PDA

View Full Version : OGDAK's ZJ moving 12/04/2022



Pages : [1] 2

ogdak
11-24-2005, 05:00 PM
Hi,
So it did take a while bud let's start a topic about my "project".
The guide in this topic are the picture's i took in chronological order
Therefore things might look a bit chaotic every now and then.
As i get closer to the present time, things will get better documented, needless to say most off it will be common knowledge
on this board. Since i have searched a lott on nagca and mallcrawlin.
But now lets start with how this "crazy" hobby started when i bought our 1994 ZJ5.2LTD in October 2003 as a DD.
These are the only pictures i have of our ZJ where it is stock, clean and polished
http://www.ogdak.eu/images/2003-10/DSCF1004.JPG

http://www.ogdak.eu/images/2003-10/DSCF1005.JPG

http://www.ogdak.eu/images/2003-10/DSCF1006.JPG

http://www.ogdak.eu/images/2003-10/DSCF1007.JPG

http://www.ogdak.eu/images/2003-10/DSCF1008.JPG

November 2003

The first event i went to do some offroading, it was held on a dirt bike track.
http://www.ogdak.eu/images/2003-11/PB090012.JPG

http://www.ogdak.eu/images/2003-11/PB090013.JPG

http://www.ogdak.eu/images/2003-11/PB090014.JPG

http://www.ogdak.eu/images/2003-11/PB090016.JPG

http://www.ogdak.eu/images/2003-11/PB090017.JPG

http://www.ogdak.eu/images/2003-11/PB090020.JPG

http://www.ogdak.eu/images/2003-11/PB090021.JPG

And after this weekend the ZJ has never been clean.
Along with it came the first costs
General Ameri Trac TR 235/75*15TR
http://www.ogdak.eu/images/2003-11/ameritrac.jpg

I also found it necessary to take the pitman-arm off, why? I can't remember
http://www.ogdak.eu/images/2003-11/Dscf1041a.jpg

http://www.ogdak.eu/images/2003-11/Dscf1042a.jpg

More to come

ogdak
11-24-2005, 06:15 PM
A little jump to february 2004
As far as i can see according to my jeep bills no problems what so ever this past winter.
Bud I did buy the official FSM and owners manual an absolute must if you are a DIY person.
Another very functional tool a "Schaarvetspuit".
http://www.ogdak.eu/images/2004-02/schaarvetspuit.jpg

A recreational area nearby called the "posbank" near the city Arnhem, no offroading allowed however.
http://www.ogdak.eu/images/2004-02/DSCF1098.JPG

http://www.ogdak.eu/images/2004-02/DSCF1101.JPG

My youngest fan in this picture 1 year old, now a days almost 3.
http://www.ogdak.eu/images/2004-02/DSCF1100.JPG

Event on a dirt bike track in "Groesbeek" near the city Nijmegen, damages
1 rear bumper reflector did cost me �18 by the stealership and
1 head lamp glas, new unit went for �192.80 to be exact, have the invoice right here.
Had a fun day though.
http://www.ogdak.eu/images/2004-02/DSCF1103.JPG

Another event this month in "Overloon", offroading in the snow.
No damages this time, only a tired son.
http://www.ogdak.eu/images/2004-02/DSCF1137.JPG

http://www.ogdak.eu/images/2004-02/DSCF1150.JPG

By now the 4x4 virus(read as JEEP virus) really hit me, it is time for mod's
So I ordered a BB, an ACOS kit and a set off BPE's in th US
Waiting for the goods I started looking localy for wheels and tires.
31" looked fine since this car was still our DD
Succeeded with a set off US wheel "blade" 15x7 with 31"x10.5lt15 bf at's
Since my BB was not in yet, I put the wheels on just for the looks and off course the pic's
http://www.ogdak.eu/images/2004-02/DSCF1117.JPG

http://www.ogdak.eu/images/2004-02/DSCF1119.JPG

http://www.ogdak.eu/images/2004-02/DSCF1120.JPG

http://www.ogdak.eu/images/2004-02/DSCF1121.JPG

http://www.ogdak.eu/images/2004-02/DSCF1123.JPG

http://www.ogdak.eu/images/2004-02/DSCF1124.JPG

In the meantime the sound off the exhaust was becoming louder
http://www.ogdak.eu/images/2004-02/DSCF1127.JPG

So the first time off electric welding to an exhaust.
http://www.ogdak.eu/images/2004-02/DSCF1131.JPG

So got the first 6 months covered, more to come

ogdak
12-01-2005, 03:24 PM
as promised march 2004

In the meantime took care of some small repairs,
Brakeshoe's for the emergency brake, oilseal rear DS and a torn CV-boot on the left
Meanwhile the stuff I ordered arrived, took well over 1 month.
So lets get on with it, first in the rear.
http://www.ogdak.eu/images/2004-03/DSCF1151.JPG

2" BB in place.
http://www.ogdak.eu/images/2004-03/DSCF1152.JPG

So some extra space in the wheelwell here with GT 235/75*15 which is almost equal to a 29" tire.
http://www.ogdak.eu/images/2004-03/DSCF1153.JPG

Up Front
http://www.ogdak.eu/images/2004-03/DSCF1154.JPG

Obviously these speak for themself, have the ACOS'ses on for a year and a half and no regrets what so ever.
http://www.ogdak.eu/images/2004-03/DSCF1155.JPG

in detail
http://www.ogdak.eu/images/2004-03/DSCF1157.JPG

here a half...
http://www.ogdak.eu/images/2004-03/DSCF1158.JPG

and here the end result.
http://www.ogdak.eu/images/2004-03/DSCF1159.JPG


And yes still on "small" tires, With an Arb bull-bar on the way it is kind off a waste to cut up a bumper.
In the meanwhile changed diff oil and pimped the cover.
bling-bling
http://www.ogdak.eu/images/2004-03/DSCF1166.JPG

grounded
http://www.ogdak.eu/images/2004-03/DSCF1169.JPG

green gehamerslagd(t)(wont know how to translate this, so learn dutch)
http://www.ogdak.eu/images/2004-03/DSCF1171.JPG

and back in place.
http://www.ogdak.eu/images/2004-03/DSCF1172.JPG

Time to start with the bull-bar.
http://www.ogdak.eu/images/2004-03/DSCF1173.JPG

The thing itself
http://www.ogdak.eu/images/2004-03/DSCF1174.JPG

All bits and pieces.
http://www.ogdak.eu/images/2004-03/DSCF1175.JPG

Soon to be continued.

ogdak
12-01-2005, 03:26 PM
A magnum 8000 winch.
http://www.ogdak.eu/images/2004-03/DSCF1176.JPG

Everything sorted out.
http://www.ogdak.eu/images/2004-03/DSCF1177.JPG

Preparation
http://www.ogdak.eu/images/2004-03/DSCF1178.JPG

It's dark and late.
http://www.ogdak.eu/images/2004-03/DSCF1179.JPG

Winch mounted.
http://www.ogdak.eu/images/2004-03/DSCF1180.JPG

The other side.
http://www.ogdak.eu/images/2004-03/DSCF1183.JPG

Brackets and "evap canister" shield in place.
http://www.ogdak.eu/images/2004-03/DSCF1182.JPG

Almost done, 31" on and some trimming on the inner fenders.
http://www.ogdak.eu/images/2004-03/DSCF1184.JPG

Next day time to check the winch on a jeep event in "Zeumeren"
http://www.ogdak.eu/images/2004-03/DSCF1185.JPG

http://www.ogdak.eu/images/2004-03/DSCF1186.JPG

Later that week, some flex pic's.
http://www.ogdak.eu/images/2004-03/DSCF1187.JPG

http://www.ogdak.eu/images/2004-03/DSCF1188.JPG

Nice fit.
http://www.ogdak.eu/images/2004-03/DSCF1189.JPG

http://www.ogdak.eu/images/2004-03/DSCF1190.JPG

http://www.ogdak.eu/images/2004-03/DSCF1191.JPG

So that was march 2004 more to come.

steves88vb
12-01-2005, 05:27 PM
just wondering why is there 8 slots in that Zj grille??????

jeepnzj1
12-01-2005, 05:54 PM
wonder why the last post is all xxxx for me any one else

1996cc
12-01-2005, 08:22 PM
just wondering why is there 8 slots in that Zj grille??????


Same reason they all have 8.

ATL ZJ
12-01-2005, 08:27 PM
Are those the foreign BFG ATs? all the ones I've seen don't look like that. Maybe retreads?

steves88vb
12-01-2005, 10:45 PM
Same reason they all have 8.

yeah YOUR right, my Zj is just a Reject model and has 7 slots

zj95
12-02-2005, 03:44 AM
yeah YOUR right, my Zj is just a Reject model and has 7 slots

93-95 have 8 slots and 96-98 have 7

ogdak
12-02-2005, 04:16 AM
Are those the foreign BFG ATs? all the ones I've seen don't look like that. Maybe retreads?

I do not know wether there is a difference in US or European market.
But the are not retreads.

And for the number off "slots", 8 is indead stock for '93 through '95 models.

jeepnzj1
12-02-2005, 01:08 PM
ive seen those bfg's before they have them here this is an awsome write up its a trip to see how its done in other countrys

Cue-Ball
12-02-2005, 01:50 PM
Nice write up.

ogdak
12-06-2005, 01:43 PM
Nice write up.

Thnx,

Here is some more.

So after March comes April 2004.
Did not do a lot this month, went to the "maaasvlakte" near the port of Rotterdam.
Was fun due to good weather and company.
So just some pic's
http://www.ogdak.eu/images/2004-04/DSCF1217.JPG

http://www.ogdak.eu/images/2004-04/DSCF1219.JPG

Some people think you can swim with a SUV, fortunately Droopy was nearby
http://www.ogdak.eu/images/2004-04/DSCF1223.JPG

http://www.ogdak.eu/images/2004-04/DSCF1224.JPG

http://www.ogdak.eu/images/2004-04/DSCF1226.JPG

from left to right
Eelco, Jeeped, Droopy en Jeepee
http://www.ogdak.eu/images/2004-04/DSCF1227.JPG

So afterall some maintenance issue's, leaky oilseal on the right rear axle.
So time for fresh oil and a diff cover paintjob.
An opened diff
http://www.ogdak.eu/images/2004-04/DSCF1231.JPG

The leaking seal, €16,51 from the stealert.
http://www.ogdak.eu/images/2004-04/DSCF1232.JPG

piece off iron
http://www.ogdak.eu/images/2004-04/DSCF1233.JPG

nicer diff cover
http://www.ogdak.eu/images/2004-04/DSCF1234.JPG

Famous mastershaft and c-clip
http://www.ogdak.eu/images/2004-04/DSCF1235.JPG

new vs. old
http://www.ogdak.eu/images/2004-04/DSCF1236.JPG


Cleaned
http://www.ogdak.eu/images/2004-04/DSCF1238.JPG

All for now, latersz

Cue-Ball
12-06-2005, 01:52 PM
Very nice detail in your posting. Awesome job.

ogdak
12-08-2005, 04:21 PM
May 2004

So got a few things done like longer shocks, adj. TB's, did not make tha many pic's.
After getting my rocker panels dented, I desided to get some protection.
Liked these a lot (http://www.jksmfg.com/supernerfs.htm).
So went to a friend who is very good on a drawing board and with iron.
He came up with this
http://www.ogdak.eu/images/2004-05/DSCF1249.JPG

http://www.ogdak.eu/images/2004-05/DSCF1250.JPG

So after one day, the unpainted result
http://www.ogdak.eu/images/2004-05/DSCF1251.JPG

So the next day went offroading with some www.jeepforum.nl guys/girls in "veldhoven". Sorry no pic's

So 1 week later, got the SB off to get powder coated, and went playing
http://www.ogdak.eu/images/2004-05/DSCF1267.JPG

http://www.ogdak.eu/images/2004-05/DSCF1268.JPG

http://www.ogdak.eu/images/2004-05/DSCF1269.JPG

http://www.ogdak.eu/images/2004-05/DSCF1270.JPG

flex-out
http://www.ogdak.eu/images/2004-05/DSCF1271.JPG

flex-in
http://www.ogdak.eu/images/2004-05/DSCF1272.JPG


So meanwhile it is june 2004
The SB are ready and mounted
http://www.ogdak.eu/images/2004-06/DSCF1284.JPG

http://www.ogdak.eu/images/2004-06/DSCF1285.JPG

detail
http://www.ogdak.eu/images/2004-06/DSCF1286.JPG

more detailed
http://www.ogdak.eu/images/2004-06/DSCF1287.JPG

Also notice the spots where I dented my rockers
http://www.ogdak.eu/images/2004-06/DSCF1289.JPG

Topview
http://www.ogdak.eu/images/2004-06/DSCF1290.JPG

So all for now, enjoy

Kraqa
12-08-2005, 05:29 PM
not to be a bitch but in the pic of your rear BB install the coil isolator go's between the coil spacer and the spring. not between the coil spacer and the coil bucket.

ogdak
12-08-2005, 05:45 PM
I agree to do it that way, makes more sense.
However, it was a nicer fit this way as a remember.
That was over a year ago, they are already long gone.

Jeepxtrem
12-09-2005, 05:41 AM
Great zj Ogdak. I want put a from ARB bumper, but is not very heavy?

ogdak
12-09-2005, 09:59 AM
If I remember correct about 40~45Kg without the winch.

ogdak
12-14-2005, 07:23 PM
So Left off last time with the SB's
So here is one more.
http://www.ogdak.eu/images/2004-06/DSCF1291.JPG

Nice thing off those heavy duty custom SB's is, is that you can put a jack underneath and lift up half the ZJ
http://www.ogdak.eu/images/2004-06/DSCF1293.JPG

Just one single pic off a weekend offroading in "schaijk"
http://www.ogdak.eu/images/2004-06/DSCF1294.JPG

So now time for a real job, we are planning to go to Sclayn in Belgium early next month.
Bud with 3 kids in the backseat it is nice to have a working CC.
So had a change to get the system put under pressure to determine what caused the CC not to work, at a
local german dealership. Happens to be one off the mechanics used to work for our well known stealerships.
He told me 90% off not working CC's in Grand's are caused by leaky evaporator's.
So went to a local airco specialist for a "track & trace", they did confirm on the 90% rule.
So the T&T did cost me €160, left me with a working CC for about 1 week.
So went back to them to have one of the mech's go over, under and in the ZJ with a UV-light and yellow goggles on.
And finally, looking through a very small hole in the heater-a/c unit found the leak, the predicted evaporator core.
They gave me a quote for approx €1000 to fix it, the evaporator is only €140 bud it is a time consuming repair
because the have to get the dash off and the complete heater-a/c unit out to change the evaporator core.
So I decided to do it myself and save like €800, went home with the new evaporator core.
Grabbed the FSM and started removing the dash, also took out the right chair for some extra space to work in.
http://www.ogdak.eu/images/2004-06/DSCF1295.JPG

http://www.ogdak.eu/images/2004-06/DSCF1296.JPG

Obvious the "black box" is the heater-a/c unit, with the evaporator core in it.
Goes from the right side right up to the steering column.
Consist off a top and bottom half, copper pipe's on top is from and to the heater core.
http://www.ogdak.eu/images/2004-06/DSCF1297.JPG

http://www.ogdak.eu/images/2004-06/DSCF1298.JPG

http://www.ogdak.eu/images/2004-06/DSCF1300.JPG

The dash
http://www.ogdak.eu/images/2004-06/DSCF1301.JPG

heater-a/c unit out
http://www.ogdak.eu/images/2004-06/DSCF1302.JPG

and opened
On the left, blower motor.
In the middle, evaporator core.
On the right, heater core.
http://www.ogdak.eu/images/2004-06/DSCF1303.JPG

The leakage is on the right side cant be seen with the bare eye. Normally for proper operation the system would be on 12 bar
so you don't need that big off a hole. On this side there was a lot off dirt and leafs.
So made a filter, from a panty off my .... on the outside right on top off the firewall where the air comes in.
http://www.ogdak.eu/images/2004-06/DSCF1304.JPG

Evaporator core out, on the right top I had to cut my coolant lines to/from the heater core
http://www.ogdak.eu/images/2004-06/DSCF1305.JPG

heater-a/c unit installed
http://www.ogdak.eu/images/2004-06/DSCF1306.JPG

So went back to the airco shop to get the system filled again, did not have to pay for the R134A the second time around
Excellent service. So off for a nice ride to "Sclayn".

ogdak
12-20-2005, 04:41 PM
July 2004

Like mentioned before we are planning a trip to "Sclayn" in Belgium.
It is also going to be our first time camping with our kids.
So the day before leaving came to the conclusion that we did not have enough lugage space. So went for a skibox.
Good thing to buy one of these in de summertime, plenty choice and nothing "out off stock".
So for de trip to sclayn put the small ones on again.
I know, not the best pictures but al I had
http://www.ogdak.eu/images/2004-07/DSCF1307.JPG

http://www.ogdak.eu/images/2004-07/DSCF1308.JPG

Due to bad waether the weekend was not to succesfull for the wife and kids,
but I had a GREAT time.

