow it with all this axle stuff going on...

Liz and I love our lawn. I have to mow it about once a week (getting closer to 2 times a week with all the rain we have had lately)

Anyway.. back to why you are here..

Flexy .. that sums it up.






I will be sure to get some great shots in Moab.

I think I could have scored close to a 1000 but I did not drive far enough up it. The rear tire still had some droop in it when I stopped.

Awesome!

I see the $ flying right outta my wallet...

John

Sexy!



25 hours for a SAS.. thats awesome. Mine took 9 months, start to finish, from scratch though.

Holy crap!

Pics look f'n sweet!

So, Carlton, what'cha doin' with all that crap you yanked out of there...

Congrats Carlton, very good job, awsome truck

Now that we saw the flex pics, do you have pics w/the truck parked (flat)?

Niiiiiiiice!!!

That looks awesome...

how much did everything end up costin
?

Good question if you don't mind answering.

Total for the entire swap?

Need to know how much I will be spending this fall.

Sweet! Any pics with the X sitting on level ground?

That's awesome.

How does she handle on-road? Steering feel/control, body roll, etc....

I have a bad case of envy.

That is nice, no, really great. Nice Job!

Carlton,
I can't believe you painted your drums "calmini blue". Your Xterra is a piece of poo and could never out wheel my Jeep. I am thoroughly glad I gave up on my X instead of waiting for the SAS kit.



Still need to make it back to Moab again. You all have a safe trip.

John
Carlton..PM me if you still want me to make that decal.

And you guys are mad at me......WTF!!!

<--------JEALOUS

holy shit dude! that is one bad ass f'in truck if i can say the least, awesome job man, two thumbs WAY up

Too bad I've had a beer with the guy and feel like I can yank his chain, and in reflection, I really do wish I still had my X. No one likes a tattle tale.

Good looking X Carlton, I will make the suggestion to paint the drums blue when I start at Nissan Monday.

John

yup... love my Jeep XJ, but the Calmini Kit makes me want to pick up a 2000 X and SAS it

No kidding. Wish I never would have sold mine. My gf still has a 200, immaculate, but 2wd. Hmm..thoughts of a 4wd conversion come to mind.

I've got a picture of it - its not on flat ground, but the jack stands are under the axle, so the suspension is compressed.

when do we get to see some shots of it in MOAB?

I think I have to go home from work early...I just creamed my pants...

tom

nice carlton. were the sway bars on and did i hear that you broke an axle?

swaybars were on all week. (minus the rear one)

Yup. Broke a front axle shaft when I wedged a tire in the crack. Calmini gears + tire wedged in Golden Crack = front axleshaft broken at the splines.

Pics to follow.

For those of you doing the upgrade I would suggest getting the Superior Crom-moly axle shafts. Part numbers will be in my write up of the event.

Very nice pic. You can see the frame flexing. Keep em comming.

I hope not ...you mean the suspension I think

Wow! THat is real impressive. The X as a vehicle just keeps getting better, with a few minor mods .

CM it looks like you tried a differnt line then what Ive seen before. (?)

holy shit.....hot

i want that, along with an X

He left out that he snapped the u-joint on the other side when he put it in reverse. Later tugging him over stuff in 2wd his tires got wedged and bent his tie-rod.

I little frame flex is normal with any vehicle. I'd be surprised if the frame weren't flexing with it that crossed up.

ouch! how did it steer out of there?

Very carfully. I’ve never seen someone with an upside down steering wheel and still drive straight.

-Doug

Wow...sorry to hear on the breakage, but it's a good excuse to buy new chromo shafts. At least you didn't have to put a tire in the crack! Awesome looking flex! I am going to have to drive the TJ out there before school starts back up.

Today was my first day in Smyrna, Nissan is going to keep me busy!

John

Carlton's got a front locker right? That was more likely the culprit. The torque had no where to go to relieve the strain on that slickrock. Welcome to wheelin' a Dana 44, should've bought a narrowed 60.

A Dana 44 is plenty strong. If you put any axle in the wrong place/the wrong way you are going to bust something. U-joints break and are cheap. The stock axle shaft could have been fatigued and it was just its time to go. Add in the Superior chromolloy shafts and it’s way strong.
A Dana 60 is just too big for a daily driver. If you want a trailer queen then go for it.

-Doug

Had a locked Dana 44 in my Ramcharger. Had a lot more power than an X can make and the axle just took it and then some.

Oddly, in my friend's Grand Waggy, which he's sunk a bunch of money fixing or modding everything, the front axle is the only thing that hasn't gone out.

Watching this thread really makes me keep an eye out for one to put in the X. It'll be a reaaaallllyyy long-term project, though...

Cost...?
Really would like to know.
Thanks

I've seen a 14 bolt pop an axle if it's in a bind...upgrade axles and cross your fingers. Its always an expensive hobby.

FWIW, I believe there's a conversion to put dana 60 guts in a 44. It might only work for full width, though....

For SAS?

$5K out the door (if you do the work yourself)

Jeff,

Superior makes 33 spline axles for the Dana 44. Match this up with some CTM u-joints and you have a very stout front end. The "guts" from a Dana 60 will not fit a Dana 44.

Take Care,

Doug