XJ Custom Lift/Build thread

[Backwoods Rambler]

Original date of post: June-7-08

To read the original post, where some comments will begin to make more sense, check here: http://www.rockfrogs.org/phpBB2/viewtopic.php?t=2442&postdays=0&postorder=asc&start=0

Wohooo, the big day has come and gone. Actually in terms of making progress on the Jeep; is was a decidedly miserable day. :cry:

I got back from NE to get the loaner vehicle at 3:30, but my wifes friend went into labor so I was watching the kids all evening until about 6:30.

So without further delay. Here's the progress pics (I know that's all everyone wants to see anyway) from 6:30pm to 9pm today:

Getting a late start on a huge project sucks :evil:
http://rockfrogs.org/members/backwoods_rambler/jeep/Getting%20startedmed.jpg


Hey this is a good sign
http://rockfrogs.org/members/backwoods_rambler/jeep/Rearaxleremove2med.jpg


I was so nervous that the brake lines would strip or bend like I've always experienced. Not this time PB Blaster rocks!!
http://rockfrogs.org/members/backwoods_rambler/jeep/Newextendedbrakelinemed.jpg


Here's a new vs old spring perch comparison
http://rockfrogs.org/members/backwoods_rambler/jeep/Newspringperchmed.jpg

I noticed what appears to be a height difference between the two......
Sure enough, about 3/8 - 1/2 difference 8-)
http://rockfrogs.org/members/backwoods_rambler/jeep/Newspringperch3med.jpg


I noticed what apprears to be a slight bend in the main leaf. Surely due to the towing :oops: I may find myself upgrading to a RE (or OME) rear leaf pack in the future :idea:
http://rockfrogs.org/members/backwoods_rambler/jeep/Stockmainleafmed.jpg

I simply cut the ends off of the S-10 main leaf, which is to be bolted under the stock XJ main leaf. Can't tell in this pic, but I also smoothed the edges of the S-10 main leaf so they don't cut into the XJ main leaf.
http://rockfrogs.org/members/backwoods_rambler/jeep/Cuts10mainleafmed.jpg


Here's one completed Hybrid XJ/S-10 spring pack. I'm not cutting the center pin until I know my ride height is good.
http://rockfrogs.org/members/backwoods_rambler/jeep/Hybridpack2med.jpg

Hybrid spring pack side bar:
For the Hybrid pack, most tend to use the Xj main, the S-10 Main, the S-10 second, the XJ third, and the S-10 overlaod.

I used the Xj main, the S-10 main, the S10 second, the S-10 third and the S-10 overload so I'm anticpating being a litter taller in the rear. I did it this way to compensate for a loaded rig while wheeling and camping. We'll see if it works.


So there it is. Axle is out and one spring pack is done (assuming I've picked the right combo of springs for the ride height I want).

My drill press could not get through the springs to open up the center pin hole :smt017 so once again I had to pull out the trusty Ryobi and once again it got the job done 8-)

I was planning on burning the midnight oil, but I think after today, I'd be better off getting a good nights sleep and cranking away at it tomorrow.

[Backwoods Rambler]

Original post date: June 8, 2008

I made a bit more progress today. Here's the proof....

Cut off old spring perches and smoothed the stock welds down
http://www.rockfrogs.org/members/backwoods_rambler/jeep/Springperchsmooth%20(Medium).jpg


Set new perches in place (not welded yet)
http://www.rockfrogs.org/members/backwoods_rambler/jeep/Testfitting1%20(Medium).jpg


Rear rear is all setup (again not welded yet) so that I can compare the height to the front and to make sure things are set once I make the control arms.
http://www.rockfrogs.org/members/backwoods_rambler/jeep/Rearlifted%20(Medium).jpg

It's might be hard to tell in these pics, but the rear is higher for sure.
http://www.rockfrogs.org/members/backwoods_rambler/jeep/Alittlehigher2%20(Medium).jpg

Moving along to the front now that the rear is mocked up.
http://www.rockfrogs.org/members/backwoods_rambler/jeep/Startfront1%20(Medium).jpg


These coils were SOOOOOO hard to install.
http://www.rockfrogs.org/members/backwoods_rambler/jeep/Movingalong1%20(Medium).jpg

I'm really having trouble figuring out where to place the axle to measure for the control arms.

This isn't helping either.
http://www.rockfrogs.org/members/backwoods_rambler/jeep/Aweebitoff%20(Medium).jpg

http://www.rockfrogs.org/members/backwoods_rambler/jeep/Aweebitoff2%20(Medium).jpg

A pretty good day so far. This evening will mostly be spent centering the front axle and working on the control arms.


Man am I glad I got a loaner car :smt115

[Backwoods Rambler]

Original post date: May 2o, 2008 - A little out of sequence, sorry

Got some cool stuff today 8-)

http://rockfrogs.org/members/backwoods_rambler/jeep/Longarm1.jpg

http://rockfrogs.org/members/backwoods_rambler/jeep/Longarm2.jpg

http://rockfrogs.org/members/backwoods_rambler/jeep/Longarm3.jpg

http://rockfrogs.org/members/backwoods_rambler/jeep/Longarm5.jpg

Regarding this image; The casing of the joint is narrower than the 2"x2" control arm. So the only thing I can think to do is cut a
wedge out of the control arm to make it a bit narrower where it meets the join casing.
http://rockfrogs.org/members/backwoods_rambler/jeep/Longarm4.jpg

[Backwoods Rambler]

Original post date: June 9, 2008

Well I got started on the arms and so far things are looking OK. I did screw up both of my threaded tube inserts by welding them all the way around in one shot instead of doing a little at a time and letting them cool in between.