August 2004

This months mod's
-F>R spring swap
-3" longer front spring's
-Adjustable CA's

F>R swap does not need further explaining.
Combined with the BB's about 5" lift in the rear.
Upfront 3" longer skycrapper's combined with the ACOS is about 6"
Nice flexxin
http://www.ogdak.eu/images/2004-08/DSCF1310.JPG

Upfront
http://www.ogdak.eu/images/2004-08/DSCF1311.JPG
Bottom
http://www.ogdak.eu/images/2004-08/DSCF1312.JPG

Like mentioned above, Adj. CA.
Tape with line around the tire is to get things roughly allignt
http://www.ogdak.eu/images/2004-08/DSCF1313.JPG

This months end result.
Personally I think it is sitting to high for a set of 31"
http://www.ogdak.eu/images/2004-08/DSCF1314.JPG

http://www.ogdak.eu/images/2004-08/DSCF1317.JPG

http://www.ogdak.eu/images/2004-08/DSCF1318.JPG

Pro to that is that the tires move up into the wheelwell very nice and easy.
Downside is that the Skycrapper coils can not take that much flex.
This is how the came off in january 2005.
I know I should have known.
http://www.ogdak.eu/images/2004-08/DSCF1422.JPG


So meanwhile it is september 2004
So things need to get tested and we are only 1 week away of The First Annual Dutch Jeepcamp
As said as done, went testing in "Ressen".
The pic's speak for them self.
http://www.ogdak.eu/images/2004-09/DSCF1321.JPG

http://www.ogdak.eu/images/2004-09/DSCF1322.JPG

http://www.ogdak.eu/images/2004-09/DSCF1323.JPG

http://www.ogdak.eu/images/2004-09/DSCF1324.JPG

Just checking the extended brake lines.
http://www.ogdak.eu/images/2004-09/DSCF1325.JPG

Former front coil now in the rear and almost fully compressed.
http://www.ogdak.eu/images/2004-09/DSCF1326.JPG

Little rubbing on the rear, needs some adjusting.
http://www.ogdak.eu/images/2004-09/DSCF1327.JPG

From below.
http://www.ogdak.eu/images/2004-09/DSCF1329.JPG

And the last one.
http://www.ogdak.eu/images/2004-09/DSCF1332.JPG

Sooooooooo all for now.

p.s. test went well.

Kraqa
12-21-2005, 02:49 AM
cut off those shock boots all they will do for you is trap mud and sludge. Eventually that stuff will score the shaft and yoru shock will leak.

ogdak
12-21-2005, 06:26 AM
cut off those shock boots all they will do for you is trap mud and sludge. Eventually that stuff will score the shaft and yoru shock will leak.

http://www.flexworx.com/images/stories/project_otto/Forum/2004-09/DSCF1325.JPG

That is why I left them loose at the bottom.

ogdak
12-22-2005, 03:35 PM
September 2004
So time for Dutch Jeep Camp
Also in 2004 lot's off poison ivy.
http://www.ogdak.eu/images/2004-09/DSCF1345.JPG

http://www.ogdak.eu/images/2004-09/DSCF1346.JPG

The camp site
Thought it would be nice to put some 33" on MT wheels on.
So just some "poser" pic's.
http://www.ogdak.eu/images/2004-09/DSCF1350.JPG

http://www.ogdak.eu/images/2004-09/DSCF1352.JPG

http://www.ogdak.eu/images/2004-09/DSCF1353.JPG

Lady's from my most favourites list.
http://www.ogdak.eu/images/2004-09/DSCF1354.JPG

So saturday in a nice piece off forrest.
http://www.ogdak.eu/images/2004-09/DSCF1357.JPG

http://www.ogdak.eu/images/2004-09/DSCF1358.JPG

http://www.ogdak.eu/images/2004-09/DSCF1359.JPG

http://www.ogdak.eu/images/2004-09/DSCF1360.JPG

http://www.ogdak.eu/images/2004-09/DSCF1361.JPG

So last day, sunday.
http://www.ogdak.eu/images/2004-09/DSCF1363.JPG

http://www.ogdak.eu/images/2004-09/DSCF1365.JPG

So that was jeepcamp 2004, till next year.

So later that same month we had the FOC trophy in Belgium http://www.4ft.be/eng/index.htm
But I wanted o go on 33". So made a deal with Mav © and went to work to make things fit.
So the adj. CA's turned out to be very usefull again. Finally had to grind half the head off the SS bolt off.
Also the sway-bar had to go. Which made driving on the highway fun, especcially on the fly over's.
So first night on the camping site with some rain.
http://www.ogdak.eu/images/2004-09/foc_1.jpg

Signin went very well, considering there where over a thousend 4x4's over the weekend.
http://www.ogdak.eu/images/2004-09/foc_2.jpg

Saturday had a flat tire after being pulled out by a traktor.
Did catch dirt between de tire en the rim.
BUt with som crow-bar's and lots off water managed to get things airtide again.
http://www.ogdak.eu/images/2004-09/foc_3.jpg

So sunday we went into a rather small piece off forest which was very swampy.
So got stuck in a ditch.
http://www.ogdak.eu/images/2004-09/foc_4.jpg

Don't think it has been this dirty before.
http://www.ogdak.eu/images/2004-09/foc_5.jpg

http://www.ogdak.eu/images/2004-09/foc_6.jpg

And this was the last time I wheeled it.
Time for a HP30, 8.8 and LA's:smt040
Stay tuned.

OverkillZJ
12-22-2005, 04:27 PM
Ewwwwwwwwwwhhhh mud!

I hate mud.

ogdak
12-22-2005, 06:04 PM
Ewwwwwwwwwwhhhh mud!

I hate mud.

I know, still got some on the inside.

So well it is November 2004.
Did not do a thing in October
Next item on my wishlist is a swing out tire-carrier.
Sjikita took some measurements and came up with this to start with
http://www.ogdak.eu/images/2004-11/DSCF1370.JPG

http://www.ogdak.eu/images/2004-11/DSCF1372.JPG

http://www.ogdak.eu/images/2004-11/DSCF1374.JPG

So a major upgrade is in this box.
http://www.ogdak.eu/images/2004-12/DSCF1385.JPG

This was in there also.
A Dana30RC 4.56 R&P and a Ford 8.8 4.56 R&P, don´t need telling which is which
http://www.ogdak.eu/images/2004-12/DSCF1387.JPG

Meanwhile more tire/carrier fittings.
http://www.ogdak.eu/images/2004-12/DSCF1388.JPG

Got the wheel jacked up in the wheelwell to determine the line behind the wheel.
However still do not know, so there are more colours on it now.
http://www.ogdak.eu/images/2004-12/DSCF1393.JPG

Swing-out piece also in place.
http://www.ogdak.eu/images/2004-12/DSCF1394.JPG

More bumper issue´s upfront
Need to get rid off some pieces off iron, due to engine cooling problems, space in the wheelwell
and offcourse lights
http://www.ogdak.eu/images/2004-12/DSCF1399.JPG

Thes lights need to go in there.
http://www.ogdak.eu/images/2004-12/DSCF1401.JPG

Where the turn signal´s used to be.
http://www.ogdak.eu/images/2004-12/DSCF1402.JPG

Got some welding practice done, top left a 16.16
http://www.ogdak.eu/images/2004-12/DSCF1405.JPG

Found a HP D 30
http://www.ogdak.eu/images/2004-12/DSCF1407.JPG

How handy a table on wheels, like it was made for it.
http://www.ogdak.eu/images/2004-12/DSCF1408.JPG

The inside it is 3.55
http://www.ogdak.eu/images/2004-12/DSCF1413.JPG

Taking it apart
http://www.ogdak.eu/images/2004-12/DSCF1415.JPG

http://www.ogdak.eu/images/2004-12/DSCF1416.JPG

Rusted, but the knuckles are gonna go anyway
http://www.ogdak.eu/images/2004-12/DSCF1417.JPG

http://www.ogdak.eu/images/2004-12/DSCF1418.JPG

Clear vieuw off being a RC
http://www.ogdak.eu/images/2004-12/DSCF1419.JPG

That will be all for 2004, see you next year.

ogdak
12-23-2005, 06:34 PM
Happy new year, January 2005, less than a year behind.

So after my lesson learned with the skycrapper coils I need an alternetif.
RE coils or some custom made ones overhere.
Well it is going to be custom made, they need to know the length off the standard coils on ride high
with all the extra weight wat is gonna be on the ZJ.
So did put back the standard coils en put like 4 bags off concrete in the back to compensate for the tire-carrier and spare.
So took the standard coils and my measurements to the factory.
So this is standard with 33"
http://www.ogdak.eu/images/2005-01/DSCF1420.JPG

http://www.ogdak.eu/images/2005-01/DSCF1421.JPG

So meanwhile started on the TCase, the 249 will be replaced with a 231 with a JB super short SYE
So oil out.
http://www.ogdak.eu/images/2005-01/DSCF1424.JPG

So my 249 had the long 23 spline input, the 231 the medium lenght 23 spline
Swapt the input to the 231.
http://www.ogdak.eu/images/2005-01/DSCF1425.JPG

The rear off the 46RH.
http://www.ogdak.eu/images/2005-01/DSCF1427.JPG

Left to right.
My 231, mav ©'s 231, my 249 and a pile off old iron.
http://www.ogdak.eu/images/2005-01/DSCF1430.JPG

From above.
http://www.ogdak.eu/images/2005-01/DSCF1431.JPG

Web viewers.
http://www.ogdak.eu/images/2005-01/DSCF1432.JPG

Difference in lenght off the mainshaft
http://www.ogdak.eu/images/2005-01/DSCF1437.JPG

So also had to replace a body part.
http://www.ogdak.eu/images/2005-01/DSCF1443.JPG

http://www.ogdak.eu/images/2005-01/DSCF1444.JPG

Some pieces I wont need.
http://www.ogdak.eu/images/2005-01/DSCF1445.JPG

The damaged piece still in place.
http://www.ogdak.eu/images/2005-01/DSCF1447.JPG

http://www.ogdak.eu/images/2005-01/DSCF1448.JPG

Gone
http://www.ogdak.eu/images/2005-01/DSCF1460.JPG

Also took the front "U" off to adjust for the new PIAA lamps.
http://www.ogdak.eu/images/2005-01/DSCF1462.JPG

All for now.

Kraqa
12-23-2005, 10:27 PM
replace that shit with tube and its starting to look liek mine. sweet thread.

iMav ©
12-24-2005, 03:40 AM
Well well..... so this is where you hang out instead of working on the ZJ in your barn :P

No kidding, that rig is going to be awesome (in fact is is awesome allready ;) ), particular for the region we live in. The jeep community isn't that big here and most of the time people rebuild their rig to dig some mud. I dare to say this is going to be the biggest & baddest ZJ in this part of western Europe ;)

Keep on going Ogdak!

ogdak
12-26-2005, 02:02 PM
February 2005
Front bumper mod's for the lights
http://www.ogdak.eu/images/2005-02/DSCF1496.JPG

http://www.ogdak.eu/images/2005-02/DSCF1499.JPG

http://www.ogdak.eu/images/2005-02/DSCF1495.JPG

http://www.ogdak.eu/images/2005-02/DSCF1502.JPG

In place.
http://www.ogdak.eu/images/2005-02/DSCF1508.JPG

Sorry a bit blury, must have been late.
http://www.ogdak.eu/images/2005-02/DSCF1510.JPG

Custom coil's are done.
They are not that much longer but a lott stiffer.
The "wire" thickness went from 1/2" up tp 3/4".
http://www.ogdak.eu/images/2005-02/DSCF1511.JPG

Wanted to see them on the ZJ right away of course.
http://www.ogdak.eu/images/2005-02/DSCF1512.JPG

http://www.ogdak.eu/images/2005-02/DSCF1516.JPG

http://www.ogdak.eu/images/2005-02/DSCF1515.JPG

Blury again.
http://www.ogdak.eu/images/2005-02/DSCF1514.JPG

Leaning to the right, no TB. and still on 33"
http://www.ogdak.eu/images/2005-02/DSCF1519.JPG

http://www.ogdak.eu/images/2005-02/DSCF1520.JPG

I do not remember why I pushed it out, but this was all for february.

March 2005
Found only 2 pic's
The replaced body part.
http://www.ogdak.eu/images/2005-03/DSCF1523.JPG

I am gonna swap to the WJ knuckles, for better braking capability, crossover steering and semi-"high" steering.
so a redrilled rotor and an oldstyle '99 dual piston caliper.
In the left background the modified front "U" profile for the headlights.
http://www.ogdak.eu/images/2005-03/DSCF1524.JPG

April 2005.
Swing out tire carrier in its final state only needs powder coating.
http://www.ogdak.eu/images/2005-04/DSCF1527.JPG

Swing-out with a 35"on it.
http://www.ogdak.eu/images/2005-04/DSCF1528.JPG

http://www.ogdak.eu/images/2005-04/DSCF1531.JPG

http://www.ogdak.eu/images/2005-04/DSCF1533.JPG


http://www.ogdak.eu/images/2005-04/DSCF1536.JPG

All for now.

TheOtherSide
12-26-2005, 03:28 PM
I like it...

Kelly

OverkillZJ
12-26-2005, 03:55 PM
Sweet. I like reading through 3 years of work in a day.

deadman
12-27-2005, 10:04 AM
I dare to say this is going to be the biggest & baddest ZJ in this part of western Europe ;)

Well... we'll see about that. :D

@ogdak:

Nice rear bumper! :supz:

OverkillZJ
12-27-2005, 11:18 AM
I just caught the web cam hanging in the garage. The locals have been joking about making me put one in mine, I wouldn't let them, haha. But as long as you have one, hook us up with the address! :finga:

ogdak
12-27-2005, 12:51 PM
I just caught the web cam hanging in the garage. The locals have been joking about making me put one in mine, I wouldn't let them, haha. But as long as you have one, hook us up with the address! :finga:

It is not hooked up on the moment, do not have a computer there anymore.
But this is the last pic broadcasted from it.
http://www.ogdak.eu/images/2005-04/cam.jpg
So maybe when this project is coming to completion I hook it up again.

zjoe
12-27-2005, 06:38 PM
Cool. yes, hook the web cam up again.
Is that a YJ tub sittin up on the right side?

Cue-Ball
12-27-2005, 06:51 PM
Looking good. I really like the tire carrier.

grnd93
12-27-2005, 07:21 PM
That looks awesome. I like the rear bumper and the customization you did to your ARB.

iMav ©
12-28-2005, 07:05 PM
Well... we'll see about that. :D

@ogdak:

Nice rear bumper! :supz:

Didn't I say "western Europe" ? ;) :smt110

No kidding, I've heard something about your plans/project and must say, that sounds pretty impressive too :D

ogdak
12-28-2005, 07:10 PM
Is that a YJ tub sittin up on the right side?

Yes it is, it is a friends tub.
But it is gone, you could look through it.
That is how "rot" it was.

Sudz
12-28-2005, 10:20 PM
ogdak-

cool thread, dude

http://www.the-jersey-devil.com/bbs/images/graemlins/kewl.gifhttp://www.the-jersey-devil.com/bbs/images/graemlins/kewl.gif

ogdak
12-29-2005, 06:32 PM
Thnx for all the compliments

Still April 2005
Preparations on a 8.8
This one has LS, diskbrakes and a R&P 4.10 which will be replaced for 4.56
http://www.ogdak.eu/images/2005-04/DSCF1552.JPG

Diff cover loose, wanted to get all the braking parts off because off the re/build.
http://www.ogdak.eu/images/2005-04/DSCF1553.JPG

Fresh oil and the contact pasta still on the ring.
http://www.ogdak.eu/images/2005-04/DSCF1554.JPG

Side gear, pinion gear mate shaft and the end's off both the axle shaft's
http://www.ogdak.eu/images/2005-04/DSCF1555.JPG

Lock screw off pinion gear mate shaft loose.
http://www.ogdak.eu/images/2005-04/DSCF1556.JPG

Pinion gear mate shaft out. Pushing the axle-shaft inside will release the c-clips.
On the right shaft you can see an little orange rubber "band", which prevents de c-clip from falling off during removal/installation.
Dispite that, I still dropped one in the diff and I did not wanted to drain it just now.
So had some fun fishing it out again.
http://www.ogdak.eu/images/2005-04/DSCF1558.JPG

So because this axle has an off-set pumpkin there is a lenght diffference in axle-shaft's.
http://www.ogdak.eu/images/2005-04/DSCF1559.JPG

Taking off the brackets.
http://www.ogdak.eu/images/2005-04/DSCF1564.JPG

http://www.ogdak.eu/images/2005-04/DSCF1565.JPG

And finaly with "grinding paper".
http://www.ogdak.eu/images/2005-04/DSCF1566.JPG

The truss made out 50*50*6mm box, for the rear upper mounting points
Yes the truss is in the middle compared to the ZJ.
http://www.ogdak.eu/images/2005-04/DSCF1575.JPG

http://www.ogdak.eu/images/2005-04/DSCF1576.JPG

http://www.ogdak.eu/images/2005-04/DSCF1577.JPG

Meanwhile got some bigger TRE's
http://www.ogdak.eu/images/2005-04/DSCF1560.JPG

For comperising the shaft is like 4.5 mm thicker
http://www.ogdak.eu/images/2005-04/DSCF1561.JPG

A reamer
http://www.ogdak.eu/images/2005-04/DSCF1562.JPG

So obvious I am gonna flip the tre's to the top, just make sure do not drill to deep.
Done with the left one
http://www.ogdak.eu/images/2005-04/DSCF1563.JPG

Working on the right one, very clear on the "high steer" arm on the right WJ knuckle.
http://www.ogdak.eu/images/2005-04/DSCF1567.JPG

And done.
http://www.ogdak.eu/images/2005-04/DSCF1569.JPG

How it will sit on the ZJ.
http://www.ogdak.eu/images/2005-04/DSCF1570.JPG

Kraqa
12-29-2005, 10:35 PM
i dig it. before you build the stearing. take back the ES2233L it will bend VERY easy. you dont' need it for the drag link so why not use a regular TRE and build a sleeve for the tie rod to connect your SS to.

ogdak
12-30-2005, 01:36 PM
i dig it. before you build the stearing. take back the ES2233L it will bend VERY easy. you dont' need it for the drag link so why not use a regular TRE and build a sleeve for the tie rod to connect your SS to.

