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View Full Version : Old Dirty - AKA The Mistress...(the saga continues)



JeepinHank
08-09-2004, 03:03 PM
It seems like a pretty cool idea to have a journal about my Jeep. So to follow suit, here's mine. My jeep has many names, but my wife has taken to calling it "The Mistress". Yeah - that doesn't take much imagination. My wife, the self proclaimed Jeep widow, seems to think that I love my Jeep more than her. Everyone else either calls it "Cooter" (like the TURTLE - ya dirty minded people) cause its green and it crawls, or "Old Dirty <insert expletive here>" pretty much cause I beat her like she's my bitch.

I'm not adding too much info right now, because I've been busting my ass over the past few weeks to get ready for a wheeling trip. I've done a pretty good job of taking pics as I go, so I should be able to put up a couple of good writeups in the near future. I would go ahead and post everything, but I'm short on time and I'm going wheeling for now.
Anyway - here's the specs:

Originally:
96 ZJ Laredo, 4.0 L Inline 6, NP 242 (Selec-Trac) Transfer case

Here are the mods listed by the date installed (As best as I can remember) You'll definately see the progression that took place as I started learning what I should spend $ on and what wasn't worth it. You can also get an idea of where I currently stand with everything in this never ending project:

Feb 01 -> Warn Winch mount and a Chicago Electric 8000 lb winch
July 01 -> Rancho 3" coils, Bilstein shocks, RE Front Bar, 31x10.50 Dunlop ATs
Feb 02 -> Kevin's LP-1 Sliderz
March 02 -> Kolak Exhaust (FM 70 series, Carsound Cat, ML 2.5" tailpipe, stainless tip) *BLING*
May 02 -> Teraflex Adjustable LCAs
June 02 -> 32x11.50 Regul Trailblazer MTs
Nov 02 -> Skid Row T-case skid
Oct 02 -> Flowkooler Water pump & 180* T-stat
May 04 -> ORGS Rear Track Bar, Anthony's 1.75" BB
July 04 -> Front Aussie Locker

Here are some pics: (I have nothing in digital format from before 12/02, so I'll have to do a little scanning later on)
This is a pic I found and scanned (forgive the quality - crappy scanner) It's from the fall of `01 from best I can remember:
http://lewis-lewis-cpas.com/Jeepin/Writeups/Baytree_on_the_lake.jpg

12/07/2002 - Kinda old, this was the day after an ice storm hit the entire state - power was out over the entire area, but we went wheeling anyway! Here's the sunrise:
http://www.dana60.com/jeepinhank/ZJ/Uwharrie/2002-12-07/IM000082.jpg

Here's one from December of 2003:
http://www.dana60.com/jeepinhank/ZJ/Uwharrie/2003-12-14/Mvc-010f.jpg

I know - not much content here yet, but at least I've got a start now.

JeepinHank
08-26-2004, 04:30 PM
Before I get started with the actual Jeep, I figured I'd give you guys a peek into the shop. Its not the nicest, but its enough for me. I'll apologize in advance, in the pics, it looks like someone chunked a shit grenade and closed the door. Its not normally like that, but I snapped those pics as I was getting ready to head up to Tellico for the weekend. (BTW - that's a 9 hour drive from home pulling a 28ft trailer.) The beast you get a glimpse of in the back ground is a 1967 CJ-5. Its a rolling frame with a good engine, tranny and t-case. I'm working on getting it out of there. It's a decent starting point for a project, but I'm having too much fun with the ZJ, and there aren't enough hours in the day. I'd love to have that bay open, and I have a guy interested in it, so we'll have to see.

My tool collection consists of the usual hand tools, a CH air compressor, assorted air tools (impact wrench, air ratchet, die grinder, air chisels, etc.), a Chi-Com drill press, B&D 4.5" angle grinder, B&D variable speed Jig Saw, GMC 14" chop saw, and my Clarke 180 MIG welder.

Not much, but more than enough for the bulk of what I do. I'm getting to know a lot of the local welding & fab shop owners, so if there's something I can't handle (bends, special cuts, etc.) I can usually find someone willing to do it.

Here are a few pics:
back corner: (now there's a mini fridge under that cabinet 8) )
http://lewis-lewis-cpas.com/Jeepin/Writeups/shop_back_corner.jpg

Other side back corner:
http://lewis-lewis-cpas.com/Jeepin/Writeups/shop_office_door.jpg

Side wall & shelving:
http://lewis-lewis-cpas.com/Jeepin/Writeups/shop_office_wall.jpg

Shop doors and shelving between doors:
http://lewis-lewis-cpas.com/Jeepin/Writeups/shop_doors.jpg

Like I said, its not always looking that nasty. Anyway that's a bit of an intro to where I get my stuff done...

Up next - the re-wire project.

JeepinHank
08-26-2004, 04:59 PM
One of my first orders of business, in the current transformation of the mistress, was to improve the electrical setup (or lack thereof) for all of the accessories I've added over the years. Before, it was pretty much a hack job with the classic birds nest at the battery and God only knows how many holes coming through the firewall. Now I've cleaned up and organized every wire for every accessory. I didn't really WANT to do it, but things look so much better now. Its easy to add accessories, and relatively simple to diagnose problems should they arise. Better yet, every wire was planned out to match the amperage demands that would possibly be placed on it. No worries about voltage drops or over powering cables. And I actually used grommets! I'm so glad I did it now that it’s done.

So what did I do? Here’s the skinny:

I put a 4 way stinger fuse block right by the battery tucked up and into the fender. I fed that with a short run of 4-gauge wire.
Fuse Block by Battery:
http://lewis-lewis-cpas.com/Jeepin/Writeups/fuseblock_engine_bay.jpg
From there, I made two runs with 8-gauge wire, each protected with a 50Amp fuse (probably a bit large). Both passed through the firewall by the MC.
Firewall:
http://lewis-lewis-cpas.com/Jeepin/Writeups/firewall.jpg
One terminated with a 6-slot fuse block under the dash (behind the drivers kick panel). I ran the other all the way back to the cargo area, to another 6-slot fuse block in the compartment behind the stock spare tire location. This gave me a place to add relays and neatly conceal my wires at both blocks. The positions are kind of awkward, but I can always unscrew the block and pull it out to assist in making changes.
I’ll have to take a pic of the fuse block under the dash, must have missed that one.
Cargo Area Block:
http://lewis-lewis-cpas.com/Jeepin/Writeups/fuseblock_rear.jpg

Right now, the rear block powers a 200watt Amp, ground isolator for amp, trailer wiring harness, aux back up lights, and a 15 amp 12 V power outlet in the cargo area. I could use a couple of extra slots, but I guess I can always move the amp and ground isolator to the front block (not much difference in terms of the distance).

The front block is pretty open. I have my rock lights, power to a relay that gives me Acc signal without overtaxing the switched cig. lighter, and my CB.

My off road lights are tapped into one of the extra slots at the battery block. They’re only 55W lights, but one day I hope to up them to some 100W lights, and the shorter run/bigger wire capacity will handle the amp draw a little better.

When you’re out shopping for parts, you’ll probably be best off going by a good car audio shop. The selection will definitely be better than any auto parts store. The guys at my local shop also got a kick out of what I was doing, and they actually knew their ass from a hole in the ground (as compared to my area Radio Shack). Another plus - they’ll probably have the gauge of wire you’re looking for in stock. If you want to take the online route – you’d probably be best off to go to a marine supply co's website.

Stay tuned for the next round....

Nordic1
08-28-2004, 02:09 AM
sweet wiring... I was thinking of doing something similar with my rig... 0 or 2 guage wire going to the trunk... large capacitor or another yelow top... then my air compressor, my 2 amps, and some aux lighting stuff

JeepinHank
08-30-2004, 01:34 PM
I’ve recently completed front and rear bumpers for my ZJ.
Here’s the rear:

I started with the rear, simply because that’s the one that needed replacing the most. I had drug my stock plastic bumper through way too much stuff, and it was beginning to hang off on the sides. I looked at a lot of bumper buildups, and asked a lot of questions. Through the help of ChadJans, AlaskaZJ, and BMRisko, I had a picture of what I wanted in my head before I ever made the first cut. I really liked the beef and utility of Risko and Alaska’s bumpers, but I was building this for a daily driven Grand Cherokee! I needed it to at least look a little nice. Then I stumbled across Chad’s great photo collection. I loved the look and the fit & finish of his bumper. I started with a base of 2 x 4 x .25 wall rect. box tubing. The bumper was mounted to the uni-frame with the bolt holes that normally are used for the gas tank skid and tow hitch. I used 2x2x.25 wall square tubing slid into the frame rails, drilled holes to match the holes already in the frame rails, and tack welded nuts to the top of the box tubing. I filled the gap between the bumper and the lift gate with a piece of 1/8” plate.

After mocking up and welding the base together, I started adding all of my other little doodads. I mounted two clevis tabs in line with the bumper- frame tie-ins. The clevis tabs are ½” by 3” plate that passes through the bumper and is welded with 2 passes on the front and three passes in the rear. There is also an integrated receiver hitch. The receiver is mounted in the same fashion as the clevis tabs. There are no safety loops as of right now. When I need to hook up the chains on my trailer, I just attach them to my clevis hooks. I haven’t had a problem yet, but if I do, it won’t be too bad to add them on.

Then, I moved on to the wrap around. I had two pieces of 5x2x1/8” u channel bent up for the wrap around pieces. When I got them home, I measured where I needed to make the 45* bends, and made my relief cuts. Then, using Risko’s patented “park on it and bend it up” method, I made the two 45* bends. Here are a couple of in progress shots:
http://www.lewis-lewis-cpas.com/Jeepin/URE_2004_04_30/2004_0503Uwharrie0070.JPG

http://www.lewis-lewis-cpas.com/Jeepin/URE_2004_04_30/2004_0503Uwharrie0068.JPG
The tire carrier came next. The carrier itself is made up of 11ga (1/8”) 1.5” square tubing. I don’t think it’s going to be a weakness, even when/if I get up to a 35” tire. If it does end up being a problem, I’ll do it again, and use 3/16”, 2” square tubing. Currently the hinge is made up of a 3” rubber bushing mounted in a double shear orientation. It works great for absorbing movement and bumps, but it allows for just a little too much sag when it’s open. Hopefully in the near future, I’ll be able to come up with something a little stiffer (some kind of urethane I guess). My latch is a simple 3” grade 8 bolt with a nut tack welded to the backside of the bumper. It's not too bad to open and close (the ¾” drive matches up to my lug wrench, so I won’t have a problem getting into the back even if I forget my socket.) There is also a ½” bolt sticking out through the backside of the bumper to serve as a guide when I’m lining everything up. Currently my license tag is zip tied to my spare. Before I get my next inspection, I’ll need to figure out a better mounting method and come up with a light for the tag.

I'll be adding the pics of the tire carrier & painted / finished bumper this afternoon when I load them up.

JeepinHank
09-08-2004, 10:18 AM
OK, so I've been a slacker in getting the conclusion of my rear bumper up. Anyway, to keep things moving along while I try to get motivated to get the rest of those pics up, I figured I'd get a start to the front bumper.

For the front bumper, I started out with a warn winch mount. Pretty rare these days, but I've had mine for years. After GSSE back in 02 I discovered that it wasn't quite as strong as it should be. Long story short - Crawford Jr. –of Crawford’s @ Tellico fame- decided to snatch my inebriated ass off the rock garden. I didn’t break anything mind you, but it did weaken a few things, sheared a couple of the mounting bolts, etc. Anyway, I decided to come up with a better mounting system.

