Total Chaos spindle gussets.

Im getting ready to install mine next week. I watched a few videos and looked at a few threads (most are second Gen) my question is any first hand advice from any one who did them? Looks pretty cut and dry but things always come up.

 

Interested in how things go. I need to do the same to mine.

 

Just did mine. i had to trim a tiny bit off the upper outer corner on the side with 3 holes to get a perfect fit (used bench grinder to slowly get it perfect). I had my spindles off the truck which made id much easier to install. Just go slow and keep switching between the two so your welds can cool so you dont cause any distortion of the spindle and you should be good!

 

Thanks for the tips. Do you have pictures of how it came out? I plan on removing the spindles and taking my time. Wish I had a bench grinder. Im going to use my vice and hand grinder.

 

Finished them a few weeks ago Here is the link for my build thread. I updated it there.
https://www.tacomaworld.com/threads/the-green-truck-an-illustrated-story.660999/

 

Nice, doing mine saturday

 

Just debating if I wanna tig or mig em.
Hmmmm.

 

Looks like once you weld the spindle reinforcement it woudl be quite difficult removing ball joint or ball joint adapter for the UCAs correct?
I will install them before welding, but thinking into the future, it would be a PITA to remove them once the reinforcement is there.

 

Definitely take your spindles off and weld off your truck. I decided to leave mine on and it was a huge PITA to weld the back side

 

I left the slugs in for the uniballs, but even so there is room to remove them it's just super tight.

 

Yup the slugs. Im going to install the Icon UCAs at the same time so ill press in the slugs before welding reinforcement

 

Definitely take them off the truck before welding. Make sure you clean up the weld area really well with a flap disc. Take your time.

Here are some pics of some spindles a guy had doner while they were on the truck and they were all bad. Sent them to me and I was able to fix them for him.



Sent them to me and I was able to fix them for him.



If you like, send them to me and I'd be happy to weld them up for you. I'm pretty cheap and I enjoy welding them up.

https://www.tacomaworld.com/threads/for-sale-total-chaos-gusseted-spindles.541987/page-3

 

yea definitely do that.
or at minimum tack in the gussets to make sure the slugs can go in and out... definitely not speaking from experience lol.

 

Lmao!!! Ouch

 

Thanks for the offer bro!
It’s much easier for me to pull em off and weld same day. Yikes, those welds hahaha. Def done that though when visibility is bad. Just slightly off of the joint. Glad you fixed em for him.

 

Well was a pain in the ass job, as expected without getting the right pullers haha.
Got it done in a day though. Couldnt pull the upper ball joint taper so removed the UCA with spindle attached. Set it up on two blocks and hammered it right off. Last time I did it with a three jaw puller and it was an explosion. This time didn’t have the patience.

Couldn’t get the right cups on the upper ball joint press fit connection at the spindle so cut the shaft off of it and made something work. Hit it with buddies impact and it slowly pressed out.

Weld wasn’t bad at all. As some said the fitment was “off” but I didn’t really wanna open can of worms and start grinding. Touched it in couple spots but just welded gaps. It’s a ducking spindle reinforcement don’t over think it. You can easily mig or tig the gaps. Some were 1/8 some maybe 3/16 but I clamped where needed.

One thing to note is for the ICON UCA the bottom puck that supports the press fit spindle insert on the spindle is quite large. On one side the gusset was touching. Could have grounded the puck a little, but I just welded the gusset on with it touching. With these reinforcement and ICON spindle inserts , you just have to accept they willl never come out.

We installed icon UCA as well

 

The rigging buddy came up with to hammer offf upper ball joint. Was easier than fucking with the puller I had.

 

lol I see what you meant now.
My slugs will be in there forever haha. Was too tight of a fit. Essentially the slug is flush with the reinforcement on one side. I thought about grinding the slug down, but because time / theory of use I decided to leave it. I’m hoping that I don’t have to replace that component. If I replace something it would be the bearing/joint in the UCA. And if I ever do, I’ll get new spindles I guess haha.

 

Yea i had to use my press to get the slugs in after welding. I like to think of it as an extra safety measure keeping it in place lol

 

What back spacing do you have on your wheels? I have OEM FJ trail team wheels and they are super close to the gussets.