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View Full Version : Finally "Finished" the ZJ



msvance
12-02-2004, 02:32 PM
Just thought I would share some pics. I'm currently doing a full write-up that I will post when completed.......

Pre-Build Specs
98 ZJ w/ 5.9
3.5" Tera Lift w/ 1" BB - ALL Adjustable Control Arms (short)
Sway Bar Disco's Front & Rear
32" BFG Mall Terrains
D30 - 4.10 & tru-trac
AL44 - 4.10 * factory trash lock
NP231 - Heavy Duty & 4:1 low
ARB Front Bumper
Custom Roof Rack
Custom Rock Sliders
Turbo City Dual Air Filter
"Blinged Out" Hood Vents
Blah, Blah, Blah

Post-Build Specs
~6" lift - 4.5" Rubicon Express springs on top of Radius arms up front and 3.5" front Tera springs in the rear
Custom Adjustable & Lengthened Ford Radius Arms up front (passenger side wristed) w/ RE Superflex Joint mated to the end & Custom Adjustable LongArms in Rear (2.5" 0.25" wall tubing, poly/RE Super-Flex Joint combo)using Clayton's Subframe - still 5-link
Front Ford "full-width" hp 44 - 4.10, lock right, warn lock-outs, over-the-knuckle steering (using 3/4" heims and 1.25" 3/8" wall tube)
Rear AL44 - 4.10 & welded :D (using 2" thick wheel adapters to match width and convert to 5x5.5 lug pattern)
Extensive trimming

and best of all 37x12.50 IROK Radials!!! :twisted:

It drives and handles GREAT (besides a little body roll w/o any sway bars. some sort of anti-rock system will come someday) The only things left for now are bumpstops/limit straps, finish the bumper I am making, build new/modify existing rock sliderz and a few other little odds and ends. A full write-up is currently in progress..........

Before Fender Trimming

http://img.photobucket.com/albums/v170/jeepcjzj/ZJ%20build-up/DSC00002.jpg

http://img.photobucket.com/albums/v170/jeepcjzj/ZJ%20build-up/DSC00003.jpg

http://img.photobucket.com/albums/v170/jeepcjzj/ZJ%20build-up/DSC00004.jpg

After Extensive Trimming

http://img.photobucket.com/albums/v170/jeepcjzj/ZJ%20build-up/DSC00020.jpg

(it actually sits 0.5" higher in the rear than the front. The pic does make it look like it's squatting tho)

http://img.photobucket.com/albums/v170/jeepcjzj/ZJ%20build-up/DSC00021.jpg

http://img.photobucket.com/albums/v170/jeepcjzj/ZJ%20build-up/DSC00022.jpg

http://img.photobucket.com/albums/v170/jeepcjzj/ZJ%20build-up/DSC00017.jpg


a few front yard wheelin' pics :D

http://img.photobucket.com/albums/v170/jeepcjzj/ZJ%20build-up/DSC00026.jpg

http://img.photobucket.com/albums/v170/jeepcjzj/ZJ%20build-up/DSC00029.jpg

http://img.photobucket.com/albums/v170/jeepcjzj/ZJ%20build-up/DSC00028.jpg

http://img.photobucket.com/albums/v170/jeepcjzj/ZJ%20build-up/DSC00031.jpg

http://img.photobucket.com/albums/v170/jeepcjzj/ZJ%20build-up/DSC00039.jpg

http://img.photobucket.com/albums/v170/jeepcjzj/ZJ%20build-up/DSC00037.jpg

a pic next to my CJ w/ flat 36" SX's. The 37" IROKS are HUGE and definitely look real money!

http://img.photobucket.com/albums/v170/jeepcjzj/ZJ%20build-up/DSC00025.jpg

MaineZJ
12-02-2004, 02:38 PM
Wow, a 44A in the rear :flipoff:

It's looking good, glad to finally see someone hacking a 5.9 :thumbsup:

BMRisko
12-02-2004, 02:45 PM
Looks sweet!!

Kraqa
12-02-2004, 03:05 PM
hey main look at JayDee, he has a very nicly modded 5.9. silver.

MaineZJ
12-02-2004, 03:46 PM
I thought JD's was less cut...

BMRisko
12-02-2004, 05:03 PM
I thought JD's was less cut...

His is MORE cut, well atleast the square-cut front fenders.

msvance
12-02-2004, 05:16 PM
thanks for the compliments!

Yeah, I'm going to wheel the AL44 until it blows then swap in a 9". We'll see how it holds up to being welded :shock: I have a lot of plans for the rear end (which includes some "body modifications") that I want to do at the same time as the 9" so I really didn't feel like opening that can of worms right now.