I started by removing the old bumper cover, and opening up the frame rails with my cutoff tool. I then took a piece of 2 x 4 x ¼ box tubing, and cut it in half on the diagonal. Basically creating 2 pieces of 2x4 angle iron. I slid one of these into each frame rail, and marked my holes to drill. After drilling the holes, I welded in some ½ inch nuts. All together, there are 5 bolts in each side - 3 on the side, and 2 coming up from the bottom of the frame rail. Then I lined up the winch tray and marked and drilled my holes there. After all of that I took the risers from the warn mount and cut off the bottom to be even with the angle iron. This piece was intended to pass below the plastic bumper and serve as protection for the radiator support – I figured I could do without all of that. To put it all together, I basically sandwiched the angle between the warn winch tray and the risers from the old mount. Giving me something that looked like this: (forgive the poser shot)
http://www.lewis-lewis-cpas.com/Jeepin/URE_2004_04_30/2004_0503Uwharrie0007.JPG

And a parking lot shot:
http://www.lewis-lewis-cpas.com/Jeepin/URE_2004_04_30/2004_0503Uwharrie0074.JPG

From there, I proceeded to cut off the left and right portions of this front cross member, and case it in with 1/8" plate that I had bent up at a local repair shop. Of course there are a few things that need to be relocated in the process. You have your left and right air bag sensors, the charcoal canister, and the horn to consider. I mounted my horn to the 1/8 plate that replaced the crossmember. I have yet to relocate my charcoal canister or re-install the air bag sensors. I guess I need to get that done one of these days. :roll: I have the completed pics on my hard drive at home, so I'll get them up this evening whenever I get up the finished pics of the rear tire carrier.

Up next - I'm cleaning up the shop, and getting ready to build some axles. My front 30 is leaking at the pinion seal, and my 35 rear is bent, so that decision is easy. New axles will be a HP 30 front, and an 8.8 rear, with 4.56 gears. Give me some time though - I'm trying to do it right. While I'm building the axles up, I'm also preparing to build my long arms. My target completion date is January 1st, but I'm probably kidding myself. I'll be happy if I can have everything finished in time to do some wheeling next spring!

MaineZJ
09-08-2004, 11:33 AM
Kinda looks like what I fabbed up.

http://cc.vtc.edu/~mgauley/start/DSCF0073.JPG

how did you bolt through the bottom of the angle? I found the nut rails for the radiator mount, sway bar and all that junk in the way.

JeepinHank
09-08-2004, 01:26 PM
Kinda looks like what I fabbed up.

http://cc.vtc.edu/~mgauley/start/DSCF0073.JPG

how did you bolt through the bottom of the angle? I found the nut rails for the radiator mount, sway bar and all that junk in the way.

Mine does look somewhat similar to what you did. To get the bolt through the bottom of the angle, I had to drill out a large hole to clear the nut plate/rails for the radiator support. I don't think I had any problem with the swaybar mount, I believe the 2x4 angle stopped just short of that. If you're looking at the radiator support on one side, I basically positioned the rear mounting bolt between the two radiator support bolts. The front bolt (on the bottom) passes through lip of the cross member. I wanted to use all four of the bolts through the side (like the factory tow hooks), but my 2x4 angle ended up being a little too short to completely catch the top most hole.

If you want me to try to snap a few more pics of it, I'll see what I can do.

Hank

MaineZJ
09-08-2004, 01:38 PM
I understand what you did.
I got my side plates fit 7" into the frame and got 3 of the 4 side bolts. I wanted to remove the nutstrips on the bottom and use 2x4 tube, but found the strips go way deep into the frame.

robselina
09-08-2004, 10:04 PM
coming along dude!

I had already torn off the plastic cover out back and up front, but ended up really nailing the stock bumper out back over labor day weekend and now it's all jacked. Going to start building a real bumper tomorrow.

Got any more progress pics on the rear bumper?

JeepinHank
09-09-2004, 09:57 AM
coming along dude!

I had already torn off the plastic cover out back and up front, but ended up really nailing the stock bumper out back over labor day weekend and now it's all jacked. Going to start building a real bumper tomorrow.

Got any more progress pics on the rear bumper?

Yeah... They're still sitting on my camera right now. You got anything in particular that you're looking for?

Basically, mine is a clone of the one Chad builds. The only difference is I incorporated the tow points and hitch. I also think his hinge is a little better than mine. Anyway, I hope to post up the pics this afternoon. I wanted to get them up yesterday, but I didn't have the opportuinty to run home and grab the camera over lunch.

I've come a long way in the past year, but I've got a long way to go. Keeping the fire seems to be my biggest problem. I can't seem to get motivated until I have a trip coming up, and that's not the way to get an axle or suspension buildup going.

robselina
09-09-2004, 06:09 PM
I've come a long way in the past year, but I've got a long way to go. Keeping the fire seems to be my biggest problem. I can't seem to get motivated until I have a trip coming up, and that's not the way to get an axle or suspension buildup going.

LOL, sounds familiar....Moab trip comming up on the 22nd, suddenly I'd been VERY motivated :lol: I think the 8.8 is going to have to wait until after then though, since I don't want to break in the gears out there.....

JeepinHank
09-10-2004, 10:42 AM
Well, it took longer than I said it would, but here are the updated/completed pics of my front and rear bumpers. I couldn't find my card with the pics at the shop (as I was finishing everything up) but here are some from my last trip (Tellico Aug 13-15):

Rear bumper, painted, w/ tire carrier, and aux back up lights:
http://www.lewis-lewis-cpas.com/Jeepin/Writeups/DSCF0195s.jpg

Another:
http://www.lewis-lewis-cpas.com/Jeepin/Writeups/DSCF0199s.jpg

Front bumper finished and painted, w/ winch installed:
http://www.lewis-lewis-cpas.com/Jeepin/Writeups/DSCF0255s.jpg
Another. Check out that short arm flex! (with some help):
http://www.lewis-lewis-cpas.com/Jeepin/Writeups/DSCF0223s.jpg
Decent pic from the side:
http://www.lewis-lewis-cpas.com/Jeepin/Writeups/DSCF0198s.jpg

Rob - I hope that does if for you, but let me know if not....

JeepinHank
09-10-2004, 10:47 AM
I feel like a whore today, so here are some general pics of where she stands currently:

http://www.lewis-lewis-cpas.com/Jeepin/Writeups/DSCF0254s.jpg

http://www.lewis-lewis-cpas.com/Jeepin/Writeups/DSCF0227s.jpg

http://www.lewis-lewis-cpas.com/Jeepin/Writeups/DSCF0187s.jpg

JeepinHank
09-27-2004, 05:37 PM
Well, I know a post is worthless without pics, but I wanted to give an update to what’s been going on.

This Saturday, my buddy and me, went junkyard shopping, and scored 2 Ford Explorer rear ends. Both are from 98 Explorers, one with 4.10’s and the other with 3.73’s. The 3.73 endowed rear end is mine since I’m going to be installing 4.56’s during this build anyway. The other axle is for my buddy’s YJ. We got motivated to go find them after pulling the diff cover on his YJ’s D-35 to inspect a weird noise / vibe. It turns out the pinion gear was missing two teeth. So after a lot of calling around, we finally found them for the low price of $250 each. So for $500, we got 2 complete rear ends with all brake lines, e-brake cables, calipers, rotors, pads, I mean everything.

So – I’ve got a rear axle ready to start my build. The front is handled as well – all I have to do is pick it up from a friends shop. I’ve got my gears for the front (Thanks TranceZJ), and I’ll be swapping my Aussie Locker over from my current LP 30 when I get the front axle swapped. Next thing on the list is a gear set and locker for the 8.8.

I’m getting there!!! Albeit slowly.

I have approximately half of the steel I’m going to need for my suspension and sub-frame. I’ve been having trouble finding 4x6x0.25 box tubing around here, so I’m probably going to end up going with 4x4x0.25 instead. Yeah – its going to create more waste than necessary, but it’ll still be cheaper than having to order a full length from an area steel supplier. I figure I can probably use the cut out part of the tubing for making tabs and brackets anyway.

Things are getting ready to get interesting!

MaineZJ
09-27-2004, 07:15 PM
8.8 minispools are like $90

JeepinHank
09-28-2004, 10:46 AM
8.8 minispools are like $90

Yeah, but for another 80 bucks, I can go to a full spool and just install it in place of the stock carrier while I'm setting up the gears. That should be a pretty substantial strength gain over the mini spool, since you're moving the all of the forces from the cross pin to the carrier itself. Or at least that's how I've always figured it.

I'm checking around for quotes on the R&P, install kit, and spool this week. I'm estimating around $450 for everything including the notched cross pin you need to run the full spool. I'll see how close I can come to that figure.

NorthernZJ (Sierra Rock Control) has been developing his new LA kit, and I've been in contact with him about getting some threaded inserts for my square tubing LCAs and possibly some axle brackets. I'm trying to keep this whole thing under a budget, but sometimes its worth the little extra $ for the peace of mind and reliability someone else's work can offer.

I still haven't made up my mind on the front mounts. I want something that tucks up and inside of the frame rails instead of below them. Kind of similar to what Clayton's cross member does. I guess its really going to boil down to the issue of $ at the time, and/or weather or not I can make it. Pretty much the same issues that have taken me this far. lol

I'm hoping to get the axles ready sometime in October. If I can, I'll take my time building the subframe and getting my remaining parts together over the month of November. Then, hopefully, I'll throw a major install fest / wrenching party that'll run from Dec 26 - New years (or untill its finished). That's when all of my usual wheeling/wrenching buddies will have some time off because I know I'll need a couple of extra hands around for this.

It sounds good in my head at least. I've got the plan, now I just have to stick to it.

JeepinHank
10-07-2004, 11:08 AM
Well, I figured I'd post up a pic of the 8.8 I ended up getting.

First off, for anyone who doesn't believe the Dana 35 is a POS here's some evidence:

http://www.lewis-lewis-cpas.com/Jeepin/URE_2004_10_2/Busted35.jpg

That's a shot of 2 pinion teeth sitting in the bottom of my friend Sidney's D-35 housing. Specs - Lock-right, 4.10's, and 33x12.50 tires - On a YJ (Which is substantially lighter than my ZJ). So, don't believe the only weak link on the 35 are the axle shafts themselves. That's what got us motivated to find some replacements. I had been planning on it, but I had been trying to get all of my cash right before hand. Looking for 2 at once gave us some bargaining power, so I bit the bullet.

Here's the cure to both of our problems:

http://www.lewis-lewis-cpas.com/Jeepin/URE_2004_10_2/35fix.jpg

Here's the 8.8 installed in the back of the YJ:

http://www.lewis-lewis-cpas.com/Jeepin/URE_2004_10_2/DSCF0295.JPG

We cut off the OE brackets moved them out about half an inch on each side, set the desired pinion angle, welded them up, welded the tubes to the center section, and painted everything. The next project is to relocate the axle side shock mounts to the top of the axle tube. Currently we're using the Ford mounts which hang down just as low as the originals on the 35. :roll: I've got a 3x4 piece of a sheet of 1/8 plate that we'll probably just make a couple of sets of tabs with and weld them to the tubes. Maybe I can talk him into pulling the axle again, so I don't have to worry about gas tanks and stuff while I'm doing it.

Hopefully, I'll be getting started on setting up the HP 30 this weekend. Its a vac disconnect, so I'll probably just remove the vac assembly, install a block off plate, and repalce the 2 piece shaft/coupler with a spare one piece shaft from my LP30. Everything should match up, I'll figure out what I want to do from thre if it doesn't. Its not like this axle has to go in so I can make it to work on Monday. I'm not going to get too far past pulling out all of the old internals because this if my first attempt at setting up gears. Sidney does that kind of stuff on a daily basis (Jeep Tech), so I'll want him there to make sure I don't screw up when everything is going back in. 8)

I'm also going to start stripping stuff off of the grand in preparation for the upcoming build. The rear bumper, tire carrier, sliders, t-case skid, and gas tank skid are all probably going to come off this weekend. The bumper and tire carrier is only coming off so I can get some measurements for Anthony to make me a new poly bushing. That should help to reduce the sagging when the tire carrier is open. I'll also drill out the gas tank skid for some extra bolts (for my rear bumper) and add some gussets to the bumper to stiffen up the wrap-arounds on the sides.