4 hrs and $40 later I have a new set and you can believe I'll be taking it slow with these ones.

Here are some progress pics:

The lower arms needed to be narrowed at the ends to fit the link ends I'm using.
http://www.rockfrogs.org/members/backwoods_rambler/jeep/Lowerarm1%20(Med).jpg

Then beveled for welding
http://www.rockfrogs.org/members/backwoods_rambler/jeep/Lowerarm2%20(Med).jpg

Then pressed and tack welded
http://www.rockfrogs.org/members/backwoods_rambler/jeep/Lowerarm3%20(Med).jpg

Looking good for the smaller end....
http://www.rockfrogs.org/members/backwoods_rambler/jeep/Lowerarm4%20(Med).jpg

And for the larger end. I will taper the ends a little more with the grinder.
http://www.rockfrogs.org/members/backwoods_rambler/jeep/Lowerarm5%20(Med).jpg

Here are the inserts that I screwed up
http://www.rockfrogs.org/members/backwoods_rambler/jeep/UpperCAend%20(Medium).jpg

Here are the new ones
http://www.rockfrogs.org/members/backwoods_rambler/jeep/Newtubeadaptors%20(Med).jpg

Big thanks to Terry for letting me use is press and welder to get the ends narrowed.

Hopefully more progress to come soon. 8-)

[Backwoods Rambler]

Original post date: June 9, 2008

Well as I've been building these arms, I've been going back and forth on how to set them up. You may recall that my original plan was to recess them into the frame completely. Then I decided to change things up, since I felt that recessing them added a level of complexity that I didn't feel was necessary. So I decided that I would recess them just enough so that I can bolt and unbolt them from a point below the frame (uni-rail)

Well, now that that I have them mocked up, and comparing how low they hang in relation to my skid, and where the fall in relation to the center of the frame; I'm thinking I will just surface mount them. An added benefit to this is that if I land on the arms and skid down, they will transition the terra firma onto the skid plate as opposed to the skid plate becoming something to get hung up on. Like it currently is :(

Also, in the interest of safety I've decided NOT to mount the upper links to the lower links. At least not right away. For now I will mount the upper links as they are from the factory with my HD upper arms and high misallignment rod ends. I figure since this is a DD I'd like to not trust my life (and others on the road) just one mount (lower frame side) until I'm confident, after a bunch driving and wheeling, that it's going to be strong and last. We don't need another Roll Frog.

Anyway, here's progress pics from this afternoon....

So the first thing was to finish welding the seam from pressing the ends of the square tube down

http://www.rockfrogs.org/members/backwoods_rambler/jeep/Finishweldseam%20(Medium).jpg

Here's the small end (axle side) being test fitted
http://www.rockfrogs.org/members/backwoods_rambler/jeep/Testfitsmallend%20(Medium).jpg

Now the large end (frame side)
http://www.rockfrogs.org/members/backwoods_rambler/jeep/Testfitbigend%20(Medium).jpg

Notice the bevel at the end and arm joint. Also, notice that my clearances came out pretty well for grinder coping.
http://www.rockfrogs.org/members/backwoods_rambler/jeep/Testfitcloseup%20(Medium).jpg

Here's the arms tackwelded so I could test fit and see if I needed to shorten them
http://www.rockfrogs.org/members/backwoods_rambler/jeep/Tackwelded2%20(Medium).jpg

http://www.rockfrogs.org/members/backwoods_rambler/jeep/tackwelded1%20(Medium).jpg

[Backwoods Rambler]

Original post date: June 9, 2008

So after I test fitted the arms I did the finish welding. This took me hours since I was afraid to screw up the threads.
http://www.rockfrogs.org/members/backwoods_rambler/jeep/Heatpattern%20(Medium).jpg

They still thread good :D
http://www.rockfrogs.org/members/backwoods_rambler/jeep/Stillthreadsgood%20(Medium).jpg

I love that these are greasable
http://www.rockfrogs.org/members/backwoods_rambler/jeep/Smallendgreased%20(Medium).jpg

Never thought I'd get this far after the way things were going last night....
http://www.rockfrogs.org/members/backwoods_rambler/jeep/Lowerarmsdone%20(Medium).jpg

Before I could mock up the lower arms again I had to cut the stock mounts
http://www.rockfrogs.org/members/backwoods_rambler/jeep/Factorymountcut1%20(Medium).jpg

Nothing fancy here, just cutting enough to make room. Hey, it's not a show car :roll:
http://www.rockfrogs.org/members/backwoods_rambler/jeep/Factorymountcut2%20(Medium).jpg

[Backwoods Rambler]

Original post date: June 9, 2008

So here they are so far.
http://www.rockfrogs.org/members/backwoods_rambler/jeep/Lowerarmsmocked1%20(Medium).jpg

Obviously the angle will be better once the axle can carry the vehicle weight

Grade 8 hardware :D
http://www.rockfrogs.org/members/backwoods_rambler/jeep/Lowerarmsmocked2%20(Medium).jpg

I will also need to make a skid for the lower arm bracket. Not the best place for the grease zerk :oops:

This shot shows where the arm lands in relation to the "frame" The jack stand is placed directly below the center of the frame.
http://www.rockfrogs.org/members/backwoods_rambler/jeep/Lowerarmsmocked3%20(Medium).jpg

This was also a deciding factor in how to mount the arms on the frame end.

Well tomorrow it's back to real work, so progress will be much slower I suspect.

