Kraqa
06-30-2004, 12:46 AM
Ok ,
Well fist off thanks for the props.
I have wanted to build Long arms ever since I got the ZJ, so the design has been well thought out.
I used Johnny joints at the frame end of all the lowers and polyurethane bushings at the axle side. I used custom bushings I had made up for me by a local urethane shop, but any urethane bushings will do (i.e. polyperformance) the only difference is that my poly bushings are in a 1/4" DOM tube sleeve where most companies out there is using 1/8" HREW pipe. Inside the poly bushing is a 1x1/8" wall DOM tube that is a sleeve for the 3/4" bolt that go's through the center. Then I got grade 8 allow 1" fine thread ready rod (6" long for adjustment) and welded nuts on the end then welded the nuts to the bushing/Johnny joint sleeve.
My front arms use 3" Johnny joints, and my rear uses 2-1/2" Johnny joints. All my poly bushings are 3" except the 2 in the front upper arms. They are 1". Everything in my suspension uses 3/4" bolts except the four (4) rear Johnny joints, they use 9/16" bolts.
My arms are 2x2x1/4" wall HSS with 1" fine thread deep nuts welded in the ends. The rod ends thread into that with jam nuts.
My rear upper arms are the same construction in the rear except I used poly bushings at the frame and Johnny joint at the top of the pumpkin.
My front uppers are a radius style (connect to my lower arms) and they are made front 1-1/2 x 1-1/2 x 3/16" HSS with the same style poly bushing at the axle end (these bushings are the same poly but they are only 1" wide, the other ones are 3" wide) and the other end is a 3/4" Teflon heim joint. My front lower arms are triangulated out about 10 degrees
The rear upper arms are triangulated (40 degrees separation) at the top of the pumpkin. The truss that it connects to is constructed from 2x4x3/16" HSS with 5x1/2" flat bar at the top.
The sub frame is 4x6x1/4" HSS cut in half to make the two sub-frame rails. 1/2 for each frame rail. I used the stock cross member but chopped about 5" off each side and welded on a plate so it could be removable from the sub frame yet it would not be in front of the lower arms. This allowed me to run incredibly long front arms. The sub frame is bolted on in three places and then welded at the ends and periodically in the middle.
My front track bar is a modified RE standard adjustable front track bar. I flipped the heim and made a new bracket at the frame.
All my brackets are made from 1/4" plate. Actually the only thing in my whole suspension setup that is not 1/4" or more is the two pieces for my rear truss and my front upper arms.
Arm Length:
Front
Upper: 21”
Lower: 46-5/8”
Rear
Upper: 40-1/2”
Lower: 38-1/2”
* These are all approximate sizes so give or take ½”.
BOM
1. 24' 2x2x1/4" HSS
2. 40" 4x6x1/4" HSS
3. 1/2 4x8x1/4 plate (approx)
4. 48" 3x 0.250 wall DOM tube
3. 48” 1x 0.125 Wall DOM
5. 20" 4x2x3/16" HSS
6. 20” 5x1/2” flat bar
7. 3 @ 36” 1” NS 14 TPI alloy ready rod
8. 14 @ 1” NS 14 TPI grade 8 nuts
9. 14 @ 1” NS 14 TPI grade 8 deep nuts
10. 8 @ 5” ¾” NF grade 8 bolts plus 2 washers, and 1 locking nut each
11. 4 @ 3” ¾” NF grade 8 bolts plus 2 washers and 1 locking nut each
12. 4 @ 2-1/2” Johny Joints
13. 2 @ 3” Johny Joints
14. 4 @ grease able 9/16” bolts (came with Johnny joints)
15. 6 @ 3” poly bushings
16. 2 @ 1” poly bushings
My steering has yet to come I will be doing a write up on that with pics and stuff.
Well fist off thanks for the props.
I have wanted to build Long arms ever since I got the ZJ, so the design has been well thought out.
I used Johnny joints at the frame end of all the lowers and polyurethane bushings at the axle side. I used custom bushings I had made up for me by a local urethane shop, but any urethane bushings will do (i.e. polyperformance) the only difference is that my poly bushings are in a 1/4" DOM tube sleeve where most companies out there is using 1/8" HREW pipe. Inside the poly bushing is a 1x1/8" wall DOM tube that is a sleeve for the 3/4" bolt that go's through the center. Then I got grade 8 allow 1" fine thread ready rod (6" long for adjustment) and welded nuts on the end then welded the nuts to the bushing/Johnny joint sleeve.
My front arms use 3" Johnny joints, and my rear uses 2-1/2" Johnny joints. All my poly bushings are 3" except the 2 in the front upper arms. They are 1". Everything in my suspension uses 3/4" bolts except the four (4) rear Johnny joints, they use 9/16" bolts.
My arms are 2x2x1/4" wall HSS with 1" fine thread deep nuts welded in the ends. The rod ends thread into that with jam nuts.
My rear upper arms are the same construction in the rear except I used poly bushings at the frame and Johnny joint at the top of the pumpkin.
My front uppers are a radius style (connect to my lower arms) and they are made front 1-1/2 x 1-1/2 x 3/16" HSS with the same style poly bushing at the axle end (these bushings are the same poly but they are only 1" wide, the other ones are 3" wide) and the other end is a 3/4" Teflon heim joint. My front lower arms are triangulated out about 10 degrees
The rear upper arms are triangulated (40 degrees separation) at the top of the pumpkin. The truss that it connects to is constructed from 2x4x3/16" HSS with 5x1/2" flat bar at the top.
The sub frame is 4x6x1/4" HSS cut in half to make the two sub-frame rails. 1/2 for each frame rail. I used the stock cross member but chopped about 5" off each side and welded on a plate so it could be removable from the sub frame yet it would not be in front of the lower arms. This allowed me to run incredibly long front arms. The sub frame is bolted on in three places and then welded at the ends and periodically in the middle.
My front track bar is a modified RE standard adjustable front track bar. I flipped the heim and made a new bracket at the frame.
All my brackets are made from 1/4" plate. Actually the only thing in my whole suspension setup that is not 1/4" or more is the two pieces for my rear truss and my front upper arms.
Arm Length:
Front
Upper: 21”
Lower: 46-5/8”
Rear
Upper: 40-1/2”
Lower: 38-1/2”
* These are all approximate sizes so give or take ½”.
BOM
1. 24' 2x2x1/4" HSS
2. 40" 4x6x1/4" HSS
3. 1/2 4x8x1/4 plate (approx)
4. 48" 3x 0.250 wall DOM tube
3. 48” 1x 0.125 Wall DOM
5. 20" 4x2x3/16" HSS
6. 20” 5x1/2” flat bar
7. 3 @ 36” 1” NS 14 TPI alloy ready rod
8. 14 @ 1” NS 14 TPI grade 8 nuts
9. 14 @ 1” NS 14 TPI grade 8 deep nuts
10. 8 @ 5” ¾” NF grade 8 bolts plus 2 washers, and 1 locking nut each
11. 4 @ 3” ¾” NF grade 8 bolts plus 2 washers and 1 locking nut each
12. 4 @ 2-1/2” Johny Joints
13. 2 @ 3” Johny Joints
14. 4 @ grease able 9/16” bolts (came with Johnny joints)
15. 6 @ 3” poly bushings
16. 2 @ 1” poly bushings
My steering has yet to come I will be doing a write up on that with pics and stuff.