Then I've got like 3 oil changes, a tune up, and a shitload of yard work to do.

MaineZJ
10-07-2004, 03:46 PM
My buddy has his ZJ setup with Claytons, 231 SYE and 8.8. The stock explorer shaft fit right in.

JeepinHank
10-08-2004, 11:25 AM
My buddy has his ZJ setup with Claytons, 231 SYE and 8.8. The stock explorer shaft fit right in.

I wish I already had the 231 with a SYE. I'll probably save the driveshaft just in case I ever go that route. Right now the 242 is holding up just fine - as it should considering its my second one. Out of curiosity, did your buddy extend the wheel base any?

MaineZJ
10-08-2004, 11:56 AM
I don't think he did. from what I remember the coils are in the same place on the body....
he is running Claytons and the rear mounts are higher than stock (even with the axle)

http://forum.neow.net/index.php?showtopic=4877&st=15 (pre-8.8)

Trancezj
10-08-2004, 12:19 PM
After locker, gears, driveshaft adapters, and all that jazz, I ended up with ~600 in my 8.8. I paid same as you. Add what I paid for the gear setup in that and the hp30, gears for it, and locker for the 30. (which I know you already have part of) and you've got a lot of money in ~fair axles. I guess it's not too hard to get rid of an 8.8 ready to bolt in, but just take my word for it and don't spend a fortune on that axle setup. I don't really know how hard you want to wheel, but if it's anything like me, that 30 won't last. Hell you'll have fun trying to make a 44 last.

best of luck

JeepinHank
10-08-2004, 12:51 PM
After locker, gears, driveshaft adapters, and all that jazz, I ended up with ~600 in my 8.8. I paid same as you. Add what I paid for the gear setup in that and the hp30, gears for it, and locker for the 30. (which I know you already have part of) and you've got a lot of money in ~fair axles. I guess it's not too hard to get rid of an 8.8 ready to bolt in, but just take my word for it and don't spend a fortune on that axle setup. I don't really know how hard you want to wheel, but if it's anything like me, that 30 won't last. Hell you'll have fun trying to make a 44 last.

best of luck

Thanks. I'm not into the axles too bad, but I see what you're saying. It adds up pretty quick. I've been really lucky since I have some friends helping me out here and there. We'll see how they hold up soon enough. Generally, I'm not too bad on drivetrain parts, and I don't plan on going bigger than 35's anytime soon, but, then again, I may start eating up parts like you did. I do always carry spare shafts and u-joints, and I have a couple of good yards within a relatively short drive, so I CAN get more.

Another plus is the fact that I'll be taking the ZJ out of Daily driver status within the next year or so. If I do happen to start eating up axle shafts and u-joints, it won't kill me to lay off the tough trails for a while, and start building up something stronger. I'm always looking for that HP60 diamond in the rough, and if I ever find it, I can always make a trip down to the local blood bank. :P I can find big rear ends all day long around here, but the fronts are a different story.

How's your 44 front holding up?

JeepinHank
10-14-2004, 11:55 AM
Well last weekend ended up being more about the house, yard, and vehicular maintenance, than it was about the Heep. I did manage to pull off the rear tire carrier, and get the bushing measurements.

I also spent a lot of time staring at the bottom of a Ford 8.8. I really don't like that lip. I'm trying to figure out how to handle that either with a skid or by welding on a piece of 1/4" flat bar to serve as something to slide across (instead of getting hung on the lip). I've got time, so this isn't something I've got to come up with today, but I do have to come up with a solution to that before I consider this thiing trail-worthy again.

This weekend, I have a little bit of welding to do for some decorative pieces I'm making, so I'll probably use the time to reinforce the rear bumper & modify the Mopar skid while I have the welder and all drug out.

We'll see how far I get past that, but I hope to get started on stripping down the HP 30 this weekend as well. The internals for the 8.8 are getting ordered this Friday, and I should be able to get started with the set up for both axles shortly after I get everything in.

Sunday is Rib day - 6 racks are going on the smoker at around 10:00 AM. Saturday night I'll be breaking out the big ol stock pot and make some sweet home made barbeque sauce. 8)

OverkillZJ
10-14-2004, 04:01 PM
Sunday is Rib day - 6 racks are going on the smoker at around 10:00 AM. Saturday night I'll be breaking out the big ol stock pot and make some sweet home made barbeque sauce. 8)

Fawk, I'm hungry now.

JeepinHank
11-11-2004, 03:52 PM
Fawk, I'm hungry now.

The ribs were really good Matt. :wink:

I should be getting around to setting up the 8.8 this weekend. That is if my buddy who has the experience at this kind of stuff doesn't have anything come up. That's the thing about buddies - some times the timing sucks, but you can't beat the price. :P

Everything is finally starting to come together. I just hope I can hold on and keep my nose to the grind long enough to see this through.

Stay tuned! I'll have a lot more info to post up soon, so I'll be updating this thread more often.

JeepinHank
12-02-2004, 12:09 PM
Things have been really slow in progressing.

I had hoped to at least be into one of the axle setups by this point, but my friends' schedules are really screwed up with work, family, school, the holidays, etc.

Last weekend, I got to the point where I couldn't take it anymore, and just had to go wheeling. So, I took a day trip Sunday up to UNF and spent the day on the trails. The group consisted of me, my buddy Sidney (Red YJ) and his three boys, and Rob (White XJ).
http://www.lewis-lewis-cpas.com/Jeepin/URE_2004_11_28/DSCF0367.JPG
We met up around 9:00 and hit the road. We were on the trails by 11:00. Since Sidney had his boys riding, we started light, and hit some of the easier trails. By lunch, we had gone over Wolf Den, Falls Dam, and Dutch John. We ate lunch in the parking area at Rocky Mtn loop. Afterwards, we tackled Dickey Bell, and decided to head over to take a run at Daniel. All of the trails were extremely sloppy. Its getting late in the season. and its been a really wet year so the trails are really rutted with lots of mud holes. (the spot in this pic starts out flat at the beginning of the season)
http://www.lewis-lewis-cpas.com/Jeepin/URE_2004_11_28/DSCF0373.JPG
There are a few areas where a rut will throw you into a tree or embankment, so you've really got to be able to control your throttle through those spots. Rob ended up catching his left rear qtr panel, tail light, and bumperette in one of those spots.
http://www.lewis-lewis-cpas.com/Jeepin/URE_2004_11_28/DSCF0391.JPG
I slid while trying to climb a rock on Daniel and bent up my tie rod pretty good. We ended up using my hi-lift to bend it back down so my tires wouldn't get screwed up on the drive home.
http://www.lewis-lewis-cpas.com/Jeepin/URE_2004_11_28/DSCF0393.JPG
Sidney bent up a front leaf pretty good after running his shackle into a rock. Fortunately, we were able to get it relatively flat again with a combination of a hi-lift and a scissor jack. This is a repaired shot:
http://www.lewis-lewis-cpas.com/Jeepin/URE_2004_11_28/DSCF0392.JPG

This was the last run of the year for me. This weekend, I'll be washing the jeep (esp. the undercarriage & engine bay), and unloading all of my tools, gear, etc. I'll also start pulling off a lot of parts - Primarily my sliders, t-case skid, and rock lights.

Its starting to look a lot like Christmas around my house, and I'm not talking about trees or decorations. I'm getting a pile of parts started out in the shop. Here's what's arrived so far and who I got it though:
HP 30 Gears (used) - TranceZJ
Yukon 8.8 Gears, Spool, Install kit, x-pin, etc. - PeakZJ (www.peakempire.com)
Kevin's TBC (used)- Tommy
RE Superflex Joints (4 large & 3 small) - AlaskaZJ (kodiakoffroad.com)

Talked to Ty last night, he should be sending my stuff out sometime late this week or early next week. Regardless everything should be here no later than 12/15 - giving me a 10 day margin of safety. Still working out my rubber bushings, springs, and shocks. I'll take care of tires in Jan. or Feb. 8)

JeepinHank
12-06-2004, 11:56 AM
Spent the weekend working on, for, and around the Jeep.

Saturday, I went and picked up my HP 30 out of an 88XJ. It was a burned vehicle so there wasn't much of anything good on this thing. We torched off the shocks, control arms and track bar, but I pulled all of the steering off so that I can replace the bent tie-rod from last weekend. We got it back to my house, and went to work stripping the axle down. Removed what was left of all of the arms, steering, shocks, hubs and axle shafts. My buddy Sidney took it and my gears / bearings home with him. He should be getting around to it sometime this week, depending on how busy things get for him at work. He'll set up the gears now, but I'll have to pull the carrier/remove the ring gear again whenever we swap the axle so that I can install my Aussie locker. The 8.8 is still sitting as it was. I pulled the shafts, and realized one of them was bent. I don't know if its just the shaft or the whole axle, so I'm going to give the JY a call about that this week to see what I can work out.

Got the outside of the ZJ washed Saturday afternoon. You know your shit is dirty when you start washing it by going around the wheel wells with a shovel. Pressure washed the entire thing, then hosed it down with purple stuff. I sprayed the entire engine bay, underside, and t-case/tranny with engine degreaser. Let everything soak a while, then went back to it with the pressure washer. After that, I broke out the soap and bucket, and hand washed the entire body. Most of the mud on the under carriage is gone now. I'll probably end up giving it one more good cleaning before the build starts. Didn't do jack with the interior for now.

Sunday, I took care of some of my X-mas present projects. The tables are on track to be completed this week. Made a couple of wine racks, and sketched out a bracket to hang a heavy punching bag for my brother.

JeepinHank
12-20-2004, 01:26 PM
Well, its been a f'd up past couple of days.

I had some classes out of town for continuing education, and, against better judgement, I decided to drive the Jeep for some reason.

Thursday night I was on my way the to the hotel I was going to be staying at in Greensboro from Hickory, and my pinion bearing took a dump. I limped it to the next exit, and found a place to work on the front axle. At 11:00 at night in 23* temps, I tore down and rebuilt my front axle in a parking lot. I was lucky that I had my tool box. Unfortunately I was tired, and I wasn't thinking too straight at the time, and I pulled the front shafts, thinking that the hub / bearing assembly would keep the wheels in place. I pulled the shafts because, even in 2wd, the front d-shaft spins because of the wheels turning the shafts, turning the R&P. I got everything back together and took off down the Interstate....

The man upstairs must have been watching out for me that night because I made it to the hotel. The next morning was a different story.

I hopped in the jeep on my way to my class in Greensboro, and, a mile out of the parking lot my front pass side wheel FELL OFF. The only thing keeping it with the rest of the jeep was the brake line. It turns out the hub / bearing separated and pulled out. I had just made a turn and I can only assume that the turn put too much stress on the hub / bearing assembly, and caused the caliper bracket to shear off. My jeep went crashing down on the knuckle, and I skidded to a halt in the left turn lane.

I ended up paying a tow service to get it out of the road, and went back to fix it after my class. I ended up having to trailer it home, and to add insult to injury, I had a blow out on the trailer. Luckily, a couple of my co-workers were at the same class, and I had someone to pick me up, and take me on a parts run.

It was pretty bad. I keep thanking my lucky stars that I survived. If that wheel had let go on the interstate, I wouldn't be here today. I didn't post this for sympathy or anything. The jeep's fawked, but that can be fixed... I just hope that someone may learn from my stupid mistake.

Peace out, and Happy Holidays.