[Backwoods Rambler]

Original post date: June 10, 2008

Got the new tube inserts welded and WORKING!! (well that was actually yesterday)
http://www.rockfrogs.org/members/backwoods_rambler/jeep/Newendsweldedok1%20%20-Med.jpg

http://www.rockfrogs.org/members/backwoods_rambler/jeep/Newendsweldedok2%20%20-Med.jpg

Tonight I started to make the axle end, of the upper control arms. Here's a few shots of that. These will be welded to the ends of the upper arms sort of like the RE arms below

http://www.rubiconexpress.com/Img_Products/Pn/9/1969/Photographs/0/324.jpg


http://www.rockfrogs.org/members/backwoods_rambler/jeep/Uppercaaxleends1%20%20-Med.jpg

http://www.rockfrogs.org/members/backwoods_rambler/jeep/Uppercaaxleends2%20%20-Med.jpg


http://www.rockfrogs.org/members/backwoods_rambler/jeep/Uppercaaxleends4%20%20-Med.jpg

http://www.rockfrogs.org/members/backwoods_rambler/jeep/Uppercaaxleends5%20%20-Med.jpg

I plan to cap the top of these also, just for a little extra strength :twisted:
http://www.rockfrogs.org/members/backwoods_rambler/jeep/Uppercaaxleends6%20%20-Med.jpg

http://www.rockfrogs.org/members/backwoods_rambler/jeep/Uppercaaxleends7%20%20-Med.jpg

I'm going to need to cut my upper control arms down a bit. I knew they would be long, so this comes as no surprise to me. I'm planning on making them 1/2" longer than stock just because Keeping them stock length seems stupid to me :shrug:
http://www.rockfrogs.org/members/backwoods_rambler/jeep/Upperarmstoolong%20%20-Med.jpg

[Backwoods Rambler]

Original post date: June 14, 2008

Sorry for the delay guys. The Grandparents unexpectedly arrived in town last Wednesday and stayed until Friday and today was my daughters first real play at the Arvada Center. It was awsome. Also today was her 7th Birthday, so needless to say I was busy today.

Anyway, I'm sure you're all just itchin' to see the next installment so here it is......8pm -to- 10pm tonight.....

I didn't really like the fact that the control arm mounts were going to need to be halfway inboard on the "frame" so I decided to do something about it....

http://www.rockfrogs.org/members/backwoods_rambler/jeep/Midarmbend1%20(Medium).jpg


http://www.rockfrogs.org/members/backwoods_rambler/jeep/Midarmbend2%20(Medium).jpg



http://www.rockfrogs.org/members/backwoods_rambler/jeep/Midarmbend4%20(Medium).jpg


http://www.rockfrogs.org/members/backwoods_rambler/jeep/Midarmbend5%20(Medium).jpg


In the picture below, if it looks to you like the arm on the right has less of a bend...well, it does. I did correct that before final welding. :idea:

http://www.rockfrogs.org/members/backwoods_rambler/jeep/Midarmbend7%20(Medium).jpg

I'm REALLY happy with these welds :D

http://www.rockfrogs.org/members/backwoods_rambler/jeep/Midarmbend8%20(Medium).jpg

Now the control arm mounts are completely "on" or "under" the frame instead of halfway off of it. I'm much happier and it makes fabricating the mounts MUCH easier.


In other news:

I do have the frame side, lower control arm mounts cut, drilled, test fitted and mocked up; but I can't take a pic of them until I can reinforce parts of the "frame" and tack weld them into place for test fitting.

I believe that tomorrow I will have the front upper and lower control arms all completed :D :D :D

Then it's on to the SYE.....

[Backwoods Rambler]

OK here's an update of the new LCA mounts.

It occured to me that I never did a side -by- side with the old arms.
http://www.rockfrogs.org/members/backwoods_rambler/jeep/100_0726%20(Medium).jpg

Cut the old mounts off and cleaned up the "frame" area in preperation for the new setup.
http://www.rockfrogs.org/members/backwoods_rambler/jeep/100_0728%20(Medium).jpg

I left some of the uni-rail reinforcement on as well

http://www.rockfrogs.org/members/backwoods_rambler/jeep/100_0731%20(Medium).jpg

Then after getting a few numbers crunched I realized that 3/16"x3"x4" square tubing has an approxomate inside dimension of 2-5/8" which comes out to 2.625"

http://www.rockfrogs.org/members/backwoods_rambler/jeep/100_0735%20(Medium).jpg

My Ballistic Joints are 2.63" wide...seems like a match made in heaven.

http://www.rockfrogs.org/members/backwoods_rambler/jeep/100_0736%20(Medium).jpg


http://www.rockfrogs.org/members/backwoods_rambler/jeep/100_0737%20(Medium).jpg

So after a bit of this....

http://www.rockfrogs.org/members/backwoods_rambler/jeep/100_0738%20(Medium).jpg

I ended up with this.....

http://www.rockfrogs.org/members/backwoods_rambler/jeep/100_0740%20(Medium).jpg

http://www.rockfrogs.org/members/backwoods_rambler/jeep/100_0741%20(Medium).jpg

http://www.rockfrogs.org/members/backwoods_rambler/jeep/100_0742%20(Medium).jpg

[Backwoods Rambler]

A little trimming off the bottom and you end up with this....

http://www.rockfrogs.org/members/backwoods_rambler/jeep/100_0743%20(Medium).jpg

Up against the frame it looks like this...

http://www.rockfrogs.org/members/backwoods_rambler/jeep/100_0746%20(Medium).jpg

I can already tell this is going to work better. :D

So today after work I went over to Terry's and did a bit of this....

