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Independent Front Suspension for Ford F-100 PickupsThe decision to install independent front suspension in your classic pickup is usually a difficult one... From the February, 2009 issue of Custom Classic Trucks By Bob Carpenter Photography by Bob Carpenter
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 The completed Kugel Komponents...  The completed Kugel Komponents Phase 2 IFS is a visual knockout and sets this F-100's bumper right down on the ground.  The Kugel Komponents kit includes...  The Kugel Komponents kit includes cast stainless steel upper and lower A-arms and spindles, a completed crossmember, coilover shocks, a sway bar, and mounting hardware. We added a power rack for the steering.  We had to include a photo...  We had to include a photo of the phenomenal packaging by Kugel Komponents. The A-arms and spindles were well-protected in this engineer's dream shipping box.  We began by measuring the...  We began by measuring the original wheelbase, marking the stock front-axle centerline on both the top and sides of the frame, then blowing apart all the old stock frontend pieces.  A bunch of rivets must be...  A bunch of rivets must be removed before the installation of the IFS (the example shown here is the original steering box). You can heat them then punch them out, or you can grind off the heads then punch them out. We chose to grind them, because we feel you end up with less frame damage.  If the frame is tweaked, it...  If the frame is tweaked, it should be straightened.  The area just behind the stock...  The area just behind the stock crossmember will be boxed with steel plates. We ground off the paint in preparation for this step.  The crew at Hot Rods & Custom...  The crew at Hot Rods & Custom Stuff used construction paper to make a pattern for the frame boxing plates.  The patterns were transferred...  The patterns were transferred to the steel plate.  A torch was used to cut the...  A torch was used to cut the plate to the right shape, then it was ground smooth.  The boxing plates were tack-welded...  The boxing plates were tack-welded to the frame.  Clamps were used to align...  Clamps were used to align the plates precisely before final welding.  The finished plates fit perfectly...  The finished plates fit perfectly and will blend into the stock frame when they are painted.  With the frame ready for the...  With the frame ready for the installation of Kugel Komponents' IFS, it was time to make sure everything was level and square. The frame should be set at the rake you desire.  Randy Clark, head dude at...  Randy Clark, head dude at Hot Rods & Custom Stuff, helps cross-measure the frame to ensure it is square. Measure from a standardized point on the frame (like a rivet) and compare the two measurements.  The legendary Jordan Quintal...  The legendary Jordan Quintal (who is the builder of America's Most Beautiful F-100, the Kingdom '51 Ford, the Bubba-mobile, and others) checked to make sure the front end was down in the weeds. He also made sure both sides were the same.  Measurements of the outside...  Measurements of the outside frame width and the inside width of the IFS unit were taken repeatedly to ensure a perfect fit. Due to the variation in frames that occurred during their original construction, you should pay extra attention to this step. You can't expect a kit to fit exactly. You may have to grind off or add a touch of metal to get it perfect.  Here's where Quintal measured...  Here's where Quintal measured the IFS. Ours was a bit loose for the frame we were using.  Quintal welded a piece of...  Quintal welded a piece of steel to the crossmember to take up the extra space, then he ground it down to fit like a glove.  The paint was ground off the...  The paint was ground off the frame in preparation for welding the crossmember.  The IFS unit was lifted slowly...  The IFS unit was lifted slowly and carefully up into the frame with a floor jack. The instructions say to install the crossmember 1/4 inch farther forward than the original axle centerline.  More measurements--you'll...  More measurements--you'll get to know your tape measure very well while you install the IFS. Here, Quintal measures from the front of the frame to the Kugel crossmember (on both sides, of course).  We measured from the back...  We measured from the back of the frame to the crossmember to see if anything was fishy.  Once everything was in place,...  Once everything was in place, Quintal used a level to square the Kugel crossmember. A lot of little taps and nudges are required for these steps, but because this is the foundation of the new IFS, it pays to take a little extra time to triple-check.  The crossmember was tack-welded...  