JeepinHank
12-27-2004, 11:57 AM
There's a silver lining to every cloud. Since I busted the Jeep, I was pretty much forced to bite the bullet and find a new vehicle. The thought crossed my mind to buy a small beater to get around town, but I went all out and picked up a tow rig. I picked up a white `01 F-250, 4x4, Crew Cab, with the 7.3L PSD. It had 65K on the clock when I bought it. I'm pretty stoked aobut that, and I think it is a really good compromise. Made my first road trip in it over the holidays, and, even unloaded, its road manners are a hell of an improvement over the ZJ. I hate the circumstances, but I'm kinda glad I finally did it. That will take a lot of the stress off of me in completing the Jeep so quickly...

Yesterday, I got a fair start on the ZJ project:

I got it up on jack stands, pulled the tires, and removed what was left of the front brakes. I got the axle shafts, drive shaft, carrier and locker removed from the front axle, and then pulled the axle itself. So right now I have half a hover jeep. Hopefully I'll get the rear axle pulled tonight. I'm still waiting on my stuff from Ty @ Sierra Rock Control. Hopefully it will arrive today, but honestly, I'm not holding my breath. We'll see what things look like this afternoon. I've got to run by a local welding shop to have my box tubing cut down to make my sleeve.

After that I need to come up with a source for end rings to press my bushings into. I thought I was on the same page with Dave at Poly Performance, but obviously there was a misunderstanding there somewhere.

Tonight's going to be devoted to removing the rear axle, and We'll see how far I get past that. I'll be taking some pics this evening. I'll try to post some up tomorrow.

JeepinHank
12-29-2004, 11:54 AM
Decided against pulling the rear axle until I get the front finished and installed.

Got the sliders pulled, there's one bolt left on the T-case skid to remove. I just ran out of steam before I finished up... The tubing is cut for my unirail sleeve, but I've got to do a lot of prep work on the unirail before I start mocking everything up. I also got started on cutting off my front CA brackets. The pass side is half off, then I've got to do the drivers side.

Got an email from Ty about my parts... It seems he had a problem with one of the shops he was having to bend the 1/4" skid plate. They screwed up the skid, so he's having to have that re-done. He sounded sincere, and I hate the idea of having to go back to square one, so I'm giving him the benefit of the doubt, and waiting for the parts to arrive. I've been assured that I'll have them by 1/15.

If I haven't already said it, I've got the gears in the HP 30 set up. I need to figure out if I want to run the 2 piece long shaft or convert it to the 1 piece from my LP 30. Right now, I'm leaning towards the 2-piece set up, since that won't require me finding a custom seal. If I go with the 2-piece, I'll figure out some sort of cable disconnect system. Still haven't called Randy's about just getting the seal to convert to the 1 piece shaft - that may be my best route. I also need to swap my hubs and brakes over to the new axle. Then prep and paint it. I also placed an order with RE for a set of 4.5" front springs. I'll my 3" front springs will get swapped to the back, and I'll even everything out with a spacer.

Cue-Ball
12-29-2004, 02:59 PM
Sounds like it is coming along nicely.

I will be meeting with Ty on the 8th of January and can follow up on your skid plate for you while I am there.

Where are you located, maybe I could pick it up if he has it ready.

JeepinHank
12-29-2004, 03:36 PM
lol - I'm way over here on the other side of the country. Lumberton, NC to be specific. About 60 miles inland from the NC coast.

I'm hoping he comes through for me. I love the looks of his kit, and if the quality is top notch, I don't mind waiting. However, I think he needs to get some things worked out with his suppliers and subs. He's just getting started, and I'm trying to keep that in mind, but he's going to have to deliver stuff when promised to make this venture a success.

That's all I'm going to say on the issue for right now. Whenever I have the parts in hand, I can look them over and tell everyone what I think. Right now, all I have is my gut feeling and an incomplete transaction. I can assure everyone that I'll do my best to provide an unbiased opinion of both the products and service I receive.

Tonight I'm going to finish pulling the t-case skid, and play with some new tools I got in the mail today: 40pc SAE Tap & Die set, 5pc spanner wrench set, and a set of transfer punches. 8)

Yeah I'm going to have to join Harbor Freight Anonymous

Cue-Ball
12-29-2004, 04:15 PM
Hank, For some reason I thought you were here in the SF Bay Area.

I will let you all know what the shop looks like and how "reputable" it all looks on the 8th.

JeepinHank
02-22-2005, 02:23 PM
Figured I'd post up an update....

I hope to get around to putting in some work on the Jeep this weekend. Work has been wide open, and that's taking up more of my time than I'd like. I've only been able to realistically put in one day a week on the Jeep, and that time has to be balanced between my wife, family, house stuff, GS cookies (yes its that time of year again), and the Jeep. Unfortunately, the Jeep has been losing out.

I've taken some good pics of the stuff I got from Ty / SRC, but I haven't gotten around to uploading them. I hope to get to do that this evening.

Basically here's where it stands:

My jeep is sitting on jack stands, front axle pulled, and LCA mounts cut off.
My t-case skid and rock sliders are off, and the exhaust has been removed.
The HP 30 is set up, I've got to install a seal, block off plate, convert it over to the ZJ shafts, and install the Aussie locker, brakes, and hubs.
The 8.8 has been on the back burner until I get the front axle / suspension finished.

Here's what has to be done:

My 4x4x0.25 tubing is cut, I've got to pull the crossmember, trim a couple of pinch welds, slide the tubing in place, and mark where it's going to go.
Then I need to drill/tap my SRC front crossmember for the trans mount and mock up where its going to end up. Tack in the front x-member mounts, mark the holes, and drill/tap the mounting holes.
Then I've got to do the same thing with the rear x-member.
After that, I'll be able to start making up my control arms - I'm still waiting on the RockLogic 4x4 endrings for my stock LCA bushings (ordered them on 2/17),
I haven't started with the UCA rings.
After I get the front finished up, I can get started on the rear axle / suspension.

Hopefully, I'll have some real progress and pics to post after this weekend.

JeepinHank
02-23-2005, 12:51 AM
As promised earlier, here are the pics of the parts I received from Ty / Sierra Rock Control:

Tubing inserts for upper and lower control arms:
http://lewis-lewis-cpas.com/Jeepin/Writeups/LA_Build/SRC_Parts/DSCF0419_s.JPG

Cross Member Brackets (1/4" thick):
http://lewis-lewis-cpas.com/Jeepin/Writeups/LA_Build/SRC_Parts/DSCF0420_s.JPG

Overall shot of everything I got (x-members, front lca brackets, inserts, belly skid, and threaded rod):
http://lewis-lewis-cpas.com/Jeepin/Writeups/LA_Build/SRC_Parts/DSCF0421_s.JPG
That's Captain & Coke in the glass... it was a good night. :drinkers:

Front LCA mount detail:
http://lewis-lewis-cpas.com/Jeepin/Writeups/LA_Build/SRC_Parts/DSCF0422_s.JPG

Rear X-member with LCA mounts:
http://lewis-lewis-cpas.com/Jeepin/Writeups/LA_Build/SRC_Parts/DSCF0425_s.JPG

Front X-member:
http://lewis-lewis-cpas.com/Jeepin/Writeups/LA_Build/SRC_Parts/DSCF0430_s.JPG

1.25 and 1.00 fine threaded rod for adjustable UCAs and LCAs:
http://lewis-lewis-cpas.com/Jeepin/Writeups/LA_Build/SRC_Parts/DSCF0432_s.JPG

There's the pics, I have some higher res shots and other angles if you want to see them. I hope to get some good progress this weekend - stay tuned.

Kraqa
02-23-2005, 12:59 AM
dang that looks nice. i wana see this go together.

ELLLLLIOTTTTT
02-23-2005, 01:47 AM
i agree. where in NC are you?

JeepinHank
02-23-2005, 09:59 AM
i agree. where in NC are you?

Lumberton, 25 miles South of Fayetteville on I-95.

You're in the Winston area right?

JeepinHank
03-21-2005, 12:02 PM
Got some good progress on the Heep this weekend. Actually did it all Sunday, but that’s all my weekend consists of right now.

Saturday, I went down to the local HF, and picked up my 5” cross slide vise. At first I was afraid it wasn’t going to work because the jaws aren’t aligned the right way. The handles wouldn’t clear the drill press post if I turned it, but after staring at it for a while, I figured out that if I did all of my adjusting (front to rear) with the vise all the way to the right, it would just barely clear. I did a test notch in the 2x2x.25 tubing with my 2.5” hole saw, and it worked out pretty well.

After playing with my new toy for a while, I decided it was time to get to work on the sub-frame. I hit everything with a wire wheel to clean it up, and tacked the front x-member brackets in place. I mocked it up, it looked good, so I finish-welded it. I did the same thing to the other sleeve. Then I went and measured from the front of the skid to the front of the rear x-member that I had bolted up to the rear of the skid. I took that measurement and transferred it to the sleeve to find the location of the rear brackets. Tacked all of that in position, mocked it up again, and finish welded them. Afterwards it was time to layout the front LCA mounts. Pretty much put them where they looked like they should go in Ty’s pics. I marked a reference point on both sleeves to make sure everything would be square, and tacked them in place. I probably could have moved them in a touch more, but I’m happy with the way they turned out.

Everything was welded front and back, if I could get to it. There's one section on one of the x-member brackets that's got a little porosity in it when a breeze came up, but other than that, I think the welds are decent. Not as pretty as a lot of you guys can do, but I don't think there will be any problem with them.

My last thing for the day was to layout the notch I’ll be cutting in my new front x-member (to accommodate the transmission mount). I got that marked, but left the cutting for next weekend.

That pretty much covers what I got done. Also did an oil change and replaced the fan belt on my wife’s car. Note really jeep related, but that gets me brownie points so I can work on the Jeep.

Took some pics, but I’ll have to wait till tonight to resize and load them up.

Vonzipper
03-21-2005, 07:57 PM
Hank,

sounds like your on your way!! Good stuff, I cant believe how this thing handles, snow wheelin this last weekend,

Cue-Ball
03-21-2005, 08:15 PM
Also did an oil change and replaced the fan belt on my wife’s car. Note really jeep related, but that gets me brownie points so I can work on the Jeep.


And you did not use AMSOIL?? :mrgreen:

Still have to say the skid plate Ty makes is AWESOME!!!

JeepinHank
03-21-2005, 11:24 PM
And you did not use AMSOIL?? :mrgreen:


Its a Pontiac with 2 payments left. When she's driving a BMW, I'll think about using Amsiol... :smt002

On another note, here's some pics:

progress on the subframe sleeves:
http://www.lewis-lewis-cpas.com/Jeepin/Writeups/LA_Build/Progress2005-3-20/DSCF0486_s.JPG

LCA Mounts:
http://www.lewis-lewis-cpas.com/Jeepin/Writeups/LA_Build/Progress2005-3-20/DSCF0487_s.JPG

Back side of the crossmember brackets:
http://www.lewis-lewis-cpas.com/Jeepin/Writeups/LA_Build/Progress2005-3-20/DSCF0488_s.JPG

Sleeves, welded from another angle:
http://www.lewis-lewis-cpas.com/Jeepin/Writeups/LA_Build/Progress2005-3-20/DSCF0489_s.JPG

Shot of the pinch seam - need to trim just a bit more!
http://www.lewis-lewis-cpas.com/Jeepin/Writeups/LA_Build/Progress2005-3-20/DSCF0490_s.JPG

Pinch seam on the other side:
http://www.lewis-lewis-cpas.com/Jeepin/Writeups/LA_Build/Progress2005-3-20/DSCF0492_s.JPG

Passenger side LCA mount cut off (No, its not really pretty, but that's what paint's for):
http://www.lewis-lewis-cpas.com/Jeepin/Writeups/LA_Build/Progress2005-3-20/DSCF0493_s.JPG

Shot of the "test piece" of 2x2x.25 bozx tubing for the hole saw with a bushing sleeve sitting in place (Not the best pic, but its between the cutting fluid and the drill press on the corner of the cabinet):
http://www.lewis-lewis-cpas.com/Jeepin/Writeups/LA_Build/Progress2005-3-20/DSCF0494_s.JPG

Vonzipper -
It's coming along nicely. Made some great progress. I hope it goes as well next weekend. If it does, I should (hopefully) be able to get my front axle finished up. Didn't forget to call this weekend. Things were just going so well that I didn't want to stop what I was doing. If I run into a problem or anything, I'll definately give you a call.