You are right about the es2233l but that's all i have now, taking it back is no option since it came from the US.
Already done on the tie rod, so I'll take my changes.
Will try to fab up some sort off brace for it.
When it is gonna fail I'll redo it.
Hope it won't be on the first time out.

ogdak
01-04-2006, 06:14 PM
So still April 2005(2)
Preparation on a HP Dana 30.
Still with stock brackets, SB, SS and TB
http://www.ogdak.eu/images/2005-04/DSCF1572.JPG

They all have to go.
http://www.ogdak.eu/images/2005-04/DSCF1573.JPG

http://www.ogdak.eu/images/2005-04/DSCF1578.JPG

Also the perch has to go because the wire diameter on the new coil is 50% bigger then a standard coil.
http://www.ogdak.eu/images/2005-04/DSCF1579.JPG

http://www.ogdak.eu/images/2005-04/DSCF1580.JPG

http://www.ogdak.eu/images/2005-04/DSCF1582.JPG

So got some stuff in for the LA's, thnx Sjikita.
2 "U" 's 105 cm long made out off 5 mm thick plate.
To be welded on to the uni-body
On the bottom side, brackets for the lower CA's.
Obvious in this pic they are up side down.
http://www.ogdak.eu/images/2005-04/DSCF1583.JPG

http://www.ogdak.eu/images/2005-04/DSCF1584.JPG

The brackets in the middle off the table will go on the 8.8 for thr LCA's and are also gonna acommodate the spring perches.
The tabs on the "U" are gonna be the rear shock mounts
http://www.ogdak.eu/images/2005-04/DSCF1588.JPG

http://www.ogdak.eu/images/2005-04/DSCF1589.JPG

So for each CA i wil use a stock bushing and a JJ, except the radius arms.
Her a JJ in parts.
http://www.ogdak.eu/images/2005-04/DSCF1571.JPG

So here it will all happen.
The traverse also needs to be modified
The chalklines represents the crossline for the ds-joints on the TC.
Which will mark the position for the lower brackets.
So therefore there will be a minimum in DS length.
Here the TC with ultra short SYE borroughed from Mav © to determine several bracket locations.
http://www.ogdak.eu/images/2005-04/DSCF1592.JPG

http://www.ogdak.eu/images/2005-04/DSCF1593.JPG

http://www.ogdak.eu/images/2005-04/DSCF1595.JPG

First time fitting.
http://www.ogdak.eu/images/2005-04/DSCF1598.JPG

During the prep. phase I mounted them with "blindklinkmoeren"( I know, can not find the english word for it.
Works the same way like rivets, only this is like a threaded cilinder, in which you can screw like i.e. a M8 Or even a M10 Bolt.
So help me out on this word.)
http://www.ogdak.eu/images/2005-04/DSCF1599.JPG

So meanwhile replaced the motormounts, old one's where gone.
And did some painting.
http://www.ogdak.eu/images/2005-04/DSCF1600.JPG

http://www.ogdak.eu/images/2005-04/DSCF1601.JPG


So here is an original redundant front LCA bracket.
http://www.ogdak.eu/images/2005-04/DSCF1605.JPG

Passed the point off no return, :rolleyes:
http://www.ogdak.eu/images/2005-04/DSCF1606.JPG
So this was April 2005, things are getting more fun to do. ;)
Mazzel

Cue-Ball
01-04-2006, 06:25 PM
Those LA brackets turned out SCHWEET!!!!

jeepnzj1
01-04-2006, 06:33 PM
nice cant wait to see some more.

DND
01-04-2006, 06:59 PM
Nice build thread and a great project coming together.

During the prep. phase I mounted them with "blindklinkmoeren"( I know, can not find the english word for it.
Works the same way like rivets, only this is like a threaded cilinder, in which you can screw like i.e. a M8 Or even a M10 Bolt.
So help me out on this word.)
- I think you were looking for the terms 'Nutsert' or 'Rivnut' - not words you would find in a dictionary.
http://www.avdel.textron.com/index.htm?products/threaded/thin_sert.htm

Is that the piece?

Cheers,
Dave

ogdak
01-04-2006, 07:41 PM
Nice build thread and a great project coming together.

- I think you were looking for the terms 'Nutsert' or 'Rivnut' - not words you would find in a dictionary.
http://www.avdel.textron.com/index.htm?products/threaded/thin_sert.htm

Is that the piece?

Cheers,
Dave

Yes, that's it. Thanks.
But I do not have a fancy electric tool with it.
Just a plain muscle powered tool.

SLO MO
01-05-2006, 06:07 AM
Great in depth write-up. Lookin good:supz:

JeepinHank
01-06-2006, 01:30 PM
Great in depth write-up. Lookin good:supz:

What he said.

BC98
01-06-2006, 02:42 PM
Yes, that's it. Thanks.
But I do not have a fancy electric tool with it.
Just a plain muscle powered tool.


It's actually pnuematic/hydraulic. I work for Textron. Anyway, great thread and nice looking ZJ.

ogdak
01-06-2006, 02:53 PM
It's actually pnuematic/hydraulic.

Did not even noticed that till now, looking at that site again.
Nice tool anyway.

ILikeMud
01-06-2006, 03:10 PM
Coming along nicely man.

ogdak
01-09-2006, 07:42 PM
Thnx

Already May 2005

Modifications to the traverse.
Stock it is bolted from down up in the bottomside off the uni-body.
And in that manner it is in the way off my future LCA's.
So got the traverse shortened to fit "between" the uni-body
The big strip will go on the inside off the uni-body.
The small strips will go on the new end's off the traverse.
http://www.ogdak.eu/images/2005-05/DSCF1607.JPG

Like this.
When using the top line off hole's the engine/tranny/t-case will sit in its original way.
When using the bottom line off hole's it will be like a t-case lowering,
so some extra option's to mess with driveline angle's.
http://www.ogdak.eu/images/2005-05/DSCF1609.JPG

http://www.ogdak.eu/images/2005-05/DSCF1611.JPG

How it finally will be.
http://www.ogdak.eu/images/2005-05/DSCF1613.JPG

Front LCA bracket.
http://www.ogdak.eu/images/2005-05/DSCF1616.JPG

Very clear, placed the bracket as far to the inside as possible.
To get a max. of clearance between wheel and front LCA.
http://www.ogdak.eu/images/2005-05/DSCF1617.JPG

From different corners.
http://www.ogdak.eu/images/2005-05/DSCF1618.JPG

http://www.ogdak.eu/images/2005-05/DSCF1619.JPG

http://www.ogdak.eu/images/2005-05/DSCF1620.JPG

http://www.ogdak.eu/images/2005-05/DSCF1621.JPG

In place, used a threaded rod for allignment purposes,
left and right must be as even as possible.
http://www.ogdak.eu/images/2005-05/DSCF1624.JPG

http://www.ogdak.eu/images/2005-05/DSCF1625.JPG

Next step, front control and radius arm's
Used 40*40 square tube for fit and measuring issue's
http://www.ogdak.eu/images/2005-05/DSCF1627.JPG

Close-up off the temp. radius arm
Also the new base off the spring perches in place.
http://www.ogdak.eu/images/2005-05/DSCF1628.JPG

front view
http://www.ogdak.eu/images/2005-05/DSCF1629.JPG

Tja, spring perch for the new coils.
This took some time to determine/simulate the slope on the coil when it is sitting on it's final weight.
Obvious want to have the coils straight up
http://www.ogdak.eu/images/2005-05/DSCF1632.JPG

http://www.ogdak.eu/images/2005-05/DSCF1633.JPG

Hopefully the above story will be clearified by the next picture.
http://www.ogdak.eu/images/2005-05/DSCF1636.JPG

http://www.ogdak.eu/images/2005-05/DSCF1637.JPG

Time for some cleanup
http://www.ogdak.eu/images/2005-05/DSCF1638.JPG

Till next time.

chadjans
01-10-2006, 12:42 AM
Gusset your tabs on the frame side for the tranny crossmember. And why did't you just use some thicker material for the cross member after the effort you put into the 1/8 thick OEM one?

Chad

ATL ZJ
01-10-2006, 01:02 AM
I like the tranny crossmember adjustability idea. Those spring perches designed for the spring to sit perfectly level are pretty nice as well.

ogdak
01-10-2006, 03:14 AM
Gusset your tabs on the frame side for the tranny crossmember. And why did't you just use some thicker material for the cross member after the effort you put into the 1/8 thick OEM one?

Chad

Gusset's on te frame site is not really an option, since it will be in the way off the LCA's. May be the tabs don't look that thick but it is 5mm which is almost 1/4" thick.

chadjans
01-10-2006, 11:30 AM
Run vertically up the side of the sleave on the interior side.

ogdak
01-10-2006, 02:06 PM
Run vertically up the side of the sleave on the interior side.

@chadjans: I see your point, BUT
I really do not see how that would work, it would mean I can no longer adjust the height off the traverse.
http://www.flexworx.com/images/stories/project_otto/Forum/2005-05/DSCF1613.JPG

http://www.flexworx.com/images/stories/project_otto/Forum/2005-05/DSCF1625.JPG

The force on the tabs will be from up to down and not sideway's.
So I think I'll be fine.
However, anybody having any other ideas about this fab work and on how it will hold up?
Thnxs

jeep4x4nut
01-10-2006, 07:12 PM
A center gusset on the tranny mounts wouldnt hurt (where the center hole is)

1996cc
01-10-2006, 07:45 PM
I like the design of your spring perches, and I'm no expert on them at all. But looking at them, it doesn't look like the spring will be able to completely compress. Shouldn't the total "ramp" of the perch only be as tall as the thickness of the first coil? The way you have it, when the spring is in full compression, it looks like all the force will be right at the high spot of the ramp, rather than evenly distributed over the whole circumference of the spring.

Just my thoughts, I may be wrong, but wanted to address the issue.

Everything else looks great.

ogdak
01-11-2006, 01:19 PM
@jeep4x4nut

Gusset's on te frame site is not really an option, since it will be in the way off the LCA's.

@1996cc
Hard to see, bud there is some play at the top end off the "ramp"
I only need about 5" inflex since max travel off the front shock is 11.75"
So made the "ramp" for ride hide, which I think is the best choice between
compressed, ride hide and extended
So obvious a "variable ramp" would be the best.

Thnx for the input.

ogdak
01-17-2006, 05:55 PM
So still May 2005, busy month
This part will be a little off everything.
To start with the removal off the stock fan, will be replaced with an E-fan from a Taurus.
http://www.ogdak.eu/images/2005-05/DSCF1640.JPG

Another visco.
http://www.ogdak.eu/images/2005-05/DSCF1641.JPG

Mig weld excersize on an outer knuckle(cast iron).
http://www.ogdak.eu/images/2005-05/DSCF1642.JPG

Close-up
http://www.ogdak.eu/images/2005-05/DSCF1643.JPG

Well obvious will not work, just had to try.
Special rod's on the way
http://www.ogdak.eu/images/2005-05/DSCF1645.JPG

This one needs to be closed, since it is in the way off the truss.
http://www.ogdak.eu/images/2005-05/DSCF1650.JPG

http://www.ogdak.eu/images/2005-05/DSCF1652.JPG

Some experimenting with drag and tie rod.
Just used some pipe for fitment purpose's
http://www.ogdak.eu/images/2005-05/DSCF1657.JPG

http://www.ogdak.eu/images/2005-05/DSCF1658.JPG

Adjusting steering geometry also asks for TB adjustment.
So I need to shorten my jks adj. TB by approx. 2".
Marked
http://www.ogdak.eu/images/2005-05/DSCF1660.JPG

Cut
http://www.ogdak.eu/images/2005-05/DSCF1668.JPG

Weld
http://www.ogdak.eu/images/2005-05/DSCF1671.JPG

And fitting
Close to parallel
http://www.ogdak.eu/images/2005-05/DSCF1673.JPG

To make this work I also had to drill out my pitman-arm which wouldn't come loose from the gear.
So flipped the whole combo, took some time but got it done.
http://www.ogdak.eu/images/2005-05/DSCF1662.JPG

So June 2005, getting closer.
Unibody sleeve's
Rear LCA brackets
http://www.ogdak.eu/images/2005-06/DSCF1679.JPG

http://www.ogdak.eu/images/2005-06/DSCF1680.JPG

Rear UCA brackets on the unibody inside
http://www.ogdak.eu/images/2005-06/DSCF1683.JPG

http://www.ogdak.eu/images/2005-06/DSCF1684.JPG

http://www.ogdak.eu/images/2005-06/DSCF1685.JPG

Finally 1 half off the whole.
http://www.ogdak.eu/images/2005-06/DSCF1686.JPG

All for now, have fun.

jeepnzj1
01-17-2006, 06:42 PM
nice write up. more, more,

ILikeMud
01-18-2006, 12:05 AM
Wow, awesome work man.

Kraqa
01-18-2006, 03:48 AM
plasma are nice eh?


i ran my tranny cross member liek that and i had mo problesm i woudn't worry abotu it. what thickness are yoru arms?

also put a slug inside that track bar. it WILL break or bend trust me i'vv done it.


looks good.

ogdak
01-18-2006, 06:04 PM
@ Kraga
I think this is what you mean with a "slug"
http://www.ogdak.eu/images/2006-01/DSCF1990.JPG

http://www.ogdak.eu/images/2006-01/DSCF1991.JPG

http://www.ogdak.eu/images/2006-01/DSCF1992.JPG

http://www.ogdak.eu/images/2006-01/DSCF1994.JPG

http://www.ogdak.eu/images/2006-01/DSCF1995.JPG

http://www.ogdak.eu/images/2006-01/DSCF1997.JPG

Here is a preview off my arms
OD is 2.5" wall is 1/4"
http://www.ogdak.eu/images/2005-07/DSCF1696.JPG

http://www.ogdak.eu/images/2005-07/DSCF1699.JPG
:)

grnd93
01-18-2006, 07:54 PM
That's looking awesome!

fr3db3ar
01-18-2006, 09:07 PM
Do you plan on bolting on that subframe or are all those holes for plug welds?

ogdak
01-19-2006, 01:24 PM
Thnx


Do you plan on bolting on that subframe or are all those holes for plug welds?

It is already in, used 4 bolts and welded the rest where the unibody is double plate. Also a total of 12 plug welds, but not at "those holes".
Pictures will be up when I start covering september 2005.

ogdak
01-23-2006, 03:34 PM
So just a little left off June 2005.