The crossmember was tack-welded to the frame at several points to make sure it was attached firmly. However, it was not finish-welded, because we needed to do one more check.  Run through all your measurements...  Run through all your measurements again, and be sure you're happy with what you've got, because soon it will be too late. Quintal tweaked our crossmember a bit using the level as a guide.  Finally, it was time to finish-weld...  Finally, it was time to finish-weld the crossmember. It may seem rather nerve-racking to this point (and it is), but the work itself is actually quite simple. You just want to make sure you do it right.  Now, the rest of the installation...  Now, the rest of the installation is easy. It's simple bolt-on stuff. The lower A-arm goes on first.  You'll wedge in a couple of...  You'll wedge in a couple of spacers before the bolt can go through the arm.  The spindle (shown here with...  The spindle (shown here with the brake rotor attached) is bolted to the lower A-arm.  The upper A-arms are mounted...  The upper A-arms are mounted with offset eccentric spacers, as shown here.  The spacers slip into the...  The spacers slip into the crossmember. The shorter eccentric goes toward the front.  You will notice that the eccentric...  You will notice that the eccentric spacers have a set screw, and the bolt has corresponding flat spots. When you install the bolt, make sure the flat spots face upward.  Shims set the caster angle....  Shims set the caster angle. More shims at the front decrease caster. Do not leave them out. You can put them in the back or split them to obtain the 1 to 2 degrees of positive caster (when the spindles tilt back) called for in the instructions.  Quintal used a flashlight...  Quintal used a flashlight to double-check the flat spot. The bolt was turned until the spot lined up with the set screws.  When the assembly was together,...  When the assembly was together, we were able to turn the bolt to achieve the 1/4-inch positive camber (where the top of the wheel tilts out) called for in the instructions.  The spindle was slipped into...  The spindle was slipped into the upper A-arm, and the ball joints were tightened.  The Kugel IFS kit comes with...  The Kugel IFS kit comes with a sway bar.  The sway bar has to be fished...  The sway bar has to be fished through and between the A-arms and the crossmember.  These very slick blocks bolt...  These very slick blocks bolt to the crossmember using predrilled holes.  Coilover shocks are included...  Coilover shocks are included with the kit.  Quintal bolted the bottom...  Quintal bolted the bottom of the shock to the lower A-arm. An extension on this bolt attaches the sway bar.  A link with Heim joints attaches...  A link with Heim joints attaches the sway bar to the lower A-arm.  We opted for power steering,...  We opted for power steering, so a power rack-and-pinion was bolted onto the crossmember.  The tie-rod ends were threaded...  The tie-rod ends were threaded onto the end of the power rack.  The other side of the tie-rod...  The other side of the tie-rod ends were bolted to the spindle.  The rack was mounted with...  The rack was mounted with a great deal of adjustability. We slid the rack up and down until it was in the perfect position, then we tightened it.  Wilwood brake calipers are...  Wilwood brake calipers are included with the kit along with very impressive caliper mounts.  The finished front suspension...  The finished front suspension is very impressive. The quality of the materials and design is evident. Kugel Komponents' Phase 2 IFS is a great choice for a high-quality truck project. The decision to install independent front suspension in your classic pickup is usually a difficult one. Not only is it hard to decide which direction to turn (Camaro et al. clip, Volare, Mustang II, IFS kit, and so forth), but even after you narrow down the choice, there are still many options from which to choose. If you want an independent front suspension kit, you should include the Kugel Komponents Phase 2 IFS in your decision-making. The cast stainless steel upper and lower A-arms (and spindles) are super-high quality, and their looks really stand out from the rest. Of course, your checkbook will notice a difference, but that's one of the reasons why the owners of higher-end trucks choose to go with Kugel products. Not only do they get a great product, but everybody else knows what they've got. We picked up a Phase 2 IFS system for a '56 Ford F-100 pickup just to see what all the fuss was about. We enlisted the aid of Hot Rods & Custom Stuff in Escondido, California, to install it for us as we took pictures to document the process. We were most impressed with the design, quality of parts, and ease of installation. Here's the step-by-step lowdown on the Kugel Komponents Phase 2 IFS.
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