Hank

Nordic1
03-22-2005, 12:18 AM
Not bad... could you post some pics of what the sleves and rear CA mounts look like when you have that thing put together?

JeepinHank
03-28-2005, 12:15 PM
Well, this weekend wasn't really as productive as last weekend... I luckily had one of my buddies around to help me. We only worked on it Saturday, I didn't do anything Jeep related Sunday.

We got a bunch of stuff done, but, for the work we did, it doesn't look like it.

We fabbed up my rear UCA mounts (that took the bulk of the day), finished cutting the pinch seams to clear the sleeves, and cut the 1.25" fine thread - threaded rod for the RE joints. *On a side note, my Chop saw wasn't worth a shit when it came to cutting that B7 hardened threaded rod. broke out an angle grinder, and cut it like hot butter.*

My buddy also drilled about half of the holes in the sleeves for plug welds while I was welding the rear UCA mounts together, and then to the sleeves.

If I get a chance during the week, I plan on drilling the rest of the plug weld holes, cleaning up a bit of spatter, and priming the sleeves inside and out with Rustoleum oil based metal primer. I figure that will help prevent rust, and I can grind away the primer in the areas I'll be welding.

I didn't get any pics while the work was going on, but I'll try to get out to the shop and take a few this evening.

ELLLLLIOTTTTT
03-28-2005, 12:49 PM
get on the ball! i wanna see this thing. I take it, this isnt your DD?

JeepinHank
03-28-2005, 05:32 PM
No, I've been driving the tow rig for going on the past 4 months.

Hoping to get some more good progress this weekend. I doubt I'll get the chance to do anything else this week. I'm shooting to have it rolling in the next couple of weeks, and take it for a shake down run by the end of April.

I write up a list of what all I've got left to finish up about every week. The sad thing is my list keeps on getting longer. You would think it should be getting shorter by now. :rock:

JeepinHank
04-28-2005, 10:18 AM
I've got the day off today, so I figured I'd spend a few minutes to get caught up a little.

Here's a short and slightly stale update, but I wanted to post up what I got done the weekend after the 15th before I post up current progress pics...

Spent about half a day Saturday working on the jeep, then this pulled up in my driveway...
http://www.lewis-lewis-cpas.com/Jeepin/Writeups/LA_Build/Longarm-4-16-05/DSCF0500_s.JPG

My buddy is a volunteer firefighter, and they just got this new (to them) truck. It had some kind of ugly water box on the back that stuck out like 3 feet. The chief backed it through the wall of the station house, so it had to go... They cut if off, and had me weld in a plate to cap it off... My welds held - leak free, but the flange they had welded on had a few pin hole leaks in it. This is the return trip to fix someone elses shitty welding. I ground out the old weld and re-welded it. No pics of the progress, but here's a shot of the finished product after priming:
http://www.lewis-lewis-cpas.com/Jeepin/Writeups/LA_Build/Longarm-4-16-05/DSCF0498_s.JPG
I think it still sticks out a little too far, but that's what they wanted. I have a feeling it'll be back after they get tired of running into it.

On the jeep, I got my notch for the transmission mount cut in the front crossmember, and cut up some pieces of 1/4" plate to cap off the sides:
http://www.lewis-lewis-cpas.com/Jeepin/Writeups/LA_Build/Longarm-4-16-05/DSCF0501_s.JPG

Piece I cut out of the x-member:
http://www.lewis-lewis-cpas.com/Jeepin/Writeups/LA_Build/Longarm-4-16-05/DSCF0502_s.JPG

I welded the piece cut out of the x-member in the bottom of the x-member, and capped off the sides. Then I marked/drilled the holes for the transmission mount. I'll post up some pics of this after I go out to the shop today.

Then I cut my 1.25" fine threaded rod for my LCAs, coped the ends, and welded them to my 2.5" RE Superflex Joints:
http://www.lewis-lewis-cpas.com/Jeepin/Writeups/LA_Build/Longarm-4-16-05/DSCF0504_s.JPG

http://www.lewis-lewis-cpas.com/Jeepin/Writeups/LA_Build/Longarm-4-16-05/DSCF0505_s.JPG

I feel pretty confident in my welds, but I'll still be a little wary on the shake down run. That's why they call it a shakedown run I guess.

OverkillZJ
04-28-2005, 10:49 AM
Sweeeeeeeeeeeet

JeepinHank
04-28-2005, 03:51 PM
To start things off, I figured I'd post up a pic of the new tow rig... Mentioned it a few posts back and never took a pic. Its a 2001 F-250 crew cab, lariat package, 4x4, 7.3L powerstroke, auto trans. Now I'm looking for a trailer so that I can tow the Mistress to GSSE, and hopefully GSW next year if I'm lucky.

http://www.lewis-lewis-cpas.com/Jeepin/Writeups/LA_Build/Longarm-4-28-05/DSCF0506_s.JPG

Now for Jeep pics:
This is a pic of the front crossmember where I notched it for the transmission mount. The holes are for the transmission mount. The first set ended up being a little too far to the passenger side, so I had to re-drill them. Remember the old adage: Measure twice, cut once.
http://www.lewis-lewis-cpas.com/Jeepin/Writeups/LA_Build/Longarm-4-28-05/DSCF0508_s.JPG

This is the belly skid after I drilled the 4 3/4" holes for the transmission mount bolts.
http://www.lewis-lewis-cpas.com/Jeepin/Writeups/LA_Build/Longarm-4-28-05/DSCF0509_s.JPG

Here's a shot of the rear crossmember where I notched it to clear the t-case. I'll get a better shot when I've got it out, but its currently in place so that I can mock everything up.
http://www.lewis-lewis-cpas.com/Jeepin/Writeups/LA_Build/Longarm-4-28-05/DSCF0510_s.JPG

Front of the sleeves in place... Just about ready to weld. I've got to drill / tap all of the holes first, and prep the sleeves just a bit more. Note my super high tech transmission support. :weedman:
http://www.lewis-lewis-cpas.com/Jeepin/Writeups/LA_Build/Longarm-4-28-05/DSCF0511_s.JPG

Rear of the sleeves - you can see the UCA mounts I fabbed up. Pretty much a copy of what Ty's doing:
http://www.lewis-lewis-cpas.com/Jeepin/Writeups/LA_Build/Longarm-4-28-05/DSCF0512_s.JPG


Last but not least, I have evidence that I haven't been in the shop enough lately. I have house guests:
http://www.lewis-lewis-cpas.com/Jeepin/Writeups/LA_Build/Longarm-4-28-05/DSCF0514_s.JPG

Its a nest for Carolina Wrens. My wife is a big bird lover, so I can't disturb the nest. There is 4 eggs, and they should be hatching sometime in the next 2 weeks. Then it'll be about another 2 weeks before the hatchilings are ready to fly. I've been voluntarily limiting my work time in the shop to about an hour at the time. Then I'll give the birdie around 2 hours to tend to the eggs.... She's used to me coming in and checking stuff out, but when I crank up the angle grinder, she scatters.

OverkillZJ
04-28-2005, 04:10 PM
LOL, I worry about not disturbing the neighbors, never had to worry 'bout the birds :supz:

ogdak
04-28-2005, 06:55 PM
Nice progress,











Be nice to the little birds :goodman:

JeepinHank
05-02-2005, 01:25 AM
Got a little more done this weekend...

I'm tired of putting those damn sleeves on and off, but I think its paying off to make sure I get everything in the right spot...

Got the front x-member mounts drilled and tapped. Mocked it up and decided that I should open up the holes in the belly skid a bit more, so I drilled them out to a little over 1" and slotted them a bit. It could look better, but it could look a hell of a lot worse too.

Then I got the belly skid and rear x-member in place and marked those holes. Pulled everything back out, and started drilling and tapping those holes. I've got the front x-member drilled and tapped, and have all of the holes in the sleeves / x-member mounts drilled except two. I'll try to get to them tomorrow.

I hope to really get going on the install this Wednesday or Thursday. Friday will probably be an all-nighter, and I'll work for as long as I can get away with Saturday. I may be able to get the front axle in this weekend, and I'd like to get both installed so that I can start working on brakes and exhaust, but we'll have to see.

I've got a bunch of buddies heading up to UNF on the 14th, and I'd love to make a shakedown run then. Of course that will all depend on how far I can get in the next two weeks.

No pics for now, but I hope to get to take a few after the sleeves are welded in this week.

Night Ya'll

JeepinHank
05-06-2005, 02:00 PM
Alright guys, its been a while with no pics or updates... Still no pics, but here's the update:

All holes are drilled and tapped. We assembled the whole deal (sleeves, x-members, & skid) and slid it up in place Wednesday night. Transmission mount has lined up nicely.

I've got to hit a couple of spots that I missed with the wire wheel before. Then I'll be doing a lot of welding.

The plan, as of right now, is to get the subframe welded in tonight, and spend all day/night Saturday swapping in the axles and building control arms.

I'll be picking up some steel brake lines tonight so we can start getting that handled as well. I've got 2 buddies coming in to town Saturday to give me a hand with everything, and I've been making up a time line / task list so that everyone will have something of their own to work on. The past couple of times I had plenty of help, it would end up that 2 people would be standing around waiting for me to tell them what to do while I was getting one other person started on a task.

Hopefully I'll have things a bit more organized for this weekend.

You can expect a pretty big update with lots of pics after this weekend.

Wish me luck!

nate
05-09-2005, 09:57 PM
With the notch in the rear crossmember, will your T Case drain into the crossmember? I thought about doing what you did, but it would have put the drain basically in the crossmember. I welded a piece of angle onto the crossmember instead. Also cut holes in the skid for the T Case drain and some holes here and there for the skid to drain instead of filling up full of mud and water.

ELLLLLIOTTTTT
05-09-2005, 10:27 PM
also could you not fab up some removeable center section in the cross member if that were a problem? seen it done on an xj before and looks like it works ok.

JeepinHank
05-10-2005, 09:41 AM
With the notch in the rear crossmember, will your T Case drain into the crossmember? I thought about doing what you did, but it would have put the drain basically in the crossmember. I welded a piece of angle onto the crossmember instead. Also cut holes in the skid for the T Case drain and some holes here and there for the skid to drain instead of filling up full of mud and water.

I cut out the notch, then reversed it and welded it back in place, and capped off the two sides. Forgive the ascii art:

Cut out:
_____
|


Welded in: _____|

Does that make any sense at all? I didn't cut all the way through, I left a 1/2" of the x-member (2" part) on the bottom to give the recessed alan head bolt clearance. The back of the "L" is a little higher than the front, so any fluid that drains into the notched area will flow out.

I didn't put any additional drain holes in the skid - I figured the big openings on either side of the front x-member would be enough. All of the notches I cut in the x-members have been blocked off and welded. I did cut 4 slots in the belly skid for my transmission mounting holes. They are about 1" x 2" each - I didn't get my transmission mount holes exactly right, so I had to slide my front x-member over to the drivers side a little.

I've got a pretty good update, but I have to get out and take a few pics... I couldn't find my memory card this weekend.