About time to say good bye to the Dana35C.
Everything disconnected.
http://www.ogdak.eu/images/2005-06/DSCF1675.JPG

This will be the replacement a Ford 8.8, hard to tell from this angle.
Spring perches at 0, pumpkin up at 12 degree's
http://www.ogdak.eu/images/2005-06/DSCF1676.JPG

Much better view.
http://www.ogdak.eu/images/2005-06/DSCF1691.JPG

So July 2005, only 6 months behind
Partial detail off front LCA. Adjustment in length is about 2 ".
Not hard to tell where this design idea came from.
So won't need to explain the pros and cons off this setup.
http://www.ogdak.eu/images/2005-07/DSCF1695.JPG

FLCA and RUCA
http://www.ogdak.eu/images/2005-07/DSCF1696.JPG

Compare FLCA
http://www.ogdak.eu/images/2005-07/DSCF1697.JPG

Same for the RUCA
http://www.ogdak.eu/images/2005-07/DSCF1698.JPG

Which is standard!
http://www.ogdak.eu/images/2005-07/DSCF1699.JPG

Sideview
http://www.ogdak.eu/images/2005-07/DSCF1701.JPG

All from above will need to fit somewhere under here
http://www.ogdak.eu/images/2005-07/DSCF1703.JPG

Part off the rear brackets on the 8.8 truss.
Very well visible the threads which make adjusting the CA's possible.
http://www.ogdak.eu/images/2005-07/DSCF1704.JPG

Some stuff in place.
http://www.ogdak.eu/images/2005-07/DSCF1705.JPG

http://www.ogdak.eu/images/2005-07/DSCF1706.JPG

http://www.ogdak.eu/images/2005-07/DSCF1707.JPG

Good view off the rear "triangel" which makes it possible to ditch the rear TB
http://www.ogdak.eu/images/2005-07/DSCF1708.JPG

http://www.ogdak.eu/images/2005-07/DSCF1709.JPG

http://www.ogdak.eu/images/2005-07/DSCF1710.JPG

http://www.ogdak.eu/images/2005-07/DSCF1711.JPG

With 35" wheels for making measurements
@JeePee, thnx for borrowing them.
http://www.ogdak.eu/images/2005-07/DSCF1712.JPG

http://www.ogdak.eu/images/2005-07/DSCF1713.JPG

That was all for July 2005

Kraqa
01-23-2006, 03:45 PM
http://www.flexworx.com/images/stories/project_otto/Forum/2005-07/DSCF1707.JPG

Might want to notch that braket for some down travel. or flip it upside down.

ogdak
01-23-2006, 04:15 PM
Yes got it covered, thnx
Little hard to tell from these pic's though.
http://www.flexworx.com/images/stories/project_otto/Forum/2005-10/DSCF1779.JPG

http://www.flexworx.com/images/stories/project_otto/Forum/2005-10/DSCF1781.JPG

Kraqa
01-23-2006, 11:19 PM
looks good.

ogdak
01-25-2006, 06:51 PM
@Kraga thnx

So August 2005, only 1 month till 2nd Dutch Jeep Camp.

Last item on the La's, is radius arms
Stock, the FUCA is between axle and unibody.
But since that will not work on a LA setup, we make 1 or 2 radius arms.
So my radius arm runs from the UCA bracket(HP30) down to the FLCA and is also lenghtwise adj.
To set, in the first place pinion angle and caster.
http://www.ogdak.eu/images/2005-08/DSCF1726.JPG

http://www.ogdak.eu/images/2005-08/DSCF1727.JPG

http://www.ogdak.eu/images/2005-08/DSCF1728.JPG

So that's just about it for August, happy holidays

September 2005, JEEPCAMP, went there as a Marshall without my ZJ.
Had fun though for all 4 days, Will be there again in 2006 WITH my ZJ

So the rest of september will be a little off everything, just looking through
http://www.ogdak.eu/images/2005-09/DSCF1742.JPG

So with a paint burner, lots off terpentine and sander cleared the area for the unibody sleeves.
http://www.ogdak.eu/images/2005-09/DSCF1753.JPG

Just plain tiles, always handy
http://www.ogdak.eu/images/2005-09/DSCF1754.JPG

So time to start painting things. I used RX5 as a ground layer on all untreated parts.
Started with the 8.8
http://www.ogdak.eu/images/2005-09/DSCF1756.JPG

The Sleeves
http://www.ogdak.eu/images/2005-09/DSCF1758.JPG

The CA's
http://www.ogdak.eu/images/2005-09/DSCF1759.JPG

And the 8.8 again
http://www.ogdak.eu/images/2005-09/DSCF1760.JPG

Fabed up some endlinks out off 50*50*5(metric)"corner line"(I know, you tell me.) for my teraflex disco's.
http://www.ogdak.eu/images/2005-09/DSCF1763.JPG

Time to do some unibody welding
When I started, Kraga's Unibody Welding Bible was not posted yet. but I have faith that things won't tear off.
Got the sleeves set-up and lined out with 4 bolts.
http://www.ogdak.eu/images/2005-09/DSCF1765.JPG

http://www.ogdak.eu/images/2005-09/DSCF1767.JPG

http://www.ogdak.eu/images/2005-09/DSCF1768.JPG

I only welded the sleeves to the unibody where there was 2 layers off sheetmetal.
And besides that a bunch off plug welds.
http://www.ogdak.eu/images/2005-09/DSCF1768.JPG

http://www.ogdak.eu/images/2005-09/DSCF1769.JPG

http://www.ogdak.eu/images/2005-09/DSCF1770.JPG

http://www.ogdak.eu/images/2005-09/DSCF1774.JPG

http://www.ogdak.eu/images/2005-09/DSCF1775.JPG

http://www.ogdak.eu/images/2005-09/DSCF1776.JPG

So here comes October 2005.

norton
01-25-2006, 07:55 PM
looking good.

nice way to hold up the body of that thang. tiles?

nate
01-25-2006, 09:33 PM
That's pretty much how I welded my subframe on as well.

I wanted to mention... that pass side UCA on the D30, you should box it in. I'll bet $20 that it will fold up after a summer of wheeling. I've run 3 D30s under my Jeep and they all have done it.

ANLPROBE
01-26-2006, 12:44 AM
Nice work.

ogdak
01-27-2006, 11:55 AM
I wanted to mention... that pass side UCA on the D30, you should box it in. I'll bet $20 that it will fold up after a summer of wheeling. I've run 3 D30s under my Jeep and they all have done it.

Wow, thought I had everything covered.
Never heard about them folding up, but I like to prevent it.
So how should I box it.
@Nate or anybody, A pic off a boxed pass. side UCA.
Would be a big help.
Thnx Nate

I already looked at Kevin's LA setup, but that would mean redoing the whole front, there must be an easier way.
I also looked at Clayton's setup, They don't seem to be doing anything for it.

Open for option's

Kraqa
01-27-2006, 04:35 PM
put a plat on the back side to make the bracket a box instead of a u-channel.

ogdak
01-29-2006, 11:07 AM
So I fixed my weak link, D30 pass side UCA mount.:D
Thnx Nate & Kraga;)
Found some pieces off metal laying around.
top is ¼" and base is even thicker like 8mm:rolleyes:
http://www.ogdak.eu/images/2006-01/DSCF2018.JPG

http://www.ogdak.eu/images/2006-01/DSCF2019.JPG

http://www.ogdak.eu/images/2006-01/DSCF2020.JPG

http://www.ogdak.eu/images/2006-01/DSCF2024.JPG

http://www.ogdak.eu/images/2006-01/DSCF2028.JPG

http://www.ogdak.eu/images/2006-01/DSCF2032.jpg

Thanks :smt041 :smt041

So what do you think, will this hold up.:smt024

OverkillZJ
01-29-2006, 11:31 AM
This is great. It's exciting seeing all the big build threads goign on right now. It's needed, because everytime I see someone else go make progress, I'm like "Ya, I need to go get something done on my rig."

ogdak
01-29-2006, 11:41 AM
I'm like "Ya, I need to go get something done on my rig."
So what are you waiting for?

OverkillZJ
01-29-2006, 12:12 PM
Well I have the inspiration, now I just need the energy :finga:

LOL I'm heading out to the garage now.

ogdak
01-29-2006, 03:35 PM
LOL, just came from there, now heading for a beer.

October 2005
So if JEEPCAMP 2005 was good for anything, then it sure was my motivation.
So on with the paintjob, after the untreated parts being done with RX5.
It is now time for some layers of RX10.
First the 8.8, obvious the first layer
http://www.ogdak.eu/images/2005-10/DSCF1779.JPG

http://www.ogdak.eu/images/2005-10/DSCF1780.JPG

http://www.ogdak.eu/images/2005-10/DSCF1781.JPG

"the" unibody.
http://www.ogdak.eu/images/2005-10/DSCF1782.JPG

http://www.ogdak.eu/images/2005-10/DSCF1783.JPG

http://www.ogdak.eu/images/2005-10/DSCF1784.JPG

"the" Long Arm's
http://www.ogdak.eu/images/2005-10/DSCF1786.JPG

http://www.ogdak.eu/images/2005-10/DSCF1787.JPG

WJ knuckles
http://www.ogdak.eu/images/2005-10/DSCF1792.JPG

http://www.ogdak.eu/images/2005-10/DSCF1793.JPG

HP D30
http://www.ogdak.eu/images/2005-10/DSCF1789.JPG

http://www.ogdak.eu/images/2005-10/DSCF1790.JPG

http://www.ogdak.eu/images/2005-10/DSCF1794.JPG

Just a forum :smt109
http://www.ogdak.eu/images/2005-10/DSCF1798.JPG

Does not need explaining I guess
http://www.ogdak.eu/images/2005-10/DSCF1799.JPG

Modified front U-beam back in place
Drilled out the oem prop weld's
http://www.ogdak.eu/images/2005-10/DSCF1802.JPG

And "stuffed" them again.
http://www.ogdak.eu/images/2005-10/DSCF1803.JPG

http://www.ogdak.eu/images/2005-10/DSCF1804.JPG

And painted
http://www.ogdak.eu/images/2005-10/DSCF1807.JPG

Part 1 off October 2005

ogdak
02-02-2006, 03:31 PM
October 2005 part 2

Where did I left of, that's right got some more detailed tire-carier close-up's with 35"
http://www.ogdak.eu/images/2005-10/DSCF1808.JPG

Because off the fact that the mounting plate is adjustable,
http://www.ogdak.eu/images/2005-10/DSCF1814.JPG

The spare is very close to the rear of the ZJ
http://www.ogdak.eu/images/2005-10/DSCF1811.JPG

The "lock"
http://www.ogdak.eu/images/2005-10/DSCF1810.JPG

http://www.ogdak.eu/images/2005-10/DSCF1815.JPG

http://www.ogdak.eu/images/2005-10/DSCF1817.JPG

The "hing"
http://www.ogdak.eu/images/2005-10/DSCF1816.JPG

Open
http://www.ogdak.eu/images/2005-10/DSCF1818.JPG

And on with the paintbrush.
http://www.ogdak.eu/images/2005-10/DSCF1820.JPG

So finally on with some stuff for the endresult.
I am usualy not in to "bling bling" but a litlle accent here and there would not hurt.
So, assembling and installation of the LONG ARM's
http://www.ogdak.eu/images/2005-10/DSCF1822.JPG

JJ's installed
http://www.ogdak.eu/images/2005-10/DSCF1824.JPG

http://www.ogdak.eu/images/2005-10/DSCF1825.JPG

Parts needed for a set of radius arm's
http://www.ogdak.eu/images/2005-10/DSCF1826.JPG

http://www.ogdak.eu/images/2005-10/DSCF1829.JPG

http://www.ogdak.eu/images/2005-10/DSCF1831.JPG

A set of FLCA's
http://www.ogdak.eu/images/2005-10/DSCF1833.JPG

Almost in place
http://www.ogdak.eu/images/2005-10/DSCF1837.JPG

In place
http://www.ogdak.eu/images/2005-10/DSCF1838.JPG

http://www.ogdak.eu/images/2005-10/DSCF1841.JPG

http://www.ogdak.eu/images/2005-10/DSCF1842.JPG

And that is the end of October 2005, only 3 months and 200 pic's behind reality.

grnd93
02-02-2006, 03:35 PM
Very Sweet!

ILikeMud
02-02-2006, 09:47 PM
Wow,
Awesome man.

2jeepsforus
02-03-2006, 04:52 PM
Smart guy.... zerk fittings on everything possible :mrgreen: even the tire carrier

8WR_ZJ
02-04-2006, 10:21 PM
Wow! very nice. Keep up the great work.

ogdak
02-05-2006, 05:16 AM
Smart guy.... zerk fittings on everything possible :mrgreen: even the tire carrier

Just have to make sure to keep my "grease" on level.

Kraqa
02-05-2006, 03:57 PM
Looks great, the passenger UCA looks nice.


One thing ot consider is that alot of people claim having that much round bar comming off yoru JJ's will cause bending problems. I run just as much as you on my joints and have had ZERO problems. but i get alot of greef from people.


on your tranny cross member did you trim the pinch weld off the frame so you could run the U channel further to the front of the vehicle?

ogdak
02-07-2006, 09:52 AM
on your tranny cross member did you trim the pinch weld off the frame so you could run the U channel further to the front of the vehicle?

Yup I did trim the pinch weld, something like 5 or 6".
Total lenght of the U-channel is approx. 41".

As for as the round bar near the JJ's and a lot of other stuff.
Time will tell if things will hold, but there will always be something called
"the weakest link"
I do not wonder what that will be.

ogdak
02-08-2006, 07:10 PM
November 2005

Something different,
What is missing in this pic.
http://www.ogdak.eu/images/2005-11/DSCF1846.JPG

That's right visco fan.
Will be replaced with this fod tauus 3.8 90-95 e-fan, does not need further explaining.
http://www.ogdak.eu/images/2005-11/DSCF1847.JPG

Made some hardware.
http://www.ogdak.eu/images/2005-11/DSCF1852.JPG

In place
http://www.ogdak.eu/images/2005-11/DSCF1855.JPG

http://www.ogdak.eu/images/2005-11/DSCF1853.JPG

Another issue, rear shocks.
I am gonna go XJ style
Near the BS on the in/downside of the unibody.
With som rivnuts
http://www.ogdak.eu/images/2005-11/DSCF1859.JPG

installed
http://www.ogdak.eu/images/2005-11/DSCF1860.JPG

some pieces of square tube and a u-beam.
http://www.ogdak.eu/images/2005-11/DSCF1866.JPG

Multiple shock mounting points for adjustment.
http://www.ogdak.eu/images/2005-11/DSCF1869.JPG

http://www.ogdak.eu/images/2005-11/DSCF1870.JPG

Almost the final looks, just some paint missing
http://www.ogdak.eu/images/2005-11/DSCF1872.JPG

8.8 install time
http://www.ogdak.eu/images/2005-11/DSCF1873.JPG

How nice:smt043 , stock 15" * 7J ZJ rim's
http://www.ogdak.eu/images/2005-11/DSCF1874.JPG

UCA and LCA in place.
http://www.ogdak.eu/images/2005-11/DSCF1875.JPG

http://www.ogdak.eu/images/2005-11/DSCF1878.JPG

http://www.ogdak.eu/images/2005-11/DSCF1876.JPG

http://www.ogdak.eu/images/2005-11/DSCF1879.JPG

http://www.ogdak.eu/images/2005-11/DSCF1880.JPG

What is in the box "More bling bling"
http://www.ogdak.eu/images/2005-11/DSCF1882.JPG

Eagle Alloys
SERIES 186, Super Finish, 16x10, Offset -24mm, BSM 4,5" en load 2100lbs
http://www.ogdak.eu/images/2005-11/DSCF1883.JPG

Good for now.

ILikeMud
02-08-2006, 09:26 PM
Those are some 'blingy' rims.

Can't wait to see it all finished man.

Cue-Ball
02-08-2006, 09:35 PM
Yea coming along nicely.

ATL ZJ
02-08-2006, 09:56 PM
There is a very good chance I'm going to copy at least some of the elements of your rear bumper. All of your work looks to be of very high quality.. What tools do you use for cutting your steel? It all appears to be laser cut..?

Once again, it's coming along nicely.

Cam

ogdak
02-09-2006, 01:39 PM
Can't wait to see it all finished man.


Me too



There is a very good chance I'm going to copy at least some of the elements of your rear bumper.
Cam

You are welcome.


All of your work looks to be of very high quality.. What tools do you use for cutting your steel? It all appears to be laser cut..?

Once again, it's coming along nicely.
Cam

Thanks, Yes most is lasercut.
But would not want to go without a 125mmø 1mm thick cut-off wheel

Kraqa
02-12-2006, 04:56 PM
cool

ogdak
02-14-2006, 03:13 PM
More from November 2005

So here is the reason why I went for 16" wheel's, dual piston WJ calipers.
They do not fit in a 15" wheel without serious grinding on the calipers.
http://www.ogdak.eu/images/2005-11/DSCF1885.JPG

Other advantage of this conversion is the right outer WJ knuckle with a "high steer arm" for the drag link to connect to.
No more "Y"steering but a "cross over" setup.
Redrilled the knuckle's to flip the ball stud's
Combined with a "over axle bracket" for the TB. Will get me a setup close to parallel between TB and DL.
http://www.ogdak.eu/images/2005-11/DSCF1886.JPG

http://www.ogdak.eu/images/2005-11/DSCF1887.JPG

http://www.ogdak.eu/images/2005-11/DSCF1888.JPG

Just a view flash-backs
Standard 15" 7J rim
http://www.ogdak.eu/images/2005-11/DSCF1893.JPG

US wheel 15" 7J with Bridgestone AT 31" 10.5
http://www.ogdak.eu/images/2005-11/DSCF1894.JPG

http://www.ogdak.eu/images/2005-11/DSCF1895.JPG

15" with 35"
http://www.ogdak.eu/images/2005-11/DSCF1896.JPG

And hopefully the last one for a while.
Eagle Alloys
SERIES 186, Super Finish, 16x10, Offset -24mm, BSM 4,5" en load 2100lbs
http://www.ogdak.eu/images/2005-11/DSCF1897.JPG

Time to press some new ball-joints in the D30
Making the adapters took more time then pressing itself.
Had to place a piece of bar between upper and lower "ear"
http://www.ogdak.eu/images/2005-11/DSCF1902.JPG

lower
http://www.ogdak.eu/images/2005-11/DSCF1903.JPG

upper
http://www.ogdak.eu/images/2005-11/DSCF1904.JPG

the benefit of a hoist
http://www.ogdak.eu/images/2005-11/DSCF1905.JPG

WJ knuckle in place.
http://www.ogdak.eu/images/2005-11/DSCF1906.JPG

http://www.ogdak.eu/images/2005-11/DSCF1907.JPG

December 2005
Time to return these, thnx JeePee
http://www.ogdak.eu/images/2005-12/DSCF1908.JPG

http://www.ogdak.eu/images/2005-12/DSCF1909.JPG

Replaced by these
Maxxis Creepy Crawler 8090 37"*12.50/16
Obvious that axle is to much forward, love those adj. CA's
http://www.ogdak.eu/images/2005-12/DSCF1910.JPG

http://www.ogdak.eu/images/2005-12/DSCF1912.JPG

http://www.ogdak.eu/images/2005-12/DSCF1914.JPG

All for now.