Yeah, I tried to cut just the amount needed to stuff the tires and keep it as clean looking as possible. no real need to cut any more than that. I didn't know if 6" of lift and the ability to fully stuff the 37's while barely noticing it was cut was going to be achievable or not, but I think it came pretty close. I didn't post any pics of the fenders completely trimmed out with the door molding stuff, but it turned out real real clean! The wife was even impressed which was a pretty big deal :D IIRC, I have it set where I have ~6" up / 8" down shock travel up front and 3.5 / 5.5 in the rear, using rancho 9000 shocks all around.

Cue-Ball
12-02-2004, 07:30 PM
Looks GREAT! :D

nate
12-02-2004, 11:55 PM
Nice! I bookmarked this page to give me ideas of what to trim. Really clean job.

It does seem like more than a 6" lift though, did you measure before/after?

snarfer86
12-03-2004, 02:04 AM
NICE!! ultimately i want my rig to be kinda like that. :D and where did you get that sexy grill?

gearhead313
12-03-2004, 10:15 AM
Looks good man.... just makes me remember how tall mine was on my Iroks: :shock:

http://img.photobucket.com/albums/v123/gearhead313/zj%20pics/DSC01215a.jpg

msvance
12-03-2004, 10:31 AM
thanks again for the compliments!!

Nate - Yeah, I was really excited about the outcome of the trim job. I got really really excited when my wife told be she couldn't tell anything different and that was before the trim molding. When I finish the write-up, I will provide some more detailed trim pics and I have a pic of the packaging for the molding I used to trim with. $5 for a 10' section! Also, I don't think I can really get the exact lift since I think I forgot to take the same height measurement as before with my old tires :( the way i estimated 6" is by knowing that the front coils are brand new 4.5" RE springs and the mount is raised 1.5" higher than the mount on the old d30. also, I assumed a f-r swap provides 3" lift (what does it really :?: ), and added that to 3.5" front Tera springs that have been supporting the 5.9 and an ARB for 80K miles or so. The rear is sitting slightly higher than the front by like 1/4 to 1/2" which is the way I prefer it. It may be at 6.5" but I don't think it's any taller than that.

snard - I think the grille is from stull industries. here's a front shot of it. i cut the lower few slots off to make room for the bumper I'm making, but not yet installed. i'll have to cut the middle part out when I add the winch....

http://img.photobucket.com/albums/v170/jeepcjzj/ZJ%20build-up/DSC00008.jpg

gh - thanks. btw, how much lift did/do you have? definitely looks quite a bit taller than mine. Everyone that's see's it keeps saying how low mine looks, which is exactly what I was going for! the roof of mine is lower than the cage of the cj which is on flat 36" SX's right now.

thanks again for the compliments!!

gearhead313
12-03-2004, 10:49 AM
gh - thanks. btw, how much lift did/do you have?


In that pic, i have 7.5" re springs + 2" tera boost. the back i have my front 4.5" re springs. If you want to get technical, 7.5 + 2 = 9.5"

i really dont feel like getting into that again... :roll:

msvance
12-03-2004, 11:16 AM
gh - thanks. i wasn't trying to bring anaything up, just wanted a comparison since the 36" bias IROK mesures the same height as the 37" radial IROK (supposedly). i just now noticed your sig which would have answered my question....

Kraqa
12-03-2004, 02:02 PM
i got a friend that will be puting my old ford 9" (i don't know if anyof you remeber that anchore) and a HPd44 front end in and he has a few Q'a about reusing the radius arms. can you snap a few close up pics? the more the marrier. and did you wrist em?

msvance
12-03-2004, 02:11 PM
yep, it's wristed, this pic shows pretty much everything....

http://img.photobucket.com/albums/v170/jeepcjzj/ZJ%20build-up/PICT0224.jpg

basically 2.5" RE Superflex joint welded to a piece of stock that was turned down and threaded to mate to the 2.5" tube that was tapped and welded to the radius arm. you can also see how the radius arm was wristed. there are easier ways to do it I am sure, but the joint end is the same way the rear longarms are made so we did it that way to keep it similar. let me know if you have any questions......

Kraqa
12-03-2004, 02:27 PM
ya ok perfict he just doesn't have any pis of it. this will give him some good ideas.

man that hammerite is getting popular.

POSJEEP
12-05-2004, 07:11 PM
i thought i was going to be the only one running this set up!
looks killer!
any pics of the rear set up?
and are you going to truss the front axel?

msvance
12-06-2004, 10:32 AM
looks killer!

thanks!!


i thought i was going to be the only one running this set up!

