Complete SFA Conversion Build Sequence
Gated phases with prerequisites, deliverables, and stop-work conditions. Your progress persists in this browser.
How to use the sequence
Work top-down. Each phase has prerequisites (what must be true before you start), deliverables (what “done” looks like), stop-work conditions (when to halt), and evidence to capture. Progress persists locally in this browser and can be printed for a shop handoff.
§ Interactive · Sequence
Build Sequence Checklist
1. Requirements & success criteria0/3
Prerequisites
- • Written mission profile (highway %, trail severity, payload)
Deliverables
- • Signed-off requirements document
Stop-work conditions
- • No proceeding without a written statement of what 'success' means
Evidence to capture
- • Requirements doc filed in Reference Build journal
2. Baseline inspection & measurements0/3
Prerequisites
- • Van cleaned and on level surface
- • Measurement tools ready
Deliverables
- • Completed Measurement Workbook
- • Frame photos front/rear/underside
Stop-work conditions
- • Rust or cracks in load-bearing frame require repair before design
Evidence to capture
- • Photos + workbook printed for shop review
3. Concept selection0/3
Prerequisites
- • Measurement Workbook complete
- • Alternatives compared
Deliverables
- • Selected axle, springs, T-case, steering approach
Stop-work conditions
- • Do not order parts until concept passes fabricator sanity check
Evidence to capture
- • Decision log entries with reasoning
4. Donor teardown & verification0/3
Prerequisites
- • Concept approved
Deliverables
- • Donor inspection report
- • Verified spline counts, WMS, brake specs
Stop-work conditions
- • Do not install unverified used axles/T-cases in a safety-critical role
Evidence to capture
- • Donor photos, ring & pinion inspection, seal condition
5. Chassis disassembly0/2
Prerequisites
- • Donor components inspected
- • Support stands rated for the vehicle
Deliverables
- • IFS removed and preserved for possible reversal
Stop-work conditions
- • Fuel lines, brake lines, wiring must be protected during grinding/cutting
Evidence to capture
- • Bagged & labeled OEM parts inventory
6. Rolling mock-up0/2
Prerequisites
- • Disassembly complete
Deliverables
- • Axle temporarily located, ride height set, WMS confirmed
Stop-work conditions
- • Do not tack anything structural before mock-up passes measurement checks
Evidence to capture
- • Photos of ride-height mock-up with dimensions on masking tape
7. Suspension & steering cycling0/3
Prerequisites
- • Mock-up located
Deliverables
- • Full-bump and full-droop cycling with no interference
Stop-work conditions
- • Bump steer or brake-hose tension = redesign before welding
Evidence to capture
- • Cycling video, measured travel, checked clearances
8. Brake & drivetrain mock-up0/3
Prerequisites
- • Cycling passes
Deliverables
- • Driveshaft angles measured, brake hose routing planned
Stop-work conditions
- • Excess U-joint angle or single-cardan on steep angles = design change
Evidence to capture
- • Angle finder readings recorded
9. Engineering / fabricator review0/2
Prerequisites
- • Mock-up documented
Deliverables
- • Written sign-off before final welds
Stop-work conditions
- • No final welds until sign-off is on file
Evidence to capture
- • Signed review sheet
10. Final welding & corrosion protection0/2
Prerequisites
- • Sign-off received
Deliverables
- • Structural welds complete, coated
Stop-work conditions
- • Fuel tank must be removed or fully protected before nearby welding
Evidence to capture
- • Weld photos with scale reference
11. Plumbing & wiring0/2
Prerequisites
- • Welding complete
Deliverables
- • Brake, ABS, VSS, and any electric-shift wiring routed & protected
Stop-work conditions
- • No shortcuts on ABS/VSS integration if the vehicle is road-registered
Evidence to capture
- • Wiring photos with abrasion protection visible
12. Alignment & static checks0/2
Prerequisites
- • Ride at target height, weight roughly as-used
Deliverables
- • Caster / camber / toe within target
Stop-work conditions
- • Do not drive on the road until static alignment passes
Evidence to capture
- • Alignment sheet on file
13. Low-speed commissioning0/2
Prerequisites
- • Alignment complete
- • Torque marks on fasteners
Deliverables
- • Slow parking-lot laps with brake, steering, and driveline checks
Stop-work conditions
- • Any bind, clunk, leak, or ABS/warning light = return to shop
Evidence to capture
- • Commissioning checklist saved
14. Road shakedown0/2
Prerequisites
- • Commissioning passes
Deliverables
- • Highway and controlled road testing without faults
Stop-work conditions
- • Vibrations or wander at speed = stop, diagnose, re-measure
Evidence to capture
- • Shakedown log — km, speed, temperature, observations
15. Trail validation0/2
Prerequisites
- • Shakedown clean over ≥ 500 km
Deliverables
- • Graduated trail testing
Stop-work conditions
- • No remote trip until easy-trail testing is clean
Evidence to capture
- • Trail log — terrain, articulation observed, findings
Related SFA articles
§ foundation
Is an SFA Swap Right for Your Astro or Safari?
Assess goals, alternatives (IFS strengthening, AWD conversion, other platforms), cost, downtime, and risk.
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§ fabrication
Tools, Welding Capability, and Safety Requirements
Lifting, measurement, welding, PPE, fire watch, torque control, and honest 'when to outsource' guidance.
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§ chassis
Astro SFA Measurement and Specification Workbook
Offline-capable workbook. Empty values show 'Not yet measured' — never fabricated zeros.
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§ commissioning
Commissioning, Shakedown, and Long-Term Inspection
Pre-start, static, low-speed, road, and trail validation. Re-torque intervals, weld/crack inspection, and trip-readiness checks.
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