JeepinHank
05-10-2005, 09:45 AM
also could you not fab up some removeable center section in the cross member if that were a problem? seen it done on an xj before and looks like it works ok.

With the rear suspension attaching to the rear x-member, I'd be a little hesitant making a removable center section. It could probably be just as strong, but I prefer the solid piece of steel just for the peace of mind.

JeepinHank
05-10-2005, 11:02 AM
Hell, since I'm here, I might as well go ahead and post up the update. Pics are to follow after I get a chance to get out to the shop, but it may be awhile if I don't want to sleep out there.

This weekend my buddy Mark came down from G-ville, and gave me a hand Saturday and Sunday morning. Here's a rundown of what we got done:

We got the subframe welded in (plug welds and most of the seams - part of the inside seam was obscured by the belly skid), mocked up the position for the front axle, and measured the LCA lengths.

Then I got to work on the LCAs and driver's side UCA. I coped one side of the 2" box tubing for the bushing sleeves, welded on the sleeves, pressed in the bushings (using Pierce's redneck shop press method) and welded in the tubing inserts. Then I fabbed up the UCA. I made a bracket that attaches to the axle side bushing, and then welded that to the 1.5" box tubing. While I was doing that, he installed my front locker, the special CR 11800 seal on the passenger side, axle shafts and hubs.

Then we slid the axle in place and bolted up the LCAs. I marked the position for my radius arm mount on the driver's side LCA, pulled it back out, and welded that on. We bolted the LCA back in and set the pinion angle. Then I took that measurement, adjusted for the jamb nut, insert, and 1/2" of inward adjustment, and cut the radius arm / UCA to length. I welded in the tubing insert, threaded in a rubber bushing / 1" threaded rod assembly, and bolted that into place. I had to grind down my UCA axle side bracket about 1/2" on the passenger side to allow for the angle and clearance on the diff. We installed the RE front 2" bumpstop extensions (thanks Puma), 4.5" springs, and hooked up the steering and shocks. My current shocks are WAY too short - they max out before the spring even starts to get loose.

My buddy Rob came by to drop off the 8.8 after he got finished up with it. He had some stuff come up at home, so he had to turn around and leave as soon as we got the axle off the back of this truck. I still haven't gotten around to checking out how they got the mini-spool installed.

That's about it for the weekend. Last night (Monday) I went out and pulled the rear axle and suspension. I got pissed at my rear brake line, so I ended up cutting the rubber line (and ABS lines of course) at the axle - I have the feeling that will end up being a costly mistake, but I'm keeping a positive attitude for now.

I think I have exceeded my allotment of days out in the shop over the past couple of weeks, so I don't think I'm going to be doing too much more for the rest of this week. I've been busting my ass on the Jeep and neglecting other husbandly duties in the process. My marriage is more important than this Jeep, but I think I have to re-convince my wife of that fact. Yeah, I can be a real shit sometimes...

I won't be making my planned shakedown run this weekend, but now I have the time I need to make sure everything is done right the first time. Things were starting to get a bit rushed, and I feel like I was starting to cut corners a bit more than I should. Now I'll have time to do the brakes and exhaust the right way, get the correct shocks, etc...

JeepinHank
05-10-2005, 11:42 AM
Oh yeah, if you're in a tight postion under your jeep welding on the frame directly overhead:

WEAR EAR PLUGS

Man, molten metal in the ear.... That shit burns in a bad way. Loud ass popping noise, then that ringing and hissing sound like you get when you leave a rock concert after being there all night. :toimonst:

JeepinHank
05-10-2005, 11:25 PM
Pics:
Just took a few quick ones, but here they are:

Front suspension in:
http://www.lewis-lewis-cpas.com/Jeepin/Writeups/LA_Build/Longarm-5-10-05/DSCF0515_s.JPG

Radius arm mount detail:
http://www.lewis-lewis-cpas.com/Jeepin/Writeups/LA_Build/Longarm-5-10-05/DSCF0516_s.JPG

Everything's connected except the trackbar:
http://www.lewis-lewis-cpas.com/Jeepin/Writeups/LA_Build/Longarm-5-10-05/DSCF0517_s.JPG

Rear LCA mounts and my crappy welds:
http://www.lewis-lewis-cpas.com/Jeepin/Writeups/LA_Build/Longarm-5-10-05/DSCF0518_s.JPG

JeepinHank
05-10-2005, 11:31 PM
More pics:

Rings and bushings welded to 1.5" box tubing for rear UCAs:
http://www.lewis-lewis-cpas.com/Jeepin/Writeups/LA_Build/Longarm-5-10-05/DSCF0519_s.JPG

Front control arm bracket, belly skid, and more of my crappy welds (still haven't ground down the plug welds yet, so no guff about that! :flipoff2: ):
http://www.lewis-lewis-cpas.com/Jeepin/Writeups/LA_Build/Longarm-5-10-05/DSCF0520_s.JPG

Close-up of the grinding on the axle side UCA connection:
http://www.lewis-lewis-cpas.com/Jeepin/Writeups/LA_Build/Longarm-5-10-05/DSCF0522_s.JPG

TrojanMan
05-10-2005, 11:46 PM
She's looking good :partyman:

nate
05-11-2005, 12:08 AM
Yeah those inserts are hard to get in. A bit too big IMO. I clamped the arm in my vice, heated it with a torch and and 5lb sledge did the trick. Now I think I made my arms too long, 48" so I will probably cut them down a bit. I think 45-46" will be more realisitc.

You ground what exactly for the front? I bolted mine up to mock it up and it all fit just fine from what I saw.

ogdak
05-11-2005, 04:34 AM
:mrgreen: nice progress :smt003

JeepinHank
05-11-2005, 09:29 AM
Yeah those inserts are hard to get in. A bit too big IMO. I clamped the arm in my vice, heated it with a torch and and 5lb sledge did the trick. Now I think I made my arms too long, 48" so I will probably cut them down a bit. I think 45-46" will be more realisitc.

You ground what exactly for the front? I bolted mine up to mock it up and it all fit just fine from what I saw.

I built my own axle side UCA bracket out of 2"x0.25" flat bar. The hole is drilled in the center (1" in, and centered across the 2" bar) The passenger side of the bracket and that lower-back corner ended up hitting the top of the diff.

The inserts weren't too bad... I just smacked it with my dead blow hammer, and it slid right in... I did take a file to the welded seam inside of the tube..

JeepinHank
07-18-2005, 10:04 AM
I know its been a while with no updates, but I have news for everyone:

The Jeep is officially sitting on all four tires again!!!!!!!!!!!!!!!!!!!!!!!

Saturday, I got the 8.8 in place and took my measurements for the rear UCAs. I got those built, pulled the front suspension, and prepped it all with the wire wheel. Then I hit them with a coat of primer and let them dry overnight. My buddy Rob came over Sunday, so we got everything painted with three coats of flat black, made a run to the parts store for some brake parts, and jumped on getting everything installed when we got back. The arms and springs are installed front and rear. The driveshafts are hooked up, and the tires are on. The only thing I have left, to be officially finished with the suspension, is install the front track bar. I would have gotten that in Sunday as well, but it was getting late, and, about the time I got the axle lined up, I realized that the new axle hadn't had the t-bar bracket drilled out to 1/2". [DOH!] I know, I should have gotten that taken care of while I was at it, but I had a dinner to get to, and was pushing my luck with the wife already. Hopefully I'll get that taken care of this week, and then I should be able to start working on my brake lines.

My remaining list is:

- Fab up block off for old vac. disconnect system, install
- Brake lines / Brakes, bleed lines & master cylinder
- Modify, repair, and install sliders
- Prep & paint subframe - already primed, but I want to grind some plug welds down before I put on the finishing coats.
- Drill and tap subframe sleeves for belly skid - paint belly skid - reinstall
- Weld up exhaust manifold, install
- Charge battery, get engine running again
- Drive to exhaust shop, and get exhaust installed - get jeep inspected
- get the jeep to my buddys to get the token forklift shots and measure for shocks
- order shocks & tires
- Install shocks & tires
- Fill up diffs, top off tranny and t-case fluids - go over entire rig to check for any potential problems
- Break in gears
- Make a shakedown run
- Wheel the snot out of it at Tellico for GSSE.

OK now that I look at all of it, I've still got a boatload of stuff to do, but I can actually see a finish line again. I was getting a little frustrated with this whole build process (basically because I haven't had the time to work on it like I wanted to), but I'm feeling MUCH better now.

My camera was dead as usual, but, as nasty & sweaty as I was, I would have been scared to take it out in the garage anyway. I'm going to try to sneak out to the shop one evening this week to take some quick pics. Wish me luck, I've got a ton of stuff to finish over the next 2 weeks. Right now I'm in night classes 4 days a week, from 6 to 10, so I can pretty much only do real work on the weekends.

On a side note, I am SO ready to get the jeep out of the shop just so I can actually clean up around there. I bet I've got a quarter inch of steel dust and silt / mud / dirt under and around the jeep. The Jeep has so much metal dust on it that I'm afraid it'll rust when I pull it out in the yard overnight.

JeepinHank
07-18-2005, 10:15 AM
Oh yeah!

I'm planning on doing a little writeup - complete with specs and part #s - for the brake line set up I'm doing. FYI, I'll be running the lines down the control arms like they do on the WJs.

I spent the better part of 2 hrs at my local napa plundering through their brake hoses and brake fittings to figure out what would or wouldn't work. They thought I was crazy, but they let me do it.

This should make it a bit easier for other folks wanting to go with a similar set up.

ELLLLLIOTTTTT
07-20-2005, 03:43 PM
I see you're still running those bumpstop extensions i sold to ya like 2 years ago. :mrgreen:

looks like the zj is coming along nicely, when are we gonna hit up tellico?

JeepinHank
07-20-2005, 04:42 PM
I see you're still running those bumpstop extensions i sold to ya like 2 years ago. :mrgreen:

looks like the zj is coming along nicely, when are we gonna hit up tellico?

Those bumpstop extensions touched rubber for the first time since I got them about a week ago.

I was hoping to make it up for GSSE, but I'm finishing up two summer school classes the day I'd be leaving. I just don't think I'm going to be able to make it up there that weekend. Considering a C is failing, I really need to pull A's out of both classes. I know if I was trying to get ready for a trip to Tellico, I wouldn't put in enough time / effort into these classes.

I'm trying to put together a run for either the 12th - 14th or the 19th - 21st. You're welcome to come along if you want. I'm hoping to make a shake down run to UNF the same weekend as GSSE. Yeah - I'm a bitch. I've punked out 2 years in a row now. The timing just hasn't worked out.

Hopefully I'll get the brake lines plumbed and bled this weekend. Then I can get the jeep down to the exhaust shop, and get that taken care of. Its coming together, but I'd rather not be rushed in these last few stages.

JeepinHank
08-01-2005, 02:45 PM
Brake lines are plumbed and bled. It was a long process that involved a lot more work than I thought, but the jeep is officially capable of stopping itself again. It took me the entire day Sunday with the help of my buddies Rob & Sidney.

Decided I'm just going to bolt the vac-disco assembly back in place for now, and worry about fabbing up a block off plate later on.

I've got to fab up some rear shock mounts. I wanted to get the brake lines in place before the shock mounts so I could make sure they wouldn't be in the way. Probably a little backwards, but I wanted my shock mounts up as high as I could get them. I hope to get around to cutting them this week, and plan on welding them in this weekend.

I charged up my Optima Yellow top, and it appears that its had a cell go bad. I've got it on a 1 Amp trickle charger right now. I hope that it will charge on up because I stopped in at Auto Zone, and it they told me I'd get $7.56 on my pro-rated warranty for a 2 year old ($150) yellow top. That really pissed me off.

I had a good deal on some tires, but that ended up falling through. So I'm on the hunt for a reasonably priced set of 35's to run for a while.