I think there are actually several running the front hp44 w/ radius arms. the one that comes to mind first is timzjatl or something like that, but I am suprised that more people don't use the radius arm set-up! it's super simple and very functional, especially when wristing and using joints on the ends instead of the stock bushings.


and are you going to truss the front axel?

no intentions to truss at this point


any pics of the rear set up?

this is the only pic I have right now. pretty standard 5-link using claytons sub-frame, however the arms aren't quite so standard :D definitely a little overkill. actually, when i triangulate the uppers (same time as the 9"), i may redo those so that aren't quite so beef.......

http://img.photobucket.com/albums/v170/jeepcjzj/ZJ%20build-up/PICT0225.jpg

nate
12-06-2004, 11:00 AM
Cool!

You that's funny, I did the same thing on my 8.8 to extend the rear bumpstops. Spring perches aren't just for springs :D

FinlayZJ
12-06-2004, 12:29 PM
Looks good. If you search on NAGCA NBaldwin and JayDee both posted pics of how the rotated the spring cups to get rid of that bow in the spring on the front end. It's pretty simple if I recall, and if that bow annoys you.

msvance
12-06-2004, 01:01 PM
finlay - thanks! actually the perches are already rotated 180 degrees to minimize the bow, but it still bows pretty good. at some point, I could shim the mounts or make a new upper mounting point, but I have no issues with it the way it is for now. it does look pretty silly when the front is slammed tho :shock:

http://img.photobucket.com/albums/v170/jeepcjzj/ZJ%20build-up/DSC00032.jpg

POSJEEP
12-07-2004, 12:22 PM
i like the fact you used bushings instead of hiem joints i would think it makes for a smother ride and they are cheaper.
what do you think of relocating the shock mounts and lower control arm mounts for clearence, also do the front radius arms act as bump stops?

msvance
12-07-2004, 02:25 PM
POS - I actually used RE superflex joints (johnny joints) for the ends. I like them much better than bushings and heims, but not really cheap. also, if you're talking about shocks in the rear, I did move the mount up to the middle of the axle tube. The main reason was because they were too short with the lift, but also to get out from under the axle tube. I haven't cut that part of the bracket of yet tho. I wanted to see how it turned out before I made that permanent change. I would love to move the control arm mounts up, but didn't want to mess with this axle. I'll wait until the 9" for all that.

As far as the radius arms go, I do not intend for them to act as a bumpstop. I haven't installed my bumpstops yet, but they will be the standard bumpstops so that I don't crush the unibody. The radius arm actually just rubs the bottom of the unibody at full stuff so i'm able to get full flex. When setting it all up, I was hoping that was going to be the case and glad it worked that way.

Hopefully this makes sense and answers your questions. glad you like it!

SOLITUDE
06-29-2007, 03:30 PM
I know, I know... Way to revive a dead thread.

But....
I'm actually about to start the exact same build... I want to know if you can answer a few questions for me to save loads of time on research.

I'm swapping in a '77 Bronco (cast) 44 w/ radius arms. What frame mounts are you using for the front? What extensions are you using on the arms? Extension length? Where did you find the johnny joints and threaded rods?

I'll be running a 44al as well in the rear. I'm swapping a Bronco 44 in and I understand they are about 3" shorter than a "full-size" 44? What is the WMS on your "full-size" 44?

P.S. I really like your rig, and it has provided loads of inspiration and help to me.

DND
06-29-2007, 04:22 PM
I know, I know... Way to revive a dead thread.

But....
I'm actually about to start the exact same build... I want to know if you can answer a few questions for me to save loads of time on research.

I'm swapping in a '77 Bronco (cast) 44 w/ radius arms. What frame mounts are you using for the front? What extensions are you using on the arms? Extension length? Where did you find the johnny joints and threaded rods?

I'll be running a 44al as well in the rear. I'm swapping a Bronco 44 in and I understand they are about 3" shorter than a "full-size" 44? What is the WMS on your "full-size" 44?

P.S. I really like your rig, and it has provided loads of inspiration and help to me.

Hmmm I hope you're not looking to msvance for a reply as it's been over a year since his last board activity.