http://www.rockfrogs.org/members/backwoods_rambler/jeep/100_0747%20(Medium).jpg

I wan't able to do both 90* bends like I was afraid of, but at least this setup minimizes the number of welds I will need to do
Original post date: June 20, 2008


So here's the start of the "Frame Strap" as I'm calling it.

http://www.rockfrogs.org/members/backwoods_rambler/jeep/100_0751%20(Medium).jpg

It will bolt through the frame at the two "peaks" and then I will get a longer 5/8" (that's .625") LCA bolt to run through this as well as the back side that I will be making to match this.

http://www.rockfrogs.org/members/backwoods_rambler/jeep/100_0752%20(Medium).jpg

Since I will be bench welding these "frame straps" and not welding them upside down on the vehicle, I'm very confident that I can make them strong enough to handle my wheeling style.

[Backwoods Rambler]

Original post date: June 22, 2008

Well after measuring for the 100th time, I finally burned in my new LCA mounts.

Not as nice as Ryan's, but again, I'm using flux core wire which is rarely pretty.

http://www.rockfrogs.org/members/backwoods_rambler/jeep/100_0753%20(Medium).jpg

Here is the basically what the outter side of the "frame straps" is going to look like. Now that they're tack welded I can finish weld them on the workbench.

http://www.rockfrogs.org/members/backwoods_rambler/jeep/100_0760%20(Medium).jpg

I think it's pretty clear to see where the bolt holes will be. There will be a total of 3: Two at the top trough the stiffeners & frame and one through the LCA joint.

Next is to create the inner side of the "frame strap" drill my holes and then creat the mounts for the UCA's to the LCA's and I can get on with the rest of my mods for the lift.

[Backwoods Rambler]

Original post date: June 23, 2008

All right, I've got the outter straps done.

I added some reinforcement for lateral support below the uni rail.

http://www.rockfrogs.org/members/backwoods_rambler/jeep/100_0766%20(Medium).jpg

I didn't get a shot of it on these, but the two pieces to intersect like a 'T' so I have welds on both sides of that area on each.

http://www.rockfrogs.org/members/backwoods_rambler/jeep/100_0767%20(Medium).jpg

http://www.rockfrogs.org/members/backwoods_rambler/jeep/100_0771%20(Medium).jpg

http://www.rockfrogs.org/members/backwoods_rambler/jeep/100_0772%20(Medium).jpg

I also got started on the inner straps.

http://www.rockfrogs.org/members/backwoods_rambler/jeep/100_0774%20(Medium).jpg

Here you can see the 'T' intersection that they all have. It's not much, but I figured much more than a weld bead would be uncessesary.

http://www.rockfrogs.org/members/backwoods_rambler/jeep/100_0775%20(Medium).jpg

Here's a sample of some of the welds.

http://www.rockfrogs.org/members/backwoods_rambler/jeep/100_0777%20(Medium).jpg

So I need to move all of the lines/hoses that run across the driver side of the uni-rail and then get that side done. Then it's time to drill the last holes and get working on mounting the UCA's to the LCA's

[Backwoods Rambler]

Original post date: June 29, 2008

Here is the shot of the completed frame bracket setup.

http://www.rockfrogs.org/members/backwoods_rambler/jeep/100_0787%20(Medium).jpg

You'll notice that they are only grade 5 bolts, the ACE in Brighton didn't have long enough grade 8 bolts, so grade 5 it is; at least for now.


http://www.rockfrogs.org/members/backwoods_rambler/jeep/100_0791%20(Medium).jpg

I used the ratchet straps to set the pinion angle with 95% of the vehicles front end weight on the front axle. Here's where it sits:

http://www.rockfrogs.org/members/backwoods_rambler/jeep/100_0794%20(Medium).jpg


It became apparent right away that the deisgn on the UCA's the way they were wouldn't work in the y-link configuration

http://www.rockfrogs.org/members/backwoods_rambler/jeep/100_0797%20(Medium).jpg

http://www.rockfrogs.org/members/backwoods_rambler/jeep/100_0796%20(Medium).jpg

So I made some new axle side brackets. I like the way these turned out much better than the first set also.....BONUS :D :D

http://www.rockfrogs.org/members/backwoods_rambler/jeep/100_0798%20(Medium).jpg

[Backwoods Rambler]

Original post date: June 29, 2008

With the y-link setup I needed to angle the UCA's sharply which required an angled cut on the end of the arms

http://www.rockfrogs.org/members/backwoods_rambler/jeep/100_0801%20(Medium).jpg

I simply did this with a grinder so I could "fine tune" the angle. I think it worked out quite well

http://www.rockfrogs.org/members/backwoods_rambler/jeep/100_0803%20(Medium).jpg

Here's an early mock-up

http://www.rockfrogs.org/members/backwoods_rambler/jeep/100_0804%20(Medium).jpg

http://www.rockfrogs.org/members/backwoods_rambler/jeep/100_0805%20(Medium).jpg

Next up was fabbing the LCA end of the UCA mounts. Simple, but effective triangle mounts.

http://www.rockfrogs.org/members/backwoods_rambler/jeep/100_0807%20(Medium).jpg

http://www.rockfrogs.org/members/backwoods_rambler/jeep/100_0809%20(Medium).jpg

Drilling with PB blaster as a lube and penetrating fluid is fun :D :D

http://www.rockfrogs.org/members/backwoods_rambler/jeep/100_0810%20(Medium).jpg

http://www.rockfrogs.org/members/backwoods_rambler/jeep/100_0813%20(Medium).jpg

[Backwoods Rambler]

Original post date: June 29, 2008

So here they are, 1/4" thick triangles

http://www.rockfrogs.org/members/backwoods_rambler/jeep/100_0815%20(Medium).jpg

http://www.rockfrogs.org/members/backwoods_rambler/jeep/100_0814%20(Medium).jpg

The pumpkin side offered a good possibility of clearance issues, but it looks to me like everything will be fine.