If I can get the shock mounts in next weekend, I'll be looking to get by the exhaust shop next weekend as well. Then I'll work on breaking in the gears, and get my measurements for the new shocks. I'll try to post up the pics I took, but I'm kinda tight on time right now with my classes.

JeepinHank
08-08-2005, 12:28 PM
SHE LIVES!!!! :supz:

Fired it up Saturday night and took a little drive.

No exhaust beyond the down pipe, so it was loud as hell! I found out my front driveshaft is worn out completely and I've got a bent shaft in the 8.8. I'm planning on trying to pick up an 8.8 shaft today. My buddy Rob is trying to take care of my front driveshaft. I bought a universal cat last night. I'm going to try to get it, my old flowmaster, and the new turn down welded up tonight, and bolt the exhaust back up. I also have to move one of my bumpstops a bit, but I don't think it will be that big of a deal - the driver's side rear is barely hitting the spring.

Hopefully I'll be able to drive it to work in the morning. :smt003

I promise I will be getting some more pics posted for everyone, I've just been busting my ass since I finished up my classes - trying to get the mistress ready to wheel. I've been going through withdrawals.

JeepinHank
08-10-2005, 09:19 AM
Dear Mallcrawlin bitches,

In typical MallCrawlin.com style, I felt compelled to get some gratuitous fork lift flex shots for everyone to enjoy:

http://lewis-lewis-cpas.com/Jeepin/Writeups/LA_Build/Longarm-8-9-05/P8090169_s.JPG

http://lewis-lewis-cpas.com/Jeepin/Writeups/LA_Build/Longarm-8-9-05/P8090172_s.JPG

http://lewis-lewis-cpas.com/Jeepin/Writeups/LA_Build/Longarm-8-9-05/P8090173_s.JPG

Both the front and rear tires were lifted a little over 26" off the ground. I only took pics of the rear, cause I was way too excited to snap pics when I was checking out the front.

I borrowed the camera so that's why none of the other cool pics are up yet. Please don't make fun of my weak ass longarm flex, I'm feeling very sensitive today.














:flipoff2:

Cue-Ball
08-10-2005, 10:17 AM
Looking good Hank.

Randy's ring and pinion has the vac disconnect block off kit for like $20 or something you might give them a call.

JeepinHank
08-11-2005, 09:02 AM
Looking good Hank.

Randy's ring and pinion has the vac disconnect block off kit for like $20 or something you might give them a call.

I took the easy way out and cut the forks off the vac disconnect. I'll eventually get around to building my own block off plate, but it'll work for now.

Kraqa
08-11-2005, 11:46 PM
is that rear full yflexed or is somepthing binding?

nate
08-12-2005, 06:30 AM
Yeah that is weird. Mine with bascially the same setup will flex the rear hard core, and the front is the one to bind... radius arms :finga:

JeepinHank
08-12-2005, 10:20 AM
No binding or anything I checked for all of that stuff. We stopped lifting when the front spring was unseated. We did the same thing when we were flexing the front. I didn't see any point in going past that. Granted, I don't have the front limit straps in there yet, so I would imagine that would cause the rear to flex a bit more. I think it also has something to do with the Rancho springs I'm using. The rear flexes a bit better when you lift the front tire, and the front flexes better when you lift the rear.

I'm making a shakedown run this weekend, so hopefully I'll have some better pics for ya'll.

Kraqa
08-12-2005, 11:02 AM
every pic i have seen with the RC kit the rear doesnt' flex. well not nearly as much.

phillyzj
08-15-2005, 03:37 PM
every pic i have seen with the RC kit the rear doesnt' flex. well not nearly as much.

yea, that doesn't look like very ballanced flex... It seems accurate to say it flexes like an XJ! Looks like some uber stiff springs in the rear causing the front to do all the work, or something binding in the back. Either way, something's not right, if you ask me...

JeepinHank
08-15-2005, 03:43 PM
Here are a few pics from the shakedown run from this past weekend. Excuse the size / quality - I forgot my camera, and my buddy, Rob, was nice enough to email them to me pretty quickly.

Here is a shot of the rear flex:

http://www.lewis-lewis-cpas.com/Jeepin/URE_2005_08_13/IMG_2507_11.JPG

That's maxing out my shocks... Detail (different obstacle):
http://www.lewis-lewis-cpas.com/Jeepin/URE_2005_08_13/IMG_2461_20_2.JPG http://www.lewis-lewis-cpas.com/Jeepin/URE_2005_08_13/IMG_2462_1_1.JPG http://www.lewis-lewis-cpas.com/Jeepin/URE_2005_08_13/IMG_2463_2_1.JPG

Here's a token shot from the front (same spot as top pic):
http://www.lewis-lewis-cpas.com/Jeepin/URE_2005_08_13/IMG_2509_13.JPG

I've got some work to do on the rear shock configuration. I raised my shock mounts to be flush with the bottom of the axle tube, and now I have very little room for up travel. As a consequence, if I get shocks that can handle my up travel limitations, then I'll have absolutely no down travel. I'm thinking of coming up with a crossmember to span the unirails between the bumpstop mounts in the rear, and triangulating my shocks inwards to allow for more travel without sacrificing any more flex than I have to.

I can't wait to get the new shocks in and take it for another trial run.... I think I've found some decent tires for now. I hope to pick them up this weekend. No tellico any time soon, but I still hope to make it up before year end. On a semi related note - The rear spool is AWESOME. I was able to climb stuff with little or no wheel spin where I had to hammer on the throttle in the past. I'm digging it despite the poor street manners. Of course, if I had to drive it everyday, I might feel otherwise.

JH

nate
08-15-2005, 03:49 PM
http://98jeepzj.com/photos/images/192-2.jpg

That's a ~570 on a 30* ramp. I don't think it's too bad. Really the shocks are what limits the travel. It's hard to find anything with more than 12-14" of travel that aren't 8 million dollars :mrgreen:


Hank, yeah I tried doing the flush shock mounts and it wasn't going to work out. Mine hang down quite a bit. Those 35s?

JeepinHank
08-15-2005, 04:22 PM
Hank, yeah I tried doing the flush shock mounts and it wasn't going to work out. Mine hang down quite a bit. Those 35s?

Nope, those are the 32"s

I hope to meet up with the guy I'm buying a set of (5) 35" Goodyear MT/R's from this weekend.

I don't know when I'll get a chance to change the shocks around. With all of the time I've been putting into the jeep lately, my wife is feeling a little neglected. So I'm going to be a good husband for a while, and chill out with the work on the mistress.

I also need to push the front axle forward a bit. I found that on full stuff, I barely catch the rear of the tire on the wheel well. That shouldn't take me too long, but it still has to get done before I can comoftably run the 35's.

MaineZJ
08-15-2005, 08:39 PM
hope that's not binding....

cause this is Clayton LA with about same size tire -

http://www.MyOnlineImages.com/Members/Mikeyg79/images/ZJramp_jpg.jpg

Kraqa
08-15-2005, 08:52 PM
I run 6" lift in the rear with 30" long shocks that are triangulated and i woudn't want anymore travel then that.

MassZJ
08-15-2005, 09:30 PM
mount your rear shocks like this (http://www.fototime.com/{E710DD49-7B3C-4B33-A9BC-9275708D9F86}/picture.JPG) <- click there or cut and paste http://www.fototime.com/{E710DD49-7B3C-4B33-A9BC-9275708D9F86}/picture.JPG :finga:

Kraqa
08-15-2005, 10:03 PM
am i missing something


Link, Pic?

MassZJ
08-15-2005, 10:07 PM
edit :drinkers:

Kraqa
08-15-2005, 10:09 PM
depending on how far back you have your rear axle the tank will get in the way. when i looked at mine when it was full bodied i woudl have had to do it in front of the axle.

JeepinHank
08-16-2005, 11:25 AM
mount your rear shocks like this (http://www.fototime.com/{E710DD49-7B3C-4B33-A9BC-9275708D9F86}/picture.JPG) <- click there or cut and paste http://www.fototime.com/{E710DD49-7B3C-4B33-A9BC-9275708D9F86}/picture.JPG :finga:

I was thinking of something along those lines. You have any pics of the mounts on the frame/body side?

I think I'll have to mount mine in front of the axle since I pushed the rear back, but, then again, I haven't really climbed up under there and looked at everything yet. You guys see any problem with mounting them in front of the axle?

Again, nothing is binding as far as I can tell. The springs are kind of stiff, and we stopped lifting the rear when the front springs were unseated. I'll be measuring for the rear shocks again after I come up with something different. I'll try to post some other pics to give you an idea of the actual rear flex.

JH

MassZJ
08-17-2005, 08:55 PM
I dont have any pics right now of the upper mount, but i'll try and get some soon. I have pushed the rear back as far as i safely could with claytons standard lenght arms. Dont know how much further back you have pushed yours. The shocks dont care if they are mounted on the front or rear of the axle. I did have to run limiting straps (that aren't in the picture) to keep from loosing a coil b/c of the amount of flex in the rear.

rob92xj
08-18-2005, 04:22 PM
nice Jeep Hank
thanks for the credit for the pics talk to ya later

JeepinHank
08-24-2005, 10:32 AM
This is how I ran hard lines down my arms with a flex hose to the frame and the stock ZJ hoses to the caliper. I'm going to start off by saying that this is just one way of running brake lines down your control arms. Its not necessarily the best way, nor is it the only way.

I started out by finding some brake hoses that would work to attach from the frame to the LCA. This little venture turned out to be quite an undertaking. I wanted plain old rubber lines. I didn't want anything that said "performance" because around here - performance = expensive.

I sweet talked to guys over at my local NAPA into letting me plunder through their warehouse to find something that would work. I ended up going with their TruStop Brake Hoses - NAPA P/N - 4136531. These are -3AN female on one side and male on the other side, and about 9" long.

I used two of them for the front brakes (one for each arm). Cost was about $14.50 each.

I picked up several lengths of 3/16" brake tubing from AutoZone. For the front I used 1 40" length and 2 30" lengths. Buy extra - its pretty cheap and you'll probably screw something up making bends or flares.

I cut the stock hardline just above where it attaches to the stock hose. I reflared that with a new flare fitting, and attached it to the new line with a coupler. I'll provide part #'s but I'd suggest you just look at what they've got and make sure the couplers and fittings actually work together.

From there, I drilled out and ran the hardline through the old UCA bolt hole and down the inboard side of the uniframe rail to my new Longarm LCA mount. I made the basic bends with a tubing bender, but I had to "finess" the tubing quite a bit after that. To prevent future failure from rubbing on the UCA hole, I split some small rubber hose and wrapped it around the brake line and zip tied it to protect this area. I attached the line to the body in 4 places using 1/4" rubber lined retainer clamps that I picked up from my local hardware store. I also used some 1/2" retainer clamps to hold down the rubber hoses where needed.

On the arms, I drilled and tapped three holes. 2 for the rubber lined clamps and 1 for the stock ZJ rubber brake hose. I ran a 20" piece of hard line with the 9" TruStop hose connecting at the frame side and the OE ZJ hose connecting from the arm to the caliper.

I know this description is kind of fuzzy, but hopefully it will give you an idea of how I went about it. Here's some pics:

Stock hardline to new hardline - 1/4" rubber lined clamp and coupler:
http://www.lewis-lewis-cpas.com/Jeepin/Writeups/LA_Build/Longarm-8-24-05/DSCF0544_s.JPG

Hardline down the arm, TruStop hose at frame side and OE hose at axle side:
http://www.lewis-lewis-cpas.com/Jeepin/Writeups/LA_Build/Longarm-8-24-05/DSCF0542_s.JPG
You may notice that I ran the lines down the inside of the LCA. I shouldn't have a problem catching a rock on them or anything. The reason I didn't run it down the top is because I was afraid of crusing the line between the body and LCA. Just for good measure, I've got 2 extra 20" lengths of hardline and a spare rubber hose that I keep in my toolbox just in case.