SOLITUDE
06-29-2007, 04:28 PM
yeah I know... But, I at least asked.

adam99wj
09-10-2007, 09:15 PM
hey solitude the 77 ford 44s in the EBs and f150s do not have cast wedges they are welded on , the 78-79 are cast , but the 77 f150hp44 is the better one to use , if you use the EB one you could swap the short side axle shaft with f150s to have 297 u joints and use the outter stub and a custom inner for the long side , EBs have the peunny little u joints

msvance
02-26-2015, 11:35 PM
http://tapatalk.imageshack.com/v2/15/02/26/cf9429d42cc0de0132ddf820481efdf3.jpghttp://tapatalk.imageshack.com/v2/15/02/26/b9a07aa539f13efb6be3de43170c8e5d.jpghttp://tapatalk.imageshack.com/v2/15/02/26/4f47ffa8b8c4cf947ecb1bd7b3a9acf0.jpghttp://tapatalk.imageshack.com/v2/15/02/26/751da950502087c4c29e5be2e3e7c2eb.jpghttp://tapatalk.imageshack.com/v2/15/02/26/38d95c9ffcc8ac1ef0e5c67abae03a36.jpghttp://tapatalk.imageshack.com/v2/15/02/26/fabc657b7cb137f3ad813583afa37d87.jpghttp://tapatalk.imageshack.com/v2/15/02/26/2765b135cc5743c11b1789189b6a2ad2.jpghttp://tapatalk.imageshack.com/v2/15/02/26/54b84e7780cd68a1ddb2ac6bb280946d.jpghttp://tapatalk.imageshack.com/v2/15/02/26/6d8231195f2f606b10793d70bbfe3635.jpghttp://tapatalk.imageshack.com/v2/15/02/26/012ceb6cbba24007a3a719bf15c02047.jpghttp://tapatalk.imageshack.com/v2/15/02/26/ebbb8cca6def2693b547e5d85ffb60fb.jpg

msvance
02-26-2015, 11:42 PM
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msvance
02-26-2015, 11:45 PM
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msvance
02-26-2015, 11:59 PM
Sorry for the delayed posts but my zJ took the back burner to life for about 7 years during which time it sat and never ran. Finally revived it late last year, triangulated the rear uppers to remove the rear track bar and built a brace to lock the center section from the diff cover to the bridge for the upper links. took it to uwharrie exploded the rear and front axle at the same time so I contacted some awesome guys at east coast gear supply and ordered up alloy axles front and rear, yukon Joints, replaced my welded carrier with new carrier, Spartan locker and I'm sure a few other things and got it going again. Also took the time to replace the rocker with metal tubing and finish the front bumper I started 10 years ago. Took it out to durhamtown plantation in GA last weekend and had a great trip although it was limited and shortened due to blown power steering hose. Hate it when $15 and 5 min of time messes up a fullbday of fun. It was still a blast and awesome. To return home in one piece. Finished off the day muddin in my sons Avalanche which use to be my tow rig. Anyhow, enough ramblin. Thought I would post up some pictures. If anyone has any questions or wants to know any details, let me know.

msvance
02-27-2015, 12:03 AM
Solitude- I know it's way late but to answer your question my radius arms included the threaded rod were custom built and lengthened by my bro in law who owns a machine shop. Can't remember where I got the joints themselves. I used claytons subframe to simplify things. The front was full width from 78/79 bronco and I used 2 or 2.5" spacers in the rear to match the front width. Hopefully this helps someone.

msvance
02-27-2015, 12:07 AM
Final thing to add is its unbelievable how much better it drives and handles with the rear locker vs being welded up. The ZJ truly could be a daily driver again but about 100 miles a day at 8 mpg using premium negates that a little. I have been driving a couple days a week though just to ensure everything is holding together. Anyhow, that's all the update I have. Can't wait to get back to wheelin again. Next up is getting my cj going again. Got new 60/14b and 42's sitting in the garage ready to go!!

msvance
02-27-2015, 12:11 AM
Just for show, my old Avalanche 2500 that I gave to my son for his 16 bday along with lift, rims and tires - 37" nitto trails on 20" ballistic jesters. We added light bar and projectors over Christmas. It's been fun working on the toys gain!

http://tapatalk.imageshack.com/v2/15/02/26/efe3e3f280c68496f45360bb6c32ac45.jpg

UTChavok
02-27-2015, 01:04 PM
Nice man glad to see you back in it. Jeep looks good!

K2
02-27-2015, 02:52 PM
Do you have cooling issues with the winch so close and covering so much of the radiator, and no slots in the rear portion of your bumper?

msvance
02-27-2015, 05:28 PM
Utchavok- thanks. I forgot how much I missed it!

K2-I didn't have any cooling issues at all on the trail and have not had much time on the street yet but no issues there either. I do have the 5.9 so I have electric fans which help. true test will be this summer.... My goal was to tuck it in as much as possible and I definitely ended up doing that and love how it turned out. I didn't have one scratch on the bumper after wheelin last weekend.

msvance
03-20-2015, 11:10 PM
Got ps hose fixed so I'm Headed back to durhamtown tomorrow To check everything out. Should be a good time. I'll post updated pics after trip.