Check the following sequence of pics from the driver side and tell me what you think.

From the drivers side....obviously :roll:

http://www.rockfrogs.org/members/backwoods_rambler/jeep/100_0817%20(Medium).jpg

Looking from above the pumpkin:

http://www.rockfrogs.org/members/backwoods_rambler/jeep/100_0821%20(Medium).jpg

From under the DS area:

http://www.rockfrogs.org/members/backwoods_rambler/jeep/100_0825%20(Medium).jpg

From under the pumpkin:


http://www.rockfrogs.org/members/backwoods_rambler/jeep/100_0822%20(Medium).jpg

Here's the passenger side, no clearance issues here

http://www.rockfrogs.org/members/backwoods_rambler/jeep/100_0826%20(Medium).jpg

http://www.rockfrogs.org/members/backwoods_rambler/jeep/100_0827%20(Medium).jpg

[Backwoods Rambler]

Original post date: June 29, 2008

Here are a few from under the belly skid area.

http://www.rockfrogs.org/members/backwoods_rambler/jeep/100_0829%20(Medium).jpg

http://www.rockfrogs.org/members/backwoods_rambler/jeep/100_0828%20(Medium).jpg

http://www.rockfrogs.org/members/backwoods_rambler/jeep/100_0831%20(Medium).jpg

Here's a nice overall shot from the belly skid area
http://www.rockfrogs.org/members/backwoods_rambler/jeep/100_0834%20(Medium).jpg


So, I'll be tacking these in tonight, removing the springs, checking how everything flexes and if there are no clearance issues, I will then burn them in and put the front end back together and get going on the SYE :D :D :D

[Backwoods Rambler]

Original post date: July 1, 2008

Well I got the arms all welded up and reinstalled.

Here's a couple shots of the UCA mounts welded to the LCA's

http://www.rockfrogs.org/members/backwoods_rambler/jeep/100_0855%20(Medium).jpg

http://www.rockfrogs.org/members/backwoods_rambler/jeep/100_0856%20(Medium).jpg



Here's a shot of the UCA axle end mount welded

http://www.rockfrogs.org/members/backwoods_rambler/jeep/100_0857%20(Medium).jpg

[Backwoods Rambler]

Original post date: July 3, 2008

I've got the front end holding it's own weight :D

http://www.rockfrogs.org/members/backwoods_rambler/jeep/100_0861%20(Medium).jpg


Got the RE track bar installed after centering the axle.

http://www.rockfrogs.org/members/backwoods_rambler/jeep/100_0865%20(Medium).jpg



I do still need quick disconnects, but that will have to come later.

http://www.rockfrogs.org/members/backwoods_rambler/jeep/100_0866%20(Medium).jpg



No clearance issues with the steering/trac bar/front skid so that's good

http://www.rockfrogs.org/members/backwoods_rambler/jeep/100_0874%20(Medium).jpg


I also checked the steering at full lock, both sides, still no issues with clearance.



Brake lines installed.

Part number at Parts America is BH38620 & BH38621. THe part number at Advanced Auto Parts is H38621 & H38620

I Got the part number from James (Signman) for some stock GMC brake lines that are about 4.5-5" longer than stock XJ lines and they worked good. I did have to shave about 1/16" off of the caliper end of the brake line to resolve clearance issues with the line and the little placeholder on the caliper that stops the line from moving and coming loose.

Here's the mfg shot of it.

http://www.partsamerica.com/product_images/img/ray/bh38620-1.jpg

The metal fitting in the middle needs to be moved to the frame end of the line, then you need to drill out the hole to fit the stock XJ brake line bolt. It was all very simple.


That neat little 'S' curve in the line at the caliper end needs to be mounted this way so there are no clearance issues from the bleeder valve or the caliper mounting bolt.


http://www.rockfrogs.org/members/backwoods_rambler/jeep/100_0879%20(Medium).jpg


Depending on how you mount them the will want to route towards the tire. This shot is with the steering straight on.

http://www.rockfrogs.org/members/backwoods_rambler/jeep/100_0877%20(Medium).jpg


This shot is with the steering at full lock. If you mount the line with the curve towards the knuckle, it will hit the knuckle.

http://www.rockfrogs.org/members/backwoods_rambler/jeep/100_0881%20(Medium).jpg




Now it's on to the SYE install .........FINALLY!!

http://www.rockfrogs.org/members/backwoods_rambler/jeep/100_0876%20(Medium).jpg


........Stay tuned :arrow:

[Backwoods Rambler]

Origianl post date: July 3, 2008

The SYE is done. I have to admit, I made suprisingly short work of the install (1pm to 4:30pm), especially considering the POS :smt013 Snap Ring Pliers I have. Very important tool for this install. If you don't have a good set, get a good set!