Cue-Ball
02-14-2006, 03:21 PM
Looking good, love the dual piston calipers.

Doing something similar to the WJ knuckle but going to use the Tera High steer knuckle on mine.

ILikeMud
02-14-2006, 11:00 PM
Wow, awesome work man!

ELLLLLIOTTTTT
02-14-2006, 11:11 PM
I've really been diggin all the professional work and quality parts that have gone into this rig. But I gotta say it...

D30 and 37's?

ATL ZJ
02-15-2006, 01:56 AM
D30 and 37's?

2nd that... I'm amazed I haven't broken anything in my 44 with 37s so far..

deadman
02-15-2006, 06:06 AM
Obvious that axle is to much forward, love those adj. CA's
http://www.flexworx.com/images/stories/project_otto/Forum/2005-12/DSCF1910.JPG


Actually it is not... Just cut a little on your bumper and fender, and you'll have a much better aproach angle. About the WJ knuckles... nice work, looks good. But I think it was a waste of time and money. With that lift/tires you are past D30 terretory.

Anyway... your doing clean work man!

chadjans
02-15-2006, 10:19 AM
Just cut a little on your bumper and fender, and you'll have a much better aproach angle.


Cutting your front bumper doesn't gain you any approach angle.

EMTimZJ
02-15-2006, 11:47 AM
Cutting your front bumper doesn't gain you any approach angle.

True, but I think his was refering to the fact that if he trims his front bumper (the part under the fender) he can leave the axle where it is (in the forward position) and still articulate without rubbing. Thus giving him a better aproach angle than if he moved his axle back.


The work looks great:supz: I dig the ball joint press.

grnd93
02-15-2006, 12:07 PM
The 30 will probably break, but I say wheel the crap out of it till it does, then build a 44 or 60 for it. Overall, incredible work...wish I lived in freaky-deaky dutch land so you could build some stuff for me.

ogdak
02-15-2006, 02:47 PM
I knew this discussion about a D30 and 37" would start sooner or later.
And you're right about it, it just has to do with AVAILABILITY of proper donor's.

According to the statistic's over the past years 2001-2004 of ownership in the Netherlands.
German manufactured car's represent 35,5% of ownership in the Netherlands.
France manufactured car's represent 24% of ownership in the Netherlands.
Japan manufactured car's represent 16% of ownership in the Netherlands.
And (sorry guys) in 11th place.
USA manufactured car's represent 0.8% of ownership in the Netherlands.
(source http://www.bovag.nl/ )

So when I go to an autoyard you know what I'll find.
So you can imagine what that means for the prices.

I looked into it when I was looking for the 8.8, turned out we only have one specialized US brand's autoyard.
So I ended up buying a new 8.8 - 31 spline - 4.10 gears - disk's.
Had it delivered as airfreight, still did cost me less then a second hand from a '97 exploder from a dutch autoyard.

So after that experience did not even start on looking for a suitable front axle donor. Just got a cheapo XJ D30.

So I'll just take my changes with it(and losses).

Further more this is my first auto build up ever.
So when my fabbing will hold up I'll continue this rig.
Maybe one day I'll find suitable European made donor's with suitable axle's
for 37" or bigger, maybe Unimog or small Army trucks.
For know I'm just enjoying this build. Getting close to have it driveable.

Thanks for the thumbs up, go have a beer.

luvthejeep
02-15-2006, 10:00 PM
http://www.flexworx.com/images/stories/project_otto/Forum/2005-12/DSCF1908.JPG

nice tow rig-

deadman
02-16-2006, 04:22 AM
True, but I think his was refering to the fact that if he trims his front bumper (the part under the fender) he can leave the axle where it is (in the forward position) and still articulate without rubbing. Thus giving him a better aproach angle than if he moved his axle back.



Exactly!

@ogdak:

You guys have a lot of K30s in the Benelux.
Me and a friend picked up a 14 bolt with Detroit locker, and a D60 Front with 4.56 gears for 650€. They were out of an ex-army 1985 K30 in Belgium.

After all that work, I would just run your stuff (or sell it if you get a really good price - unlikely) But I would start looking around for an old K30 and store its axles for the (maybe not all that far) future.

nate
02-16-2006, 09:24 AM
It all depends on what terrain your wheeling. In Alaska, guys were running 37 Boggers, 38 TSLs on D30s. I think maybe a broken shaft in the mix, but nothing serious. And this is going out wheeling every couple weekends, not pavement pounders.

crawlin' zj
02-16-2006, 01:17 PM
Just get some alloy shafts and hope those bad boys don't hook up with the skinny pedal down!

ILikeMud
02-16-2006, 03:13 PM
Just get some alloy shafts and hope those bad boys don't hook up with the skinny pedal down!

And have the ring gear break on you?
I rather replace a shaft, easier then a ring gear.

chadjans
02-16-2006, 04:04 PM
Or don't waste your fing money on a 30:confused:

ogdak
02-16-2006, 07:06 PM
@Deadman, thanks for the info. will keep an eye on that.

I'll just wheel it and see what is gonna happen.
Pro is , it wont see any rocks, why? cause we do not have them overhere.

About that front bumper, it is already cut but that is in next month's.

ogdak
03-09-2006, 05:09 PM
The story continue's

Back again, still december 2005
Because off the bigger wheels/tires I need to create some space in the front wheelwells.
How? well with a cut-off wheel.
Mainly on the front
http://www.ogdak.eu/images/2005-12/DSCF1930.JPG

http://www.ogdak.eu/images/2005-12/DSCF1931.JPG

http://www.ogdak.eu/images/2005-12/DSCF1932.JPG

http://www.ogdak.eu/images/2005-12/DSCF1933.JPG

On the back off the front wheelwell only minor adjustments.
stock
http://www.ogdak.eu/images/2005-12/DSCF1936.JPG

cut
http://www.ogdak.eu/images/2005-12/DSCF1937.JPG

Space enough
http://www.ogdak.eu/images/2005-12/DSCF1939.JPG

http://www.ogdak.eu/images/2005-12/DSCF1940.JPG

http://www.ogdak.eu/images/2005-12/DSCF1941.JPG

Reason why the inside rear-view mirror can go
http://www.ogdak.eu/images/2005-12/DSCF1946.JPG

http://www.ogdak.eu/images/2005-12/DSCF1947.JPG

The evap canister has to be moved also.
The rightside mounting point is the stock location
http://www.ogdak.eu/images/2005-12/DSCF1953.JPG

http://www.ogdak.eu/images/2005-12/DSCF1954.JPG

From below, outside the reach off the left front tire.
http://www.ogdak.eu/images/2005-12/DSCF1955.JPG

Front bumper sides shortend about 2"
http://www.ogdak.eu/images/2005-12/DSCF1957.JPG

http://www.ogdak.eu/images/2005-12/DSCF1956.JPG

Because I had damaged my rockers in the past.
Drilled a bunch off holes to restore its original(more or less) shape
http://www.ogdak.eu/images/2005-12/DSCF1958.JPG

And plumbed the holes
http://www.ogdak.eu/images/2005-12/DSCF1962.JPG

Took the grinder.
http://www.ogdak.eu/images/2005-12/DSCF1963.JPG
And done for tonight.

ogdak
03-22-2006, 06:19 PM
Hmm, time for an update.
Before you know you are a year behind again.
I left off with December 2005
To be precise, with a stock front DS which is now almost 4" short.
So I cut it in half
http://www.ogdak.eu/images/2005-12/DSCF1969.JPG

Took some solid bar, 6" length almost 2" in diameter.
Took some off on both end's to match the inner DS diameter, which is 39mm.
http://www.ogdak.eu/images/2005-12/DSCF1970.JPG

Used the press and welder to get things together.
DS still needs to be balanced, then I'll know wether this will work or not.
Do not have anymore pic's off it.

Made some bumpstop's for the frontaxle, still gonna need some fine tuning.
http://www.ogdak.eu/images/2005-12/DSCF1971.JPG

So finally it is 2006.
I plan to drive my ZJ this year, big Q is WHEN

Starting with CB and antenna location
http://www.ogdak.eu/images/2006-01/DSCF1983.jpg

http://www.ogdak.eu/images/2006-01/DSCF1985.jpg

Not even completely done, I already need to change something on the RUCA
The angle off the frame side bracket is not inline with the CA's
http://www.ogdak.eu/images/2006-01/DSCF1998.JPG

So cut the arms for about ¾ off the ø
http://www.ogdak.eu/images/2006-01/DSCF1999.JPG

Some extra grinding
http://www.ogdak.eu/images/2006-01/DSCF2000.JPG

Used the press to get the right angle, approx 5 degrees and welded it up again.
http://www.ogdak.eu/images/2006-01/DSCF2001.JPG

http://www.ogdak.eu/images/2006-01/DSCF2002.JPG

http://www.ogdak.eu/images/2006-01/DSCF2007.JPG

http://www.ogdak.eu/images/2006-01/DSCF2008.JPG

Dry practice in the garage, turns out I hit the rear coil with me wheel.
So ordered a set off 1¼" wheelspacers.
http://www.ogdak.eu/images/2006-01/DSCF2003.JPG

http://www.ogdak.eu/images/2006-01/DSCF2004.JPG

http://www.ogdak.eu/images/2006-01/DSCF2005.JPG

http://www.ogdak.eu/images/2006-01/DSCF2006.JPG

Setting up on the rear.
http://www.ogdak.eu/images/2006-01/DSCF2010.JPG

12 degrees
http://www.ogdak.eu/images/2006-01/DSCF2011.JPG

All for now.

ILikeMud
03-22-2006, 06:34 PM
Looking awesome man.

ogdak
03-22-2006, 06:42 PM
Looking awesome man.

Thnx, going slowly but getting there!

ILikeMud
03-22-2006, 08:13 PM
How far away are you from having it driveable right now?

ogdak
03-23-2006, 01:27 PM
How far away are you from having it driveable right now?

Is gonna take a while.
Still need to take care off a lot of small stuff
-currently working on the exhaust.
-need to set up both axles.
-dialing in suspension.
-DS's need's to be balanced.
-Dual battery set-up.
-Wiring on the E-fan.
-Air intake.
-Waiting on parts to complete steering setup.

I'm sure I'm forgetting things. But I hope this is it.

jsteves
03-23-2006, 01:56 PM
what rotors did you use on the front after the knuckle swap?
BTW looks really good!

ogdak
03-23-2006, 04:21 PM
what rotors did you use on the front after the knuckle swap?
BTW looks really good!

Thnx
I'm using WJ rotor's which I redrilled to 5 on 4,5"

ogdak
03-29-2006, 04:50 PM
So almost life, early March 2006.

Kept in mind wat was said last year.

i dig it. before you build the stearing. take back the ES2233L it will bend VERY easy.
you dont' need it for the drag link so why not use a regular TRE and build a sleeve for the tie rod to connect your SS to.


http://www.ogdak.eu/images/2006-03/DSCF2097.JPG

Time to box it.
http://www.ogdak.eu/images/2006-03/DSCF2099.JPG

http://www.ogdak.eu/images/2006-03/DSCF2101.JPG

http://www.ogdak.eu/images/2006-03/DSCF2102.JPG

Obvious needs some further attention and paint.

Time to fab an adjuster on the WJ knuckle for max steering.
Why? Cause I do not want to rub my tires on the fresh painted LCA's.
First to create a flat surface
http://www.ogdak.eu/images/2006-03/DSCF2104.JPG

Drill a 8 mm hole in it.
http://www.ogdak.eu/images/2006-03/DSCF2106.JPG

It is working.
http://www.ogdak.eu/images/2006-03/DSCF2107.JPG

Tap M10 in.
http://www.ogdak.eu/images/2006-03/DSCF2108.JPG

Install and adjust.
http://www.ogdak.eu/images/2006-03/DSCF2110.JPG

http://www.ogdak.eu/images/2006-03/DSCF2111.JPG

After a lot off thinking to get this ZJ street legal or haul it on a trailer, decided to put a catalytic converter in.
I need it to pass an annual check which is mandatory for cars which are 3 years and older.
Started with this!
http://www.ogdak.eu/images/2006-03/DSCF2113.JPG

And finally came up with this.
http://www.ogdak.eu/images/2006-03/DSCF2133.JPG

http://www.ogdak.eu/images/2006-03/DSCF2134.JPG

So I can put the cat over the traverse and still have room in the rear for a muffler.
http://www.ogdak.eu/images/2006-03/DSCF2115.JPG

Nice spot even the stock heat shield will fit again.
http://www.ogdak.eu/images/2006-03/DSCF2116.JPG

http://www.ogdak.eu/images/2006-03/DSCF2121.JPG

It is a highflow cat from random technology.
http://www.ogdak.eu/images/2006-03/DSCF2122.JPG

Shortened the front pipe to about 2" behind the lambda
http://www.ogdak.eu/images/2006-03/DSCF2137.JPG

http://www.ogdak.eu/images/2006-03/DSCF2138.JPG

So, next time the rest off the catback.

ogdak
04-10-2006, 03:44 PM
like said, the rest off the exhaust.
Nothing more then a big puzzle with pieces off pipe.
The custom muffler,made by Mav © which was a surplus leftover off an other project
Roughly in place, need something to aim for, right.
http://www.ogdak.eu/images/2006-03/DSCF2118.JPG

It is sort off between the r. upper and r.lower.
On the left, the end off the cat. converter.
http://www.ogdak.eu/images/2006-03/DSCF2119.JPG

The first pieces, straight pipe, flange, flange 45 degree turn down and straight again.
http://www.ogdak.eu/images/2006-03/DSCF2124.JPG

http://www.ogdak.eu/images/2006-03/DSCF2125.JPG

On with 45 degree up, straight pipe, 22,5 degree turn out, 22,5 degree turn in, and a muffler.
http://www.ogdak.eu/images/2006-03/DSCF2127.JPG

http://www.ogdak.eu/images/2006-03/DSCF2128.JPG

Grinding on the welds
http://www.ogdak.eu/images/2006-03/DSCF2135.JPG

http://www.ogdak.eu/images/2006-03/DSCF2139.JPG

http://www.ogdak.eu/images/2006-03/DSCF2140.JPG

Muffler followed by a 45 degree turn up, held in place with installation wire.
http://www.ogdak.eu/images/2006-03/DSCF2143.JPG

http://www.ogdak.eu/images/2006-03/DSCF2144.JPG

Again piece off straight pipe and down with a 90 degree turn
http://www.ogdak.eu/images/2006-03/DSCF2145.JPG

Between coil and shock
http://www.ogdak.eu/images/2006-03/DSCF2146.JPG

Followed by a 45 degree turn up and a slightly bend piece off pipe all the way to the back.
http://www.ogdak.eu/images/2006-03/DSCF2147.JPG

http://www.ogdak.eu/images/2006-03/DSCF2148.JPG

http://www.ogdak.eu/images/2006-03/DSCF2149.JPG

The full lenght
http://www.ogdak.eu/images/2006-03/DSCF2151.JPG

Roughly done.
http://www.ogdak.eu/images/2006-03/DSCF2153.JPG

In place.
http://www.ogdak.eu/images/2006-03/DSCF2154.JPG


After the first soundcheck (http://www.jeepforum.nl/index.php?showtopic=4857) "rightclick" - "save as" - etc.(it is 24 Mb), found a little leak.
http://www.ogdak.eu/images/2006-03/DSCF2161.JPG
SU.

Deltron
04-10-2006, 04:20 PM
it amazes me how much time and precision you put into your jeep. BTW what are your impressions of the maxxis creepy crawlers? know anybody who has used them yet? Im thinking of getting some.

ogdak
04-10-2006, 05:23 PM
BTW what are your impressions of the maxxis creepy crawlers? know anybody who has used them yet? Im thinking of getting some.