So, you may wonder what's the real benefit of doing this as opposed to just having a long rubber line. Well, first off, I feel this has less of a chance of getting hung on something than a long rubber line. Secondly, I have NO worries about over-extending this line. I can lift the ZJ another 10 inches and not have to worry about it. Also, the total amount of rubber line used in this setup is still less than what would be required in a long rubber line to acheive the same goal. Although its pretty much a non issue - rubber brake lines do swell, and less is better in my opinion.

Here's the part #'s:
Description - Supplier - Part #

40" - 3/16" Steel Brake Tubing (w/ fittings) - AutoZone - AZ340
30" - 3/16" Steel Brake Tubing (w/ fittings) - AutoZone - AZ330
-3 AN Unions - NAPA - WH 302 x 3
9" TruStop Rubber Brake Hoses (-3AN (M) -> -3AN (F)) - NAPA - 4136531
-3 AN Tubing Fittings - NAPA - WH 100 x 3

If anyone has a question, post up or PM me.

JH

JeepinHank
08-26-2005, 09:37 AM
Got the 35s mounted this past weekend, figured I'd post up some parking lot pics. They're 35x12.50 Goodyear Wrangler MT/Rs. Got a set of 5 with 80% tread for $650. I couldn't pass that deal up.
Enjoy:
http://www.lewis-lewis-cpas.com/Jeepin/Writeups/LA_Build/Longarm-8-24-05/DSCF0539_s.JPG

http://www.lewis-lewis-cpas.com/Jeepin/Writeups/LA_Build/Longarm-8-24-05/DSCF0540_s.JPG
It's on a slope - that's why it looks like it leaning to the right.

http://www.lewis-lewis-cpas.com/Jeepin/Writeups/LA_Build/Longarm-8-24-05/DSCF0541_s.JPG

http://www.lewis-lewis-cpas.com/Jeepin/Writeups/LA_Build/Longarm-8-24-05/DSCF0546_s.JPG

I still need to get some spacers for the rear axle. Then I need shocks, and need to extend the front arms by about 1/2" cause I'm getting a little scrubbing on the fender when turned at full lock.

And here's a pic of two of my buddies that helped make this all possible after a night of dri.... err wrenching.
http://www.lewis-lewis-cpas.com/Jeepin/Writeups/LA_Build/Longarm-8-24-05/DSCF0530_s.JPG

That's Rob & Sidney. Great guys - couldn't have gotten this far without them. :partyman: And also have to thank their wives, Stephanie & Lorie, who were getting lit in the house, and keeping my wife occupied at the time this pic was taken. They were great in dealing with me keeping their husbands out late all the time. I hope I didn't get them into too much trouble. They have decided they're going to start their own Jeep club - The Jeep Widow's Club. :heart:

ELLLLLIOTTTTT
08-26-2005, 10:06 AM
good lookin pics. did you get those tires from the dude off NC4x4 no too long ago? i was actually bout to pick those up from him but decided to stick with my tried and true BFG's.

Also do you ever catch crap from po-po's about your license plate?

JeepinHank
08-26-2005, 11:07 AM
good lookin pics. did you get those tires from the dude off NC4x4 no too long ago? i was actually bout to pick those up from him but decided to stick with my tried and true BFG's.

Also do you ever catch crap from po-po's about your license plate?

Yep. Picked them up last Saturday. They seem to be pretty good tires. They need to be balanced, but we couldn't get them to balance very well when we mounted them. I think he had them stacked when he stored them, so I figure I needed to drive around with them for a while.

I was also looking at a set of Pro Comp MTs, but I'm glad I got these GYs instead.

I haven't had any problems with po-po's yet. Granted I've only driven it about 600 miles in the past 2-3 weeks. I also know most of the officers in town, and they all know my Jeep, so that doesn't hurt.

I usually just zip-tie the plate to the spare tire, but I haven't gotten around to doing it yet. I've been thinking about coming up with some kind of mounting plate that bolts on with the tire lugs and a quick connect plug for a light to shine on the plate, but I also like the way Kraqa did the plate on his / your bumper.

Kraqa
08-26-2005, 11:41 AM
looks good man. my/puma's licence plate holder doubles as a gerry can holder.

BMRisko
08-27-2005, 06:21 PM
Looks good man...alot like my old Heep which is running around NC somewhere right now.

Vonzipper
08-28-2005, 12:51 AM
Hank,

Rig came out bad a$$!! Now get it off the concrete and lets see some real shots..... :smt003


Cheers

Scott

ogdak
08-29-2005, 01:05 PM
Looks very nice, but way to clean :mrgreen: :mrgreen:

MassZJ
09-05-2005, 12:07 AM
looks great. here is a pic of the upper shock mount. http://www.fototime.com/{42741FE2-FDD9-488A-92E7-6162C13168A6}/picture.JPG

ELLLLLIOTTTTT
09-05-2005, 02:13 AM
just say no to drunk posting.

Hurricane 4x4
11-06-2005, 09:56 PM
I got to see the mistress in person on saturday... she looks great!

I met Hank at a gas station right off of I-95 to pick up his old skidplate for use on my jeep. I was in the process of filling my tank when I heard tires chirping... looked up and there she was.

JeepinHank
11-07-2005, 01:12 PM
Thanks for the compliment dell30rb... It was cool meeting you. I look forward to wheeling with you sometime down the road. I hope that skid plate works as well for you as it did for me!

Just so ya'll don't think I'm a total web wheeler.... I've been working on the Jeep, its just not anything really glamorous. I've been selling some parts to recoup some of the $$ I've dumped into this thing recently.

I've ordered my new shocks. Installed some new aux. reverse lights. Been planning out some rock lights that I think ya'll will dig. Replaced a battery, finally. And balanced the tires!

Actually the tire balancing was pretty trick. I'd been considering the dyna beads ( www.innovativebalancing.com (http://www.innovativebalancing.com) ), but knew it could be done cheaper somehow. I searched around and found where people had been running airsoft pellets with varying degrees of success. (Same principle as the dynabeads.) One day I figured what the hell and checked out the price of them at Wal-Mart. It must have been my lucky day, because they had just marked them half off. So, I picked up a container of 10,000 pellets for ~$16.00 and snuck them into the house with me. The next day I came up with a super high tech way to divy the pellets out without having to count up 2,500 four times or look like a crack dealer buying a triple beam. I took 4 zip lock bags and a 1 cup measuring cup, and scooped 1 level cup into each bag, repeating until I was out of pellets. I want to say it ended up being 3 or 4 scoops each. Then I sealed up the bags and headed down to the local post office to measure them up. (Yeah - you should have seen the looks.) I ended up with 10.1 oz in 2 bags and 10.3 oz in the other 2. The innovative balancing web site recommends 8 ozs per tire for a 35x12.50 r 15, but I'd rather have too much than not enough. I thought 2 thenths of an inch was pretty darn good considering my measurement method, and called it good. I marked the 2 heavier bags for the front tires and put the lighter ones in the rear. Won't make much of a difference after I rotate the tires, but I figured it wouldn't hurt.

After all of that, I headed to the tire shop next door, and had them break the bead on each tire, I carefully dumped in one bag, and let them re-seat the bead. Yeah, I could have done that myself, but for a total of ten bucks, the time saved was priceless. Got the tires mounted back up, and took off for a test drive.....

I'm happy to say that they worked great! Still have a little bit of a wobble in my steering wheel, but I think that's mostly due to my bent tierod. I'd say that this is definitely something you guys aught to consider if you're tired of unbalanced tires or losing lead wheel weights after one wheeling trip.

Hurricane 4x4
11-07-2005, 08:34 PM
well you might get a chance to recoup some more funds because I think I may want to buy those trackbars from you...

but first i gotta recoup some funds! time to search the basement and put some crap on ebay

JeepinHank
04-18-2006, 11:54 AM
Well, it's been a while with no updates, but I've been busting my ass at work, and haven't had much time to put into the mistress.

As you may or may not know, My last wheeling trip was December 10th, and I managed to break my junk less than an hour into the trip. Broke a shock mount, causing me to drop a spring after a hard bounce, which caused me to break my driveshaft yoke. The driveshaft was a little too short, and when the wheel well hit the tire, it fully extended the shaft, and the extra resistance on the tires caused it to twist off and break.

The ensuing recovery project consumed the rest of the weekend, and I finally drove it home with one rear shock, front wheel drive, and no locker late Sunday night.

Since that debacle the jeep has sat other than the occassional start up, warm up, and moving around the yard because of a nagging feeling of guilt.

Then last week, as always this time of year, the bug bit me again. I'm ready to go wheeling again Dammit!
I started tinkering again, and working up my to do list. My first priority was to get the driveshaft problem fixed. The dealer wanted ~$75 for the yoke, and, being the cheap bastard I am, I refused to do that. Thanks to Ken L on here, I got a used driveshaft complete for $50 + shipping.

I then took my 2 driveshafts to the best shop in town and had them lengthen my old shaft 1 3/8" and install Ken's old yoke. $200 and a day later, I had a driveshaft as good as new. They shot peened all of my old parts and installed 2 new dana spicer u-joints.

Driveshaft - Check.

Next on the list was shock mounts. Triangulating them sounded appealing, but I just couldn't decide on a good way to mount them on the frame side, so I started the task of designing some that would mount similar to stock and be bomb proof. I feel that I succeeded. I started with an 11" piece of 2"x4"x0.25" rectangular tubing, and proceeded to cut it in half with a 3.5" hole saw in my drill press, and my angle grinder. That gave me a radius for the axle tubes. Then I marked and drilled my hole for the shock eyes, and commenced to cutting out the shapes of the shock mounts that look somewhat similar to stock. They'll hang about 2" below the axle tube, but they're angled back at 45* (like this \ from the side with the jeep facing <- that way) so they should be able to slide up and over anything they hit. That should allow me to run a shock that's long enough to use my suspension without bottoming out on uptravel.

The shock mounts are cut out, but need to be cleaned up a bit more so they're nice and pretty before I install them.

Hopefully I'll be able to get them cleaned up and welded in this evening.

That's it for now. I'll take a few pics and post them up tonight.

JeepinHank
09-05-2006, 03:58 PM
Damn, it has been a while hasn't it?

The last trip out I broke my rear axle (Ford 8.8). Just about everything inside the differential was toasted. I sheared the cross pin, which found its way into my ring and pinion and chewed them up, the resulting carnage caused me to break my mini spool, and somewhere along the lines, I warped my carrier. I have all of my parts ready to go, but I haven't had a chance to press the new bearings onto the new-to-me carrier.

I hope to be making a run this weekend to pick up an old XJ to butcher up and scavenge parts from, so I'll be out in the shop and plan to take a few pics while I'm out there. Anyway I haven't made a run since this May, and I'm really feeling depressed and missing going out and abusing my ZJ. Considering I've become quite adept at tearing it up, leaving it broke is probably the only way I'll be able to keep it in one piece.

:rant:

I do have some pics to post up, but they're at home and I'm at work. I won't promise to put them up tonight because I seen to be the master of not following through with those comments, but we'll see.

Firestarter
09-06-2006, 05:30 PM
i see you have some Bilstein 5150s. How do you like them?

I need new shocks for my WJ and although i'm short on cash it's not something i'd like to cheap out on.

Also, what valving did you use?

JeepinHank
09-07-2006, 08:57 AM
They were OK. I don't run them anymore because I lifted more, and needed more travel. I got them used, so I'm not too sure on the valving and all. I don't know how well the previous owner treated them, but I maxed them out on compression and extension and never seemed to have a problem.