Here are some pics to drool over :smt118


The JB Conversions SYE kit contents
http://www.rockfrogs.org/members/backwoods_rambler/jeep/100_0882%20(Medium).jpg


Old Tailhousing out!
http://www.rockfrogs.org/members/backwoods_rambler/jeep/100_0884%20(Medium).jpg

http://www.rockfrogs.org/members/backwoods_rambler/jeep/100_0883%20(Medium).jpg

The Backhalf out!
http://www.rockfrogs.org/members/backwoods_rambler/jeep/100_0885%20(Medium).jpg


The inside
http://www.rockfrogs.org/members/backwoods_rambler/jeep/100_0886%20(Medium).jpg

http://www.rockfrogs.org/members/backwoods_rambler/jeep/100_0887%20(Medium).jpg


The guts are out
http://www.rockfrogs.org/members/backwoods_rambler/jeep/100_0888%20(Medium).jpg


The new shaft is in!!
http://www.rockfrogs.org/members/backwoods_rambler/jeep/100_0889%20(Medium).jpg


The new tailhousing is on :supz:
http://www.rockfrogs.org/members/backwoods_rambler/jeep/100_0892%20(Medium).jpg

Damn that orange silicone is bright :smt103


So that's all good news........


......... The bad news is that my rear shaft from my ScoutII is about 2" too long. :smt093 and the money that I'm going to have to spend to get it shortened means I won't be able to buy a spare 33" tire, which means I won't be installing my 33's anytime soon :smt009

Maybe that's not such a big deal since I can't afford to regear anytime soon either :?: :?:

[Backwoods Rambler]

Original post date: July , 2008

OK a few more things going on. Just trying to tie up some of the loose ends here.

Got the rear shaft to fit after I put the skid plate back on, which lifted the x-fer case about 4" higher.

http://www.rockfrogs.org/members/backwoods_rambler/jeep/100_0970%20(Medium).jpg



Setting the pinion angle

http://www.rockfrogs.org/members/backwoods_rambler/jeep/100_0975%20(Medium).jpg

http://www.rockfrogs.org/members/backwoods_rambler/jeep/100_0974%20(Medium).jpg



The pinion looks a little low to me, but all of the measurements I took indicate that things are right where they need to be.

http://www.rockfrogs.org/members/backwoods_rambler/jeep/100_0977%20(Medium).jpg

I read somewhere that you need to set the pinion so that it points at the X-fercase while under load. How do you determine where that setting is?



No more jack stands under the front end :D :D

http://www.rockfrogs.org/members/backwoods_rambler/jeep/100_0979%20(Medium).jpg

http://www.rockfrogs.org/members/backwoods_rambler/jeep/100_0980%20(Medium).jpg



So here are the before and after measurements:

Before / After

Pass side rear bumper -to- ground: 24" / 26-1/8" = + 2-1/8"

Driver side rear bumper -to- ground: 23-3/8" / 26-3/8" = + 3"

Pass side front bumper -to- ground: 23" / 27-1/4" = + 4-1/4"

Driver side front bumper -to- ground: 22-1/2" / 27" = + 4-1/2"

Belly skid -to- ground: 10-3/8" / 14-1/2" = + 4-1/8"

The rear measurements are a bit disapointing, but it was a crapshoot with the S-10 springs. Plus my stock springs were a bit saggy and the new shocks aren't bolted up yet (not that they should make much of a difference, but they are nitrogen charged). But this is why I planned to run the TnT lift shackles.

I do have a question though: If I run the lift shackles, won't that change my pinion angle, and the need for me to get the DS cut? If so, I need to get those ordered up QUICK!!

[Backwoods Rambler]

Original post date: July 7, 2008

OK, new extended shackles are in. :smt026 But there is a problem with them. :( Check it out.


Here's the "Kit" that I purchased
http://www.rockfrogs.org/members/backwoods_rambler/jeep/100_0981%20(Medium).jpg


Here's how they go together.
http://www.rockfrogs.org/members/backwoods_rambler/jeep/100_0983%20(Medium).jpg

http://www.rockfrogs.org/members/backwoods_rambler/jeep/100_0984%20(Medium).jpg


Man they look so clean. I hate to weld on 'em with my flux core wire :oops:
http://www.rockfrogs.org/members/backwoods_rambler/jeep/100_0986%20(Medium).jpg



But I had to get 'em dirty
http://www.rockfrogs.org/members/backwoods_rambler/jeep/100_0987%20(Medium).jpg



I'm really happy with 'em. They went together very easily.
http://www.rockfrogs.org/members/backwoods_rambler/jeep/100_0990%20(Medium).jpg

http://www.rockfrogs.org/members/backwoods_rambler/jeep/100_0991%20(Medium).jpg

http://www.rockfrogs.org/members/backwoods_rambler/jeep/100_0992%20(Medium).jpg

[Backwoods Rambler]

Original post date: July 7, 2008

Compared to the stock ones they look more like 3" lift shackles
http://www.rockfrogs.org/members/backwoods_rambler/jeep/100_0994%20(Medium).jpg



Then I had to install them. A little tough, but it could have been a lot harder. Thank GOD for Impact Tools.
http://www.rockfrogs.org/members/backwoods_rambler/jeep/100_0993%20(Medium).jpg

And don't worry about the high lift jack, I have the vehicle supported with my two jack stands, one of which you can see on the right.



Check out that shackle angle* though :( :( I definitely don't need to worry about hitting the body with these.
http://www.rockfrogs.org/members/backwoods_rambler/jeep/100_0995%20(Medium).jpg

http://www.rockfrogs.org/members/backwoods_rambler/jeep/100_0997%20(Medium).jpg


*I'm guessing it's because I'm using the stock main spring which got shorter when I added the arched S10 springs to it. I suspect that this issue will go away when I get new lift springs for the rear down the road.