I have heard a few and seen 2 guys, both running 35" on their CJ's.
They were happy with the performence off the crawlers.
Have not seen them on ZJ's though. Time will tell.

ogdak
04-23-2006, 03:55 PM
Time to start doing some electric's
For starters an extra battery tray.
Some part's fot the bottom part.
http://www.ogdak.eu/images/2006-03/DSCF2141.JPG

Did not take a lot off pic's in this stage.
So here it is in place.
http://www.ogdak.eu/images/2006-03/DSCF2165.JPG

http://www.ogdak.eu/images/2006-03/DSCF2170.JPG

From below.
http://www.ogdak.eu/images/2006-03/DSCF2171.JPG

With the optima yellow top's
http://www.ogdak.eu/images/2006-03/DSCF2166.JPG

http://www.ogdak.eu/images/2006-03/DSCF2167.JPG

On the second batt.tray also a place to put the control box.
I do not like it to sit on the bull-bar.
http://www.ogdak.eu/images/2006-03/DSCF2174.JPG

So like this, I like it better.
http://www.ogdak.eu/images/2006-03/DSCF2176.JPG

To memorize how it was original mounted.
http://www.ogdak.eu/images/2006-03/DSCF2173.JPG

Will be "wired" pretty soon
Other issue is the stock alternator, which is only good for 90 Amp's
With a dual batt. setup, winch and e-fan probably not sufficiant.
picked up a MG "high output alternator"
Side by side, overall the MG alt. is bigger.
Little trick from MG to produce more power on idle, is the smaller poulie diameter wise.
http://www.ogdak.eu/images/2006-04/DSCF2183.JPG

Like stated on there website "Easy 5 Minute Installation", no suprises fit's nicely.
http://www.ogdak.eu/images/2006-04/DSCF2184.JPG

http://www.ogdak.eu/images/2006-04/DSCF2186.JPG

The poulie has an extra "groove", multi functional?
http://www.ogdak.eu/images/2006-04/DSCF2185.JPG

Has put this one also in place.
http://www.ogdak.eu/images/2006-04/DSCF2187.JPG

Time to start on the wireing, by somebody who know's what he is taking about. www.jeepie.nl aka Rene and Willem
Here a detailed view on the profi cable work, 35MM² litze kabel, solid cable shoe's and shrinking stocking, lol.?
(feel free to help me on my english guy's, don't have a clue how you call it. translate site's suck.)
http://www.ogdak.eu/images/2006-04/DSCF2208.JPG

Extra negative.
http://www.ogdak.eu/images/2006-04/DSCF2209.JPG

Tools and parts
http://www.ogdak.eu/images/2006-04/DSCF2210.JPG

Control box rewired.
http://www.ogdak.eu/images/2006-04/DSCF2212.JPG

In action, thnx guy's
http://www.ogdak.eu/images/2006-04/DSCF2216.JPG

And the other side.
http://www.ogdak.eu/images/2006-04/DSCF2213.JPG

To be continued.

OverkillZJ
04-23-2006, 04:24 PM
bling bling

ATL ZJ
04-23-2006, 06:51 PM
Looking purdy. I take it you're going to add an in-cab winch control? I know I wouldn't want to be pulling cable with my hood open and not be able to see where I was going..

ogdak
04-24-2006, 11:11 AM
I take it you're going to add an in-cab winch control?


that's right.

ILikeMud
04-24-2006, 03:25 PM
Damn, looks awesome man.
The quality of work you do is simply awesome.

Cue-Ball
04-24-2006, 03:30 PM
That's exactly where I put my 2nd yellow top.

Looks great!!!

ogdak
04-24-2006, 04:17 PM
Hey Ogdak, check your mail box, i sent an plane ticket to u, therefore u can come the NC and pimp my mallmobile out like yours is. haha, looked nice man

Ha ha, make sure it's a roundtrip


Damn, looks awesome man.
The quality of work you do is simply awesome.

THNX


That's exactly where I put my 2nd yellow top.

Looks great!!!

Only place available after ditching the airbox.

ogdak
04-27-2006, 02:16 PM
Zoomed in on where I left off.
http://www.ogdak.eu/images/2006-04/DSCF2225.JPG

Mounted up underneath the front crossmember.
http://www.ogdak.eu/images/2006-04/DSCF2226.JPG

cable spaghetti, love those coloured tie rap's
http://www.ogdak.eu/images/2006-04/DSCF2214.JPG

I thought to have some nice battery-terminal's, turned out that the threaded end is to short
to fit 3 cable shoe's, washer and nut.
http://www.ogdak.eu/images/2006-04/DSCF2220.JPG

Cut off
http://www.ogdak.eu/images/2006-04/DSCF2221.JPG

Drilled and tapped M10 thread
http://www.ogdak.eu/images/2006-04/DSCF2223.JPG

Before end after.
http://www.ogdak.eu/images/2006-04/DSCF2217.JPG

With RVS bolt looks much better.
http://www.ogdak.eu/images/2006-04/DSCF2224.JPG

Time for something else, to set up the rear axle.
Jacked up the rear on one side and ran into the rear off the rocker panel, with still enough
space on the rear and top off the wheel.
http://www.ogdak.eu/images/2006-04/DSCF2188.JPG

http://www.ogdak.eu/images/2006-04/DSCF2189.JPG

Set the adj. CA's longer, now clear on the rocker, but need to trim the rear bumper.
http://www.ogdak.eu/images/2006-04/DSCF2192.JPG

http://www.ogdak.eu/images/2006-04/DSCF2194.JPG

For now this will do.
http://www.ogdak.eu/images/2006-04/DSCF2196.JPG

http://www.ogdak.eu/images/2006-04/DSCF2199.JPG

Because the axle get pushed towards the rear, my upper shock mount's are off-line.
http://www.ogdak.eu/images/2006-04/DSCF2197.JPG

The "old" but never used mounting points
http://www.ogdak.eu/images/2006-04/DSCF2200.JPG

The new location, advantage is I can use the stock location/bracket for the fuel filter
http://www.ogdak.eu/images/2006-04/DSCF2203.JPG

http://www.ogdak.eu/images/2006-04/DSCF2204.JPG

All for April. SU

zjinprogress
04-27-2006, 07:03 PM
ultra slick rear shock bar!!! not that i would expect anything else! are those nut-zerts in the frame?

Mike

northgazj
04-27-2006, 08:10 PM
Dude, you're like the European Kraqa! Nice buildup!!

ogdak
04-28-2006, 02:39 AM
are those nut-zerts in the frame?


jep, M10 threaded

Kraqa
04-28-2006, 10:02 AM
haha, Riv nuts are freekin awsome.

keep up the progress looks great.

ogdak
05-09-2006, 03:21 PM
On with the rear, still need to make some Bump-stops.
Some off the materials I used.
http://www.ogdak.eu/images/2006-04/DSCF2233.JPG

http://www.ogdak.eu/images/2006-04/DSCF2235.JPG

Got the rear upper spring post cleared from paint and dirt.
http://www.ogdak.eu/images/2006-04/DSCF2236.JPG

Welded the piece with the nut on.
http://www.ogdak.eu/images/2006-04/DSCF2237.JPG

Pipe is on.
http://www.ogdak.eu/images/2006-04/DSCF2238.JPG

http://www.ogdak.eu/images/2006-04/DSCF2239.JPG

Using oem stops from the front off Beest's ZJ, leftovers after his ACOS install, thnx.
http://www.ogdak.eu/images/2006-04/DSCF2240.JPG

http://www.ogdak.eu/images/2006-04/DSCF2241.JPG

Fabbing a plate on the lower spring perch, otherwise I'll still damage my shocks
http://www.ogdak.eu/images/2006-04/DSCF2242.JPG

http://www.ogdak.eu/images/2006-04/DSCF2245.JPG

All followed by a "flextest"
http://www.ogdak.eu/images/2006-04/DSCF2247.JPG

http://www.ogdak.eu/images/2006-04/DSCF2248.JPG

Started to clean up a bit.
http://www.ogdak.eu/images/2006-04/DSCF2249.JPG

http://www.ogdak.eu/images/2006-04/DSCF2251.JPG

Left a little dust here and there
http://www.ogdak.eu/images/2006-04/DSCF2250.JPG

Also found a sticker spot.
http://www.ogdak.eu/images/2006-04/DSCF2252.JPG

And then finally last week a parcel arrived from Charlotte(NC).
Through this thread http://www.mallcrawlin.com/forum/showthread.php?p=75427#post75427
I came in contact with Andy from http://www.carolinarockshop.com
It took some time but he had to sort out some stuff to make this work, thanks Andy.
What's in the box.
http://www.ogdak.eu/images/2006-05/DSCF2255.JPG

First off all, a SG-621MR steering gear.
http://www.ogdak.eu/images/2006-05/DSCF2259.JPG

Combined with this,
SP-1405 Hi-Displacement P-Series PS Pump w/Reservoir Can

and this.
SC-2201K 1.75"Bore x 8"Stroke Cylinder Assist Steering Cylinder

makes this pile off parts.
http://www.ogdak.eu/images/2006-05/DSCF2262.JPG

Unfortunatly the package was damaged during transport, and some parts are now missing.
Got in contact with Andy, I'm sure things will be taken care off.

Finally old vs. new.
http://www.ogdak.eu/images/2006-05/DSCF2268.JPG

ILikeMud
05-09-2006, 10:35 PM
I can't wait to see the finished product.

ogdak
05-19-2006, 03:33 PM
I can't wait to see the finished product.
x 2

On with the steering.

Steering gear "PSC SG621MR" install.
Difference with the stock gear are the 2 ports for the hydro assist.
http://www.ogdak.eu/images/2006-05/DSCF2270.JPG

Other difference is the 3 vs 4 bolts for mounting the gear.
http://www.ogdak.eu/images/2006-05/DSCF2269.JPG

So first step is to make a mal to make sure the 4th hole is in the right place at the first attempt.
http://www.ogdak.eu/images/2006-05/DSCF2272.JPG

http://www.ogdak.eu/images/2006-05/DSCF2274.JPG

Mal in place.
http://www.ogdak.eu/images/2006-05/DSCF2276.JPG

Drilled with 6mm.
http://www.ogdak.eu/images/2006-05/DSCF2277.JPG

With a 11mm drill from the inside to the outside.
http://www.ogdak.eu/images/2006-05/DSCF2279.JPG

Reason to do so is because the 4th hole is right on an edge off plate.
http://www.ogdak.eu/images/2006-05/DSCF2281.JPG

Cut a big 45mm * M15 washer in half, to level the height difference.
http://www.ogdak.eu/images/2006-05/DSCF2282.JPG

On the inside cut a shock adapter to the right lenght.
e voila, steering gear in place.
http://www.ogdak.eu/images/2006-05/DSCF2285.JPG

http://www.ogdak.eu/images/2006-05/DSCF2284.JPG

Started experimenting to fab a bracket where the hydro hooks up to the tie-rod.
http://www.ogdak.eu/images/2006-05/DSCF2287.JPG

http://www.ogdak.eu/images/2006-05/DSCF2288.JPG

something like this.
http://www.ogdak.eu/images/2006-05/DSCF2289.JPG

http://www.ogdak.eu/images/2006-05/DSCF2290.JPG

The other side goes on the OA TB B ha ha
http://www.ogdak.eu/images/2006-05/DSCF2292.JPG

Cylinder in place.
http://www.ogdak.eu/images/2006-05/DSCF2291.JPG

Also started on a bracket for the Hi-Displacement pump, but without the proper pouley kind of useless.
Just to get an idea.
http://www.ogdak.eu/images/2006-05/DSCF2298.JPG

http://www.ogdak.eu/images/2006-05/DSCF2299.JPG

http://www.ogdak.eu/images/2006-05/DSCF2300.JPG

Till next time.

ogdak
05-19-2006, 04:16 PM
i am guessing that u still need to hook up the lines still?

I'll hook up the lines when the hardware fits.

ELLLLLIOTTTTT
05-20-2006, 01:58 PM
Looking good. I've never seen a buildup with so many detailed large scale pics. I love it!

ogdak
05-20-2006, 03:58 PM
I've never seen a buildup with so many detailed large scale pics.

I know, I get carried away every now and then.

ogdak
06-09-2006, 03:32 PM
So time to get back at it.
Because off the new high-displacement steering pump I need to find a spot to mount the remote reservoir.
Well it is gonna sit next to the winch relay box on the 2ND battery tray
http://www.ogdak.eu/images/2006-05/DSCF2318.JPG

Drilled and tapped 4 M10 holes.
http://www.ogdak.eu/images/2006-05/DSCF2319.JPG

And mounted the reservoir
http://www.ogdak.eu/images/2006-05/DSCF2321.JPG

http://www.ogdak.eu/images/2006-05/DSCF2322.JPG

Another part on the new steering setup, the bracket for the hydro assist.
DAMN it doesn't fit, when turning left it rums into the diff. cover.
So back at it with a cut-off wheel
http://www.ogdak.eu/images/2006-05/DSCF2320.JPG

And reweld it again
http://www.ogdak.eu/images/2006-05/DSCF2330.JPG

Result, not much play,
http://www.ogdak.eu/images/2006-05/DSCF2333.JPG

but it should be enough!!
http://www.ogdak.eu/images/2006-05/DSCF2331.JPG

Something totally different.
Cooling.
A loooooooooooooong time ago I took out the stock fan and installed the famous Tau.us E-fan.
But an E-fan needs to be controled by something, I don't want it to run at 50% or full power
everytime I switch on the ignition.
So this little probe will turn it on/off.
http://www.ogdak.eu/images/2006-05/DSCF2340.JPG

So this probe needs to be inserted between the radiator fins.
Either on the bottom or the right side depending on the type off radiator(crossflow or downflow)
And connected to the control unit which will turn the fan on/off at variable speeds.
it is factory set at 180 but can be adjusted with jumpers to the following values
148, 158, 166, 173, 180(default), 187, 194, 202 and 212.
It can be installed with/without continued cooling after engine shut-off(yellow wire)
Also equiped with an A/C input option(blue wire).
On that piece off paper the difference between(crossflow or downflow).
Obvious my Zj is crossflow
http://www.ogdak.eu/images/2006-05/DSCF2343.JPG

Mounted on the left inner fender, where the ABS controller was installed
http://www.ogdak.eu/images/2006-05/DSCF2344.JPG

Main wiring installed
http://www.ogdak.eu/images/2006-05/DSCF2346.JPG

To test the whole thing.
http://www.ogdak.eu/images/2006-05/DSCF2347.JPG

Used a paintstripper to get some heat, and yes it turns on nice and smooth.
http://www.ogdak.eu/images/2006-05/DSCF2348.JPG

And finally
Do.ge Dur.ngo parts to make the steering work.
"Thanks to OverkillZJ's project thread" for finding out that this might work, well it is a nice but tight fit
Need to fab up something to get the pressure line connected to the steering box, not much space left.
Anyone know wether there are 90 degree connector's for this purpose?
Let me know.
http://www.ogdak.eu/images/2006-06/DSCF2351.JPG

http://www.ogdak.eu/images/2006-06/DSCF2352.JPG

Well that is about it for now.

Cue-Ball
06-09-2006, 03:38 PM
Well Damn you are either going to need to bring that thing to the states when it is done or I am going to need to take the wife on a little vacation to the Netherlands to see it.

You might not move as fast as Matt does, but it sure looks great and the attention to detail is nothing less than spectacular.

ogdak
06-09-2006, 04:22 PM
I am going to need to take the wife on a little vacation to the Netherlands to see it.


You're welcome, good oppurtunity to get me some missing parts(ha ha).

Cue-Ball
06-09-2006, 04:24 PM
Maybe in 2008 we will be ready for a big vacation, she has always wanted to go to Australia though, I just don't want to take a 3 week trip so I have been reluctant to go there.

ogdak
06-09-2006, 05:12 PM
In 3 weeks you can cover the whole off Europe.
That is like 20 to 1 countries to visit.
I would know what to do.

Cue-Ball
06-10-2006, 12:25 AM
When the time comes I will hit you up for sure.

ZJARCHER
06-10-2006, 03:29 AM
Man! Great job as usual... Youve covered so much in this build..Im surprised youre not designing your own ECU :) haha, beautiful work...

ogdak
06-10-2006, 04:47 AM
Im surprised youre not designing your own ECU :) haha,

LOL, that would come closer to my day to day job, then al that other stuff I did on the ZJ so far.

Thanx.

steves88vb
06-10-2006, 04:42 PM
what do u do for a living?

ogdak
06-13-2006, 12:12 PM
what do u do for a living?