But, they accomplished the goal for now. The vehicle is about an inch (or so) higher in the rear than in the front.
http://www.rockfrogs.org/members/backwoods_rambler/jeep/100_0999%20(Medium).jpg


Didn't have time tonight to reset the pinon angle and burn in the perches (I had some domestic housework to take care of. Gotta keep the wife happy). Don't worry though, I plan to finish that tomorrow night and possibly take it for a test drive :jump:

[Backwoods Rambler]

Original post date: July 8, 2008

Got the spring perches welded on tonight. Check it out.....

I broke the tack welds that I had set before I got the lift shackles. Then I reset the pinion to 2 degrees below the DS like Don said and retacked them.

Then I removed the axle......
....and burned them in


I didn't do full runs since I didn't know if that could bend an axle tube.
http://www.rockfrogs.org/members/backwoods_rambler/jeep/100_1004%20(Medium).jpg


http://www.rockfrogs.org/members/backwoods_rambler/jeep/100_1001%20(Medium).jpg

The drum side.
http://www.rockfrogs.org/members/backwoods_rambler/jeep/100_1005%20(Medium).jpg


Buttoning up the loose ends after reinstalling
http://www.rockfrogs.org/members/backwoods_rambler/jeep/100_1007%20(Medium).jpg













Oh yeah, I took it for a test drive also WOHOOOOOOO!!!!! :smt026 :smt026 :smt026 :smt026 :smt026

http://www.rockfrogs.org/members/backwoods_rambler/jeep/100_1013%20(Medium).jpg

http://www.rockfrogs.org/members/backwoods_rambler/jeep/100_1014%20(Medium).jpg


It took me one month, June 7th -to- July 8th. Maybe not too bad for a hombrew fab-on-the-fly custom suspension that I had to redo a major portion of after realizing it was under engineered. Anyway, I'm stoked that it's back on the road.


OK, a few things.


I only took it up to 25mph tonight since my son was with me and I didn't want to take any unecessary chances with him (or anyone) in the vehicle for the maiden run. Just around the block with a few dips and speed bumps. No issues up to 25mph.

The rear DS has about an inch, maybe inch & 1/4, of travel before it fully compresses. Is this enough considering that when my springs compress the axle moves rearward??? If not, I still have a wee bit of cash left to get it shortened.

Still need to get an alignment, but I'm running my small tires so I'm not worried about scuffing them. Probably by the end of this week, or first of next week I'll get it done.

I did an initial brake bleed, and although it does stop well, they are squishy. Terry recommended doing them again, maybe two more times, so that's in the plan for this week.

Still no anti-sway bar links, so I know I need to take it easy on the turns, especially on the highway.

This is the first vehicle I've taken from stock DD, to lifted DD, and WOW what a difference. :shock: 4.5" of lift makes a BIG difference in how the vehicle feels on the road, higer COG of course.

I like it alot so far :D :D :D :D

[Backwoods Rambler]

Original post date: Jly 11, 2008

So I always hear guys post up about "What tools they would need to do XYZ job" well here it is......well......everything I remembered to write down throughout the project anyway :wink:

Lug Nuts 19mm

Stock U-bolt nuts 18mm

Lower rear shock bolts 18mm

Upper rear shock bolts 13mm

Front & rear brake lines 3/8"

Rear brake bleeders 5/16"

Front brake bleeders 3/8"

Rear yoke straps 5/16"

Rear axle vent tube/brake line bolt 9/16"

New leaf spring center pin 14mm

Coil spring retainer 13mm

Lower front shock bolts 13mm

Upper front shock post 6mm

Upper front shock nut 15mm

Sway bar bolt 18mm

Lower control arm nuts & bolts 21mm (frame side)

Upper control arm nuts & bolts 15mm (frame side)

Tie rod end nuts 16mm

Steering stabilizer bolt 19mm

Front brake line bolt T40 Torx (star bit)

Front driveshaft bolts 5/16"

Transfer case tail housing bolts 10mm

Transfer case yoke nuts 1-1/8"

Transfer case "half bolts" 15mm

Transfer case "top bolt" 12point 10mm

Stock upper trac-bar nut 16mm

RE & Stock Lower trac-bar bolt 15mm

RE upper trac-bar bolt 15/16"

Then of course there was the 4.5" grinder, 15 grinder wheels, the sawzall, 15 14TPI blades, the welder (plus wire and gas - if you use gas), the drill press, the 10lb sledge, the rubber mallet, the bench vice, Terry's 20 ton press (with ~90* bend "dies"), the breaker bar, the torque wrench, the grease gun, the ratchet straps, the floor jack (wish I had a bigger one), the jack stands (2 big and 2 small worked well for me), the creeper rocked!, the drop light, the chop saw with abrasive disc, the impact wrench rocked also.....

Oh, and don't forget the month of "free time" :roll:














and last, but not least,







the daily driver......(thanks Gene :wink: )












http://www.rockfrogs.org/members/backwoods_rambler/other/100_1022%20(Medium).jpg

That's all it took :D

[Backwoods Rambler]

Original post date: August 5, 2008

Update:

Well, it's been almost another month since my initial test drive, so I thought another "feedback segment" was in order.

On the daily commute I had been noticing a random and vaugue clicking noise that appears to have come from my Ballistic Flex joints. (http://www.rockfrogs.org/phpBB2/viewtopic.php?t=2565) Hopefully that is gone now.

The next issue I have is still the RE Trac-Bar. I regret not having the cash to have upgraded to the Extreme Duty RE Trac-Bar. (http://www.rubiconexpress.com/Products.aspx?Cn=271&Pn=1796&XnPath=173,180,251,271&Vid=93E3F97152449) I'm getting increasingly uncomfortable with the single sheer 5/8" Grade 8 Trac-Bar mount. My solution to this will be to purchase the TnT HD upper Track-Bar mount. (http://www.tntcustoms.com/page.asp?pageid=100) This will give me a double sheer setup at the upper mount, drastically increasing my faith in my Trac-Bar.

Barring these two issues, one of which I believe is resolved now, the on road ride is fantastic. Most would argue that the rear rides a bit rough, but that's a sacrfice I chose since I tow fairly regularly (which I have yet to test) and carry a lot of gear when camping. Honestly it's not really rough, just firm, which I like.

The off-road ride is also great. Most of my trail riding to this point has been on trails rated 4 or easier. I really need to get onto a harder trail to test the flex and ride in the really rocky/rough stuff.

Really though, the place I'm most impressed with the ride, is over some of the reduculous RR Tracks and contruction zones on the commute to work. One particular set of tracks could induce some Duke of Hazzard style action if the speed limit was 65 instead of 45. I usually hit it at 40 and always wonder if my front end will come off of the ground, but without fail my path always stays true, with no noticeable bump steer.

[Momrocks]

Geez, I just had to take a knee! What a fabrication sensory overload. I look forward to reviewing this at length.

[SeaRubi]

wow - great writeup! I like the bend you put on the front LCA's to inboard them. I think, too, I'd make a similar judgement call too on going with a double shear on the trac-bar mount.

Did you think about gusseting the LCA side of the upper y-links? there's probably not a whole lotta force there but I could see 'em deforming under impact. probably not a concern, just thought I'd ask.

Your beads look pretty good! I'd say the flux wire treated you pretty well.

How does anti-squat / anti-dive seem driving on pavement? I know trying to engineer 3-link setups that separation was always a big issue - with the Y-arms and that spread from the stock tower it probably has pretty good characteristics on a panic stop.

Looks like a pretty thorough build - congrats on the clean fab and install.

[97 zj steve]

wow...great fab work...nice looking xj

[Backwoods Rambler]

wow - great writeup!

Did you think about gusseting the LCA side of the upper y-links? there's probably not a whole lotta force there but I could see 'em deforming under impact. probably not a concern, just thought I'd ask.

How does anti-squat / anti-dive seem driving on pavement? I know trying to engineer 3-link setups that separation was always a big issue - with the Y-arms and that spread from the stock tower it probably has pretty good characteristics on a panic stop.

Looks like a pretty thorough build - congrats on the clean fab and install.

Thanks. I haven't thought about gusseting them since I was able to place a bead on the inside of the mounts, I feel that it's solid.

I'm honestly not familiar with anti-dive and anti-squat, but I just panic stopped this morning and it handled better than when stock, since the front end didn't dive really hard, just a little bit.

[SeaRubi]

sounds like it's going to stand up well! those terms refer to the vehicles resistance to dive under braking, or to squat excessively during acceleration (producing the dreaded wheel-hop). I'm no expert on suspension design by any means; not much more than an armchair fabricator that sold is welder (and the garage attached to it).

Look forward to seeing some pics of this thing in the dirt - you're going to be able to get some mad articulation with the LA's. How does it feel on the street without a swaybar?

[Big Daddy Chia]

Dude, sweet bumper. Did you make that ur self.

[Backwoods Rambler]

Dude, sweet bumper. Did you make that ur self.

Thanks! Yeah, I made everything myself, except the rock sliders and frame stiffeners, which are both TnT products.

FRONT BUMPER BUILD (http://www.rockfrogs.org/phpBB2/viewtopic.php?t=1948)

REAR BUMPER BUILD (http://www.rockfrogs.org/phpBB2/viewtopic.php?t=1947)

BELLY SKID BUILD (http://www.rockfrogs.org/phpBB2/viewtopic.php?t=1834)

ROOF RACK & HATCH LIFT TIRE CARRIER BUILD - IN PROGRESS (http://www.rockfrogs.org/phpBB2/viewtopic.php?t=2173)

[Backwoods Rambler]

Sounds like it's going to stand up well! those terms refer to the vehicles resistance to dive under braking, or to squat excessively during acceleration (producing the dreaded wheel-hop).

In that case it has almost zero noticeable Anti-squat or Anti-dive (or would that be squat & dive??)





Look forward to seeing some pics of this thing in the dirt - you're going to be able to get some mad articulation with the LA's. How does it feel on the street without a swaybar?

I hope it flexes well, but my primary objective was actually a comprimise between flex and a good ride for my daily commute and those long expedition trips. I'm hoping to get it on a flexy trail in a couple of weeks. My time so far has been making sure it's dependable on the street and on rugged washboard trails. Sort of an "endurance test" for my suspension design and execution. So far, so good; I put 180 mountain road miles on it last saturday alone, and I've been driving it to work every day for the last month and a half now.

I feel like the swaybar delete causes me no negative side effects on the street (I'm a very casual diver, almost never in a rush, so that helps), but for the trail I wouldn't mind having a Currie Anti-Rock setup, but cash dictates otherwise.

[Backwoods Rambler]

I recently upgraded my front control arms by removing the poly bushings is originally used and replacing them with RE 3-piece rubber busings. The ride is noticeably less harsh, handling potholes and other road imperfections much better. Also the in-cab road noise is also reduced despite the flex joint on the frame side of the control arms.

[4Rescue]

Wow man, beautiful fab work, you're doing an amazing job on this truck.

Cheers

Dave