It is listed in my profile info "software tester"

ogdak
06-20-2006, 03:50 PM
Continuation
Finally got the airintake done
Cause the lack off space in the engine bay, the stock airbox and intake had to go.
So I put a "Dual air tube intake" in.
http://www.ogdak.eu/images/2006-06/DSCF2356.JPG

With filter,
http://www.ogdak.eu/images/2006-06/DSCF2362.JPG

and pre-filter.
http://www.ogdak.eu/images/2006-06/DSCF2363.JPG

Looks like this.
http://www.ogdak.eu/images/2006-06/DSCF2361.JPG

Made some progress on the steering with some 90 degree connector's.
http://www.ogdak.eu/images/2006-06/DSCF2364.JPG

tubing.
http://www.ogdak.eu/images/2006-06/DSCF2365.JPG

An used trannycooler which from now on will be a steeringoilcooler
http://www.ogdak.eu/images/2006-06/DSCF2366.JPG

Next to the stock tranny cooler
http://www.ogdak.eu/images/2006-06/DSCF2370.JPG

Trying to fit everything together in a limited space.
http://www.ogdak.eu/images/2006-06/DSCF2369.JPG

Well it doesn't fit. Not enough "height" between steering gear and powersteerpump.
So had to cut that nice and shinny do.ge du.angry bracket from the bottom, but still not enough.
Thankfully over a year ago I made an adjustable tranny traverse.
So mounted the tranny traverse in the "low" position.
This gave me like little less off an ¼" between the multibelt and steering gear.
http://www.ogdak.eu/images/2006-06/DSCF2377.JPG

http://www.ogdak.eu/images/2006-06/DSCF2378.JPG

Tubing cut to the right lenght, only need to press the connector's on.
http://www.ogdak.eu/images/2006-06/DSCF2386.JPG

Cooler mounted and hooked on
http://www.ogdak.eu/images/2006-06/DSCF2389.JPG

Tubing pressed and mounted
http://www.ogdak.eu/images/2006-06/DSCF2390.JPG

http://www.ogdak.eu/images/2006-06/DSCF2392.JPG

Some regular maintenance stuff
http://www.ogdak.eu/images/2006-06/DSCF2367.JPG

the old,
http://www.ogdak.eu/images/2006-06/DSCF2385.JPG

the new one.
http://www.ogdak.eu/images/2006-06/DSCF2394.JPG

Need to replace this seal.
http://www.ogdak.eu/images/2006-06/DSCF2397.JPG

Also adjusted the tranny bracket for the t-case lever's
http://www.ogdak.eu/images/2006-06/DSCF2395.JPG

Poored the first fresh oil(powersteer) tonight. This thing is starting to get in it's final stage.
Only ?? nights off sweet dreams

KansasCrawlin
06-20-2006, 10:58 PM
Glad to see your progress, your project is about to come alive! Congrads:)

ILikeMud
06-21-2006, 12:19 PM
Awesome as usual.

Getting closer to having it running huh?

ogdak
06-21-2006, 01:56 PM
Thnx,
Hope to have the engine running again within the next 2 weeks.

ogdak
07-01-2006, 04:06 PM
Engine upgrade.
Changing the stock thermos for an 160 unit.
What a (^&(^)(* job to do, eventually took the whole top mounting bracket(generator A/C pump) off to get some clearence.
http://www.ogdak.eu/images/2006-06/DSCF2372.JPG

Here the 160.
http://www.ogdak.eu/images/2006-06/DSCF2373.JPG

With a fresh gasket.
http://www.ogdak.eu/images/2006-06/DSCF2374.JPG

Pipe on and installed the rest of the parts involved.
http://www.ogdak.eu/images/2006-06/DSCF2375.JPG

Some electric parts, new distributor cap with rotor.
Doesn't lool like a waste
http://www.ogdak.eu/images/2006-06/DSCF2410.JPG

http://www.ogdak.eu/images/2006-06/DSCF2411.JPG

Time consuming job, wrenching in a very small area.
Got it done thanks to a "Wrenching Platform"
http://www.ogdak.eu/images/2006-06/DSCF2408.JPG

http://www.ogdak.eu/images/2006-06/DSCF2412.JPG

Also new plugs, ignition wires and a HO coil.
http://www.ogdak.eu/images/2006-06/DSCF2413.JPG

http://www.ogdak.eu/images/2006-06/DSCF2414.JPG

Started on installing some small parts to be able to crank it again.
New rear tranny seal and trannyoil pan with new gasket
http://www.ogdak.eu/images/2006-06/DSCF2387.JPG

Unfortunatly a damaged thread in the tranny, damn
Tried to get a heli-coil, but no luck. So tappped it with M8 thread
http://www.ogdak.eu/images/2006-06/DSCF2405.JPG

Very carefully an allenbolt M8 in, not to tight only 17Nm required.

Filling up several fluid level's, checking, double check and re-check.
Started to be in doubt after all.
Left the engine oil and filter because I added a portion off Forte Motor Flush.
To get this chemical to do its job, the engine needs to be running for 20 to 25 minutes, then do the oil change.
Also a good test for the modified cooling system.
Fabbed up some sort of waste duct.
http://www.ogdak.eu/images/2006-06/DSCF2407.JPG

Result, Big smile (let me translate this for you "It runs again") doesn't need more explaining I guess
http://www.ogdak.eu/images/2006-06/DSCF2409.JPG

The girls are ready to roll.
http://www.ogdak.eu/images/2006-06/DSCF2401.JPG

http://www.ogdak.eu/images/2006-06/DSCF2402.JPG


E-fan and steering working perfect, cooling temp just stayed below 176
Oil pressure just below 3

Earlier this year when testing the custom muffler I heard thicking from the engine, probably a valve rod or something.
Have not heard it anymore.

Finaly changed the engine oil and filter.

An final(for now) underhood view
http://www.ogdak.eu/images/2006-06/DSCF2416.JPG

Saturday with new engine oil had it running again and shot a video
TESTRUN (http://www.ogdak.eu/vid/testrun.wmv) 1.1Mb

Updated my checklist
http://www.ogdak.eu/images/2006-06/DSCF2417.JPG

Got to say this last weekend definatly was a mile stone................

Kraqa
07-01-2006, 04:52 PM
right on!!!

looks/sounds freeking awsome

ogdak
07-01-2006, 05:05 PM
Thnx, sounds a lot better when standing next to it.

Cue-Ball
07-01-2006, 05:24 PM
Awesome, I know that getting it fired is HUGE and CONGRATS!!!!!!!!!!

2jeepsforus
07-01-2006, 05:45 PM
did you fabricate the duel intake setup, or buy it somewhere. I was thinking of running a second battery setup, but I would have to ditch the K&N I have now.

Thanks,
Dave

Beest
07-01-2006, 06:04 PM
http://www.turbocity.com/product_info.php?products_id=107

ILikeMud
07-01-2006, 07:19 PM
Congrats on getting it fired up man.
Bet you can't wait for the shake down.

ogdak
07-02-2006, 01:35 AM
Thnx Beest

dads5.9
07-04-2006, 12:25 AM
What a fabulous thread. I set here most of the evening looking through all the pictures and comments.

I don't know how you take all the pictures. At the end of a long day in the garage the last thing I'm looking to do is a photo documentary of all the work.

Great job!

ogdak
07-05-2006, 10:52 AM
Thnx,
Most off the time I take the pic's while wrenching, unless my hands get to dirty. Needless to say my camera is pretty greased up. haha

Skyline
07-05-2006, 11:44 AM
Great thread. Your girls are really cute. Looks like they were preparing for the match against Portugal, (sorry about the result...I was rooting for you!)

ogdak
07-06-2006, 02:18 PM
Thnx,
But that wasn't because off the worldcup football.
It was because off the 4th and last night off the evening marches which my oldest 2 attended this year.

Firestarter
07-11-2006, 05:33 PM
great build mate. looks like it's all coming together.

whats your exhaust setup like? i saw that you used a random tech cat and stock manifolds (i think), but didn't see the muffler. sounds like either a small magnaflow, a bullet muffler, or maybe a glasspack. regardless, sounds great.

ogdak
07-12-2006, 08:08 AM
great build mate. looks like it's all coming together.

whats your exhaust setup like? i saw that you used a random tech cat and stock manifolds (i think), but didn't see the muffler. sounds like either a small magnaflow, a bullet muffler, or maybe a glasspack. regardless, sounds great.

Thnx

All correct, as for the muffler it is home made by Mav ©
There are a few pic's here in this thread.

and some more
http://www.flexworx.com/images/stories/project_otto/Forum/2006-07/IMG_2221.jpg

http://www.flexworx.com/images/stories/project_otto/Forum/2006-07/IMG_2222.jpg

ogdak
07-19-2006, 06:25 PM
What have we done lately, well not much.
After all it is my vacation
Earlier this month I "lifted" the hood
Used squarre tube for this 40*40*2 220 long, all millimetrs
http://www.ogdak.eu/images/2006-07/DSCF2424.JPG

http://www.ogdak.eu/images/2006-07/DSCF2425.JPG

http://www.ogdak.eu/images/2006-07/DSCF2421.JPG

Also started on a pair off mini ramps, to help fine-tuning the "flex" later on.
Used corner 30*30*3 and bar 40*5(all millimeters again)
http://www.ogdak.eu/images/2006-07/DSCF2438.JPG

Tested by Beest, watch the Mallcrawlin.com sticker.
http://www.ogdak.eu/images/2006-07/DSCF2434.JPG

http://www.ogdak.eu/images/2006-07/DSCF2436.JPG

After some minor adjustments, the final result.
http://www.ogdak.eu/images/2006-07/DSCF2439.JPG

http://www.ogdak.eu/images/2006-07/DSCF2440.JPG

Because there will be some extra switches and warning lights, I´m gonna adjust the center console a little.
First in wood, to get some idea´s
Something like this.
http://www.ogdak.eu/images/2006-07/DSCF2442.JPG

The passenger side out off 1mm stainless steel.
http://www.ogdak.eu/images/2006-07/DSCF2441.JPG

In place including the top side.
http://www.ogdak.eu/images/2006-07/DSCF2443.JPG

http://www.ogdak.eu/images/2006-07/DSCF2444.JPG

http://www.ogdak.eu/images/2006-07/DSCF2445.JPG

http://www.ogdak.eu/images/2006-07/DSCF2448.JPG

After ´bending´ the top piece it will be something like this.
http://www.ogdak.eu/images/2006-07/DSCF2449.JPG

in the "project".
http://www.ogdak.eu/images/2006-07/DSCF2450.JPG

http://www.ogdak.eu/images/2006-07/DSCF2453.JPG

That´s right it was hot in the garage today, just a little over 100 Fahrenheit.
http://www.ogdak.eu/images/2006-07/DSCF2454.JPG

First attribute in place, winch control lock.
You never know with small and big children in a jeep toy.
http://www.ogdak.eu/images/2006-07/DSCF2456.JPG

Have a nice vacation.

Cue-Ball
07-19-2006, 06:30 PM
Center console looks trick.

ogdak
07-19-2006, 06:36 PM
Center console looks trick.

Sorry Dirk, but I don't understand what you mean to say.

Grandsrus
07-19-2006, 06:44 PM
He means it looks bad ass!

Might I add, your whole ZJ progression looks "trick".
Nice work.

ogdak
07-19-2006, 06:46 PM
thanks, learning slang every day.

ILikeMud
07-19-2006, 06:50 PM
Very nice center console, I like it.

Beest
08-13-2006, 06:39 AM
I want a update.......

ogdak
08-13-2006, 07:08 AM
I want a update.......

Ja ja,

nice avatar btw.

ogdak
08-13-2006, 08:27 AM
So it has been a while, but have done some minor things.
A month ago I was working on the center console, let's proceed.
Made 2 incab whinch control switches
http://www.ogdak.eu/images/2006-07/DSCF2457.JPG

http://www.ogdak.eu/images/2006-07/DSCF2459.JPG

http://www.ogdak.eu/images/2006-07/DSCF2458.JPG

http://www.ogdak.eu/images/2006-07/DSCF2461.JPG

http://www.ogdak.eu/images/2006-07/DSCF2460.JPG

http://www.ogdak.eu/images/2006-07/DSCF2463.JPG

http://www.ogdak.eu/images/2006-07/DSCF2462.JPG

Major thing however this week was, DS's are done.
http://www.ogdak.eu/images/2006-08/DSCF2466.JPG

http://www.ogdak.eu/images/2006-08/DSCF2467.JPG

I couldn't resist so last night I drove it on it's own engine power.
4 feet backwards and 2 feet up.
In 2 wheel drive, since the front pumpkin is still empty.
Don't mind my big smile.
http://www.ogdak.eu/images/2006-08/DSCF2476.JPG

http://www.ogdak.eu/images/2006-08/DSCF2477.JPG

http://www.ogdak.eu/images/2006-08/DSCF2478.JPG

http://www.ogdak.eu/images/2006-08/DSCF2480.JPG

Next update will be quicker, I think.

ILikeMud
08-13-2006, 11:02 AM
Awesome man.
Close and Closer to being finished.

nate
08-13-2006, 11:07 AM
I need to built some ramps like that so I can sit under low cars when I'm working on them... wonder if I would built 4... it'd be like a homebuilt lift kinda sorta

BigDaveZJ
08-13-2006, 11:26 AM
I need to built some ramps like that so I can sit under low cars when I'm working on them... wonder if I would built 4... it'd be like a homebuilt lift kinda sorta

I've got some 8" high plastic ones I got at Pep Boys. They work fine when trying to get a drive axle up, but not so hot on non-drive axles. I was trying to pull the ZJ up onto them once after blowing up the front d-shaft and part of the t-case, only had RWD. The fronts kept pushing the ramps, they wouldnt stay put, so I was trying to really ease the ZJ up them. Somehow or another I ended up shooting the rear ramps out from underneath the Jeep, out of the garage (door was open), and into the street. It was pretty badass.

2jeepsforus
08-13-2006, 11:48 AM
I was trying to pull the ZJ up onto them once after blowing up the front d-shaft and part of the t-case, only had RWD. The fronts kept pushing the ramps, they wouldnt stay put, so I was trying to really ease the ZJ up them.

Why didn't you just block them with a cinder block or something that was somewhat heavy. I would hope that you figured that out soon there after :best:

spykosshow
08-13-2006, 12:55 PM
I've got some 8" high plastic ones I got at Pep Boys. They work fine when trying to get a drive axle up, but not so hot on non-drive axles. I was trying to pull the ZJ up onto them once after blowing up the front d-shaft and part of the t-case, only had RWD. The fronts kept pushing the ramps, they wouldnt stay put, so I was trying to really ease the ZJ up them. Somehow or another I ended up shooting the rear ramps out from underneath the Jeep, out of the garage (door was open), and into the street. It was pretty badass.

Or jack it up and set them under the wheels?

ogdak
08-13-2006, 01:26 PM
I need to built some ramps like that so I can sit under low cars when I'm working on them... wonder if I would built 4... it'd be like a homebuilt lift kinda sorta

They won't work well for low cars since the ramp is 38 degrees up.
They are only 4 ft long and 2 ft high approx.
Made just a pair for fine tuning on the suspension, seems to work out pretty wel.

ogdak
08-13-2006, 04:04 PM
Quick enough?
Obvious had to try the front on the ramp also.
Got the ramp fixed too the ground to avoid it shooting away, so still in 2 wheel drive.
By the way, I'm a little over 6 ft, standing eye to eye with my left headlamp
http://www.ogdak.eu/images/2006-08/DSCF2486.JPG

http://www.ogdak.eu/images/2006-08/DSCF2482.JPG

Enough travel on the rear shocks
http://www.ogdak.eu/images/2006-08/DSCF2483.JPG

http://www.ogdak.eu/images/2006-08/DSCF2494.JPG

Coils are doing better then exspected
http://www.ogdak.eu/images/2006-08/DSCF2484.JPG

http://www.ogdak.eu/images/2006-08/DSCF2491.JPG

http://www.ogdak.eu/images/2006-08/DSCF2485.JPG

http://www.ogdak.eu/images/2006-08/DSCF2492.JPG

Little dusty
http://www.ogdak.eu/images/2006-08/DSCF2487.JPG

Detail
http://www.ogdak.eu/images/2006-08/DSCF2488.JPG

The hydro assist still fit
http://www.ogdak.eu/images/2006-08/DSCF2490.JPG

http://www.ogdak.eu/images/2006-08/DSCF2493.JPG

All for now

ogdak
08-13-2006, 04:20 PM
Awesome man.
Close and Closer to being finished.

Jup, it's about time.
It is almost about two years since I drove it on/off - road.

cashflowdub
08-13-2006, 05:55 PM
this is about the sickest BUILD EVER I WANT MORE

ILikeMud
08-13-2006, 06:51 PM
Jup, it's about time.
It is almost about two years since I drove it on/off - road.

Wow, bet you can`t wait till it`s finished.

ogdak
08-14-2006, 10:13 AM
Wow, bet you can`t wait till it`s finished.

Guess one off the biggests lessons on this project is, to have all(or a lot) off the needed parts in storage before taking things a part.
So the actual build time will be a lot shorter.

ILikeMud
08-14-2006, 11:59 AM
I hear you but at the same time, gather parts can be a pain too. I've been gathering parts for my trans swap since Feb of this year.

Did you buy most your parts from the US or a mix?

violatedppl
08-14-2006, 12:00 PM
I still think that is the most badass rear bumper Ive seen on a ZJ.

ogdak
08-14-2006, 12:09 PM
Did you buy most your parts from the US or a mix?

steel, tires, e-fan and the Xj D30 are bought local.
probably forgetting som small parts.




I still think that is the most badass rear bumper Ive seen on a ZJ.

x2
Thanx, Sjikita did the drawing and manufacturing off it.

ILikeMud
08-14-2006, 12:21 PM
What tires are those anyhow? Maxxis?

ogdak
08-14-2006, 03:18 PM
What tires are those anyhow? Maxxis?

jup, Creepy Crawler

ogdak
08-30-2006, 02:50 PM
Since Dutch Jeep Camp 2006 originaly scheduled for early september, then canceled and now rescheduled for late oktober.
I thought, well that must be possible so get at it.
Took out the front axle
http://www.ogdak.eu/images/2006-08/DSCF2505.JPG

Got it on the bench
http://www.ogdak.eu/images/2006-08/DSCF2506.JPG

To finish the upper CA mount and the tabs for the hydro assist
http://www.ogdak.eu/images/2006-08/DSCF2507.JPG

Done.
http://www.ogdak.eu/images/2006-08/DSCF2510.JPG

Other issue to be done, welding the spacers on the wj kuckles to get the u-joints inline withe the ball-joints.
That will acquire stick welding with a nikkel rod
http://www.ogdak.eu/images/2006-08/DSCF2511.JPG

Cleaned the surface
http://www.ogdak.eu/images/2006-08/DSCF2512.JPG

http://www.ogdak.eu/images/2006-08/DSCF2514.JPG

Put it in the oven for an hour at a little over 500
http://www.ogdak.eu/images/2006-08/DSCF2516.JPG

Started welding, but not really happy with the result, so that is gonna need some more attention
http://www.ogdak.eu/images/2006-08/DSCF2523.JPG

Other thing on the front to do is changing R&P
Empty axle and all what came out off it
http://www.ogdak.eu/images/2006-08/DSCF2520.JPG

http://www.ogdak.eu/images/2006-08/DSCF2521.JPG

Overhaul kit
http://www.ogdak.eu/images/2006-08/DSCF2522.JPG

Used a knife puller the get the pinion bearing going,
http://www.ogdak.eu/images/2006-08/DSCF2525.JPG

On to the press, just to get the oil slinger out to reuse it.
http://www.ogdak.eu/images/2006-08/DSCF2527.JPG

3.73 vs. 4.56
http://www.ogdak.eu/images/2006-08/DSCF2528.JPG

New bearing with old oil slinger pressed in place.
http://www.ogdak.eu/images/2006-08/DSCF2530.JPG

http://www.ogdak.eu/images/2006-08/DSCF2532.JPG

After the nescesary math adjusted the shimpack thickness and pressed the bearing housing in
http://www.ogdak.eu/images/2006-08/DSCF2533.JPG

http://www.ogdak.eu/images/2006-08/DSCF2534.JPG

http://www.ogdak.eu/images/2006-08/DSCF2535.JPG

Next time ringgear and more.

ILikeMud
08-30-2006, 03:13 PM
Coming along nicely. Can`t wait to see it all finished.

ogdak
09-16-2006, 03:53 PM
He,
Like said, on with the ring gear, cleaned the surface
http://www.ogdak.eu/images/2006-08/DSCF2502.JPG

http://www.ogdak.eu/images/2006-08/DSCF2503.JPG

New bolts
http://www.ogdak.eu/images/2006-08/DSCF2536.JPG

Old bearings removed, did not come off easy
http://www.ogdak.eu/images/2006-09/DSCF2579.JPG

http://www.ogdak.eu/images/2006-09/DSCF2580.JPG

http://www.ogdak.eu/images/2006-09/DSCF2581.JPG

But got it done
http://www.ogdak.eu/images/2006-09/DSCF2583.JPG

New bearings on, now the shims are on the outside, much easier to adjust
http://www.ogdak.eu/images/2006-09/DSCF2582.JPG

http://www.ogdak.eu/images/2006-09/DSCF2584.JPG

Most time consuming must have been to get the preload right with these kind off shims.
http://www.ogdak.eu/images/2006-08/DSCF2539.JPG

On to the 8.8
Fresh gear oil out, it is a new axle but with the wrong 4.10 ratio
http://www.ogdak.eu/images/2006-08/DSCF2540.JPG

pinion mate shaft out to clear the axle's
http://www.ogdak.eu/images/2006-08/DSCF2542.JPG

Oem shims out off one piece, just a very slight difference between left
http://www.ogdak.eu/images/2006-08/DSCF2543.JPG

and right
http://www.ogdak.eu/images/2006-08/DSCF2544.JPG

Wow. lot off space in there
http://www.ogdak.eu/images/2006-08/DSCF2546.JPG

To clearify what goes where
http://www.ogdak.eu/images/2006-08/DSCF2548.JPG

4.10 off
http://www.ogdak.eu/images/2006-08/DSCF2549.JPG


4.56 on, then the pinion mate shaft does not fit anymore
But that is discussed here (http://www.mallcrawlin.com/forum/showthread.php?t=9318)

On the left the 4.56, just 1 teeth less
http://www.ogdak.eu/images/2006-08/DSCF2552.JPG

Did not make anymore R&P pic's, 8.8 went smooth.

Did make a new airvent on the 8.8
Driled out a M10 bolt and fitted in a drilled out grease nipple
http://www.ogdak.eu/images/2006-08/DSCF2556.JPG

Just need a piece off tube on it.
http://www.ogdak.eu/images/2006-08/DSCF2557.JPG

All for now, enjoy

RiPPiNiTuP7
09-17-2006, 12:01 AM
this may have already been asked, but what do you do for a living ogdak? your fab skills and work quality are awsome. keep us updated.

ogdak
09-17-2006, 12:17 PM
what do you do for a living ogdak? your fab skills and work quality are awsome.

Thnx
I´m in ICT.

1996cc
09-18-2006, 12:31 PM
With the grease zerk air vent, did you remove the little metal ball in it? Or have one without that ball in it? Otherwise, it isn't going to vent. Otherwise, looks good.

ogdak
09-18-2006, 02:44 PM
With the grease zerk air vent, did you remove the little metal ball in it? Or have one without that ball in it? Otherwise, it isn't going to vent. Otherwise, looks good.



Driled out a M10 bolt and fitted in a drilled out grease nipple


thnx

EMTimZJ
09-18-2006, 05:22 PM
Cool idea with the zerk vent.

Looking very nice!

-Tim

1996cc
09-19-2006, 12:14 PM
Totally missed that, sorry.

ogdak
09-21-2006, 02:20 PM
About time to hook up the brakes.
Reused the front flex brakelines in the rear.
http://www.ogdak.eu/images/2006-09/DSCF2564.JPG

"T" section in the middle off the truss.
http://www.ogdak.eu/images/2006-09/DSCF2568.JPG

Some pieces off new hardline and a handfull off clamps.
http://www.ogdak.eu/images/2006-09/DSCF2571.JPG

http://www.ogdak.eu/images/2006-09/DSCF2573.JPG

Still had to paint here and there, also done now.
Every now and then, stock rim's come in handy.
http://www.ogdak.eu/images/2006-09/DSCF2618.JPG

Extended the fixed brake line
http://www.ogdak.eu/images/2006-09/DSCF2619.JPG

http://www.ogdak.eu/images/2006-09/DSCF2622.JPG

Painted some other stuff, then finally time to start putting things together.
Rear bumpstops
http://www.ogdak.eu/images/2006-09/DSCF2620.JPG

Brackets for the upper shockmounts.
http://www.ogdak.eu/images/2006-09/DSCF2621.JPG

Shockmount in place.
http://www.ogdak.eu/images/2006-09/DSCF2625.JPG

http://www.ogdak.eu/images/2006-09/DSCF2626.JPG

Axle, coils and shocks,
http://www.ogdak.eu/images/2006-09/DSCF2627.JPG

with limiting straps.
http://www.ogdak.eu/images/2006-09/DSCF2628.JPG

http://www.ogdak.eu/images/2006-09/DSCF2629.JPG

Almost everything checked!
http://www.ogdak.eu/images/2006-09/DSCF2576.JPG

Longer studs for the front hubs, because off the alu rims and 0.5" spacers.
http://www.ogdak.eu/images/2006-09/DSCF2574.JPG

So more painting to do on the traverse, 4 weeks left to get everything done for
The 3rd Edition Off Dutch Jeep Camp, so SU

ILikeMud
09-21-2006, 03:09 PM
Finally coming together, very nice.

RUYellow
09-21-2006, 10:41 PM
Looking good, I love the rear bumper.

Where did you get the front spacers, I am looking for some .5 or .75?

Sudz
09-21-2006, 11:13 PM
copper brake lines?

ogdak
09-22-2006, 01:41 AM
Looking good, I love the rear bumper.

Where did you get the front spacers, I am looking for some .5 or .75?

Thnx. I just cut up a set off old XJ front brake rotors.
I can post a pic, but i think it is not that hard to visualize!





copper brake lines?
You seem suprised, It is pretty commenly used when redoing brake lines.

ogdak
10-13-2006, 11:09 AM
Due to a server problem, the pic's were gone.
Started to restore today on a other server.
I'll post an update this weekend.

ogdak
10-13-2006, 11:42 AM
So after a small break due to a server error on the dutch jeep forum, on with this thread.
Time to install the front axle.
http://www.ogdak.eu/images/2006-09/DSCF2633.JPG

CA's in place
http://www.ogdak.eu/images/2006-09/DSCF2634.JPG

Shocks and straps.
http://www.ogdak.eu/images/2006-09/DSCF2635.JPG

Axle hanging on the straps, nice to see that the coils will not fall out off place.
http://www.ogdak.eu/images/2006-09/DSCF2636.JPG

Knuckles and tie-rod.
http://www.ogdak.eu/images/2006-09/DSCF2639.JPG

Wheelhubs with the longer studs and rotor's in place.
http://www.ogdak.eu/images/2006-09/DSCF2640.JPG

http://www.ogdak.eu/images/2006-09/DSCF2641.JPG

Callipers in place.
http://www.ogdak.eu/images/2006-09/DSCF2645.JPG

http://www.ogdak.eu/images/2006-09/DSCF2646.JPG

Drag link and track bar back on.
http://www.ogdak.eu/images/2006-09/DSCF2647.JPG

Time to start bringing levels up to level
http://www.ogdak.eu/images/2006-09/DSCF2643.JPG

Every now and then I have trouble finding things, don't know why?
http://www.ogdak.eu/images/2006-09/DSCF2642.JPG

Zo after testdriving recently with Beest(also a member on this board) Zj.
I could no longer resist, so with a slightly raised harbeat I drove it out off the garage.
http://www.ogdak.eu/images/2006-09/DSCF2661.JPG

Where as soon I got out, My 8 year old son Dennis took over the steering wheel.
http://www.ogdak.eu/images/2006-09/DSCF2659.JPG

http://www.ogdak.eu/images/2006-09/DSCF2660.JPG

Almost forgot how much space I have in the garage
http://www.ogdak.eu/images/2006-09/DSCF2662.JPG

So back on its spot, the only problem that occured was the E-fan running on max pretty soon.
Cause off that the engine temp didn't came above 40 celsius, so it seems to have enough cooling capacity
which is nice to know. So looks like it that I shortcircuited the dc control unit.
Luckily I was able to borough the unit from Beest. Thnx Rene
Small world ha, this used to be Cue-Ball's unit
http://www.ogdak.eu/images/2006-09/DSCF2664.JPG

Time to get the bumpers powder coated.
http://www.ogdak.eu/images/2006-09/DSCF2665.JPG

http://www.ogdak.eu/images/2006-09/DSCF2668.JPG

http://www.ogdak.eu/images/2006-09/DSCF2667.JPG

If everything works out they should be back in early next week.
I should be able to get it ready in less then a week.
Dutch Jeep Camp 2006 is only 1 week away.

ILikeMud
10-13-2006, 12:07 PM
Looks awesome man!

SuicideTireZJ
10-13-2006, 04:31 PM
Congrats on moving it under its own power!

EMTimZJ
10-13-2006, 06:32 PM
Very nice! Finally getting to drive it will be a blast:smt023

-Tim

Cue-Ball
10-13-2006, 06:53 PM
Time to start bringing levels up to level
http://www.jeepforum.nl/ogdak/2006-09/DSCF2643.JPG



Hey now, those don't look like Amsoil containers to me :confused: :confused: :confused:


Just kidding man, glad to see it up and around so to speak.

ogdak
10-13-2006, 07:08 PM
Ha ha, It would have been if it would be in store's overhere.
Don't worry Dirk, I'll keep the amsoil stickers on the ZJ.

Cue-Ball
10-14-2006, 12:41 AM
No worries man.

ogdak
10-29-2006, 03:36 PM
Soo, Jeepamp 2006 is behind us.
Bud somethings had still to take care off before that.
Some electronic parts still needed to be installed.
http://www.ogdak.eu/images/2006-10/DSCF2669.JPG

http://www.ogdak.eu/images/2006-10/DSCF2671.JPG

Found a spot for several relais
http://www.ogdak.eu/images/2006-10/DSCF2672.JPG

Left to right 40A, 70A and 2 off 20A.
40A for low-speed e-fan.
70A for high-speed e-fan controlled by "DC control" unit.
20A for left and right line lock to lock the front brakes independently.
To make things act like a locker
http://www.ogdak.eu/images/2006-10/DSCF2673.JPG

Here is one off them on the right hand side.
http://www.ogdak.eu/images/2006-09/DSCF2577.JPG

Part off the controll's
Keyswitch is for on/off to activate the incab whinch control.
Bottom left switch to use the front whinch.
Bottom right switch to use for the rear whinch(still on my whish list, ha ha)
On-Off-On switch
Towards front combined with green control light, is for Hi-speed e-fan controlled by "DC Control" unit.
Center to switch e-fan off, in case off deep water crossing's.
Towards rear combined with red control light, is for Lo-speed e-fan in case "DC Control" unit fails.
http://www.ogdak.eu/images/2006-10/DSCF2674.JPG

Time to clean things up, still without bumpers.
http://www.ogdak.eu/images/2006-10/DSCF2701.JPG

http://www.ogdak.eu/images/2006-10/DSCF2703.JPG

http://www.ogdak.eu/images/2006-10/DSCF2705.JPG

Does makes a difference
http://www.ogdak.eu/images/2006-10/DSCF2707.JPG

Foc Trophy stickers from 2004 took a lot off time to get them off, finally used a razor blade.
http://www.ogdak.eu/images/2006-10/DSCF2714.JPG

Dennis helped
http://www.ogdak.eu/images/2006-10/DSCF2710.JPG

Some "flexxin" with disconnects still on.
http://www.ogdak.eu/images/2006-10/DSCF2715.JPG

http://www.ogdak.eu/images/2006-10/DSCF2716.JPG

http://www.ogdak.eu/images/2006-10/DSCF2717.JPG

Putting on "some" stickers
http://www.ogdak.eu/images/2006-10/DSCF2721.JPG

http://www.ogdak.eu/images/2006-10/DSCF2723.JPG

Time to mount the fresh powder coated bumpers.
http://www.ogdak.eu/images/2006-10/DSCF2724.JPG

http://www.ogdak.eu/images/2006-10/DSCF2725.JPG

He he, Arrival on Friday 20th october at JEEPCAMP 2006 in Erm
http://www.ogdak.eu/images/2006-10/DSCF2728.JPG










Finally, SU.

TheOtherSide
10-29-2006, 03:47 PM
Very nice...

ogdak
10-29-2006, 03:54 PM
Very nice...
thnx.

ZachJ
10-29-2006, 04:54 PM
Looks good, Im sure you are glad to have it out of the garage.

ogdak
10-29-2006, 05:02 PM
Looks good, Im sure you are glad to have it out of the garage.
Thnx, got that right.


Ready to go.
http://www.ogdak.eu/images/2006-10/DSCF2730.JPG

Kids too
http://www.ogdak.eu/images/2006-10/DSCF2732.JPG

Cheking the details
http://www.ogdak.eu/images/2006-10/DSCF2733.JPG

http://www.ogdak.eu/images/2006-10/DSCF2734.JPG

Technical Jeepcamp check, popped the hood again
http://www.ogdak.eu/images/2006-10/DSCF2741.JPG

http://www.ogdak.eu/images/2006-10/DSCF2743.JPG

Still friday, after 10 min on the trail the P/S goes out.
After being towed back by Mav, thnx and a closer observation.
Turns out that the edge on the P/S pulley has cut through the 90 degree connector
on the steering gear from the pressure line.
I knew the distance about ¼" was close, but that close?
No worries got the tools out and took out the line from P/S pump to the steering gear
Sjikita knew a shop close by where a new 90 degree connector was pressed on which was "lower" then the original one.
Wrenching help and audiance enough
http://www.ogdak.eu/images/2006-10/DSCF2744.JPG

Job done before dark
Saturday on the same trail all things go well now.
http://www.ogdak.eu/images/2006-10/DSCF2748.JPG

http://www.ogdak.eu/images/2006-10/DSCF2749.JPG

http://www.ogdak.eu/images/2006-10/DSCF2752.JPG

http://www.ogdak.eu/images/2006-10/DSCF2753.JPG

And get it dirty again.
http://www.ogdak.eu/images/2006-10/DSCF2755.JPG

http://www.ogdak.eu/images/2006-10/DSCF2758.JPG

Monday to check on further capabilities
http://www.ogdak.eu/images/2006-10/DSCF2768.JPG

http://www.ogdak.eu/images/2006-10/DSCF2769.JPG

http://www.ogdak.eu/images/2006-10/DSCF2771.JPG

Up on some concrete
http://www.ogdak.eu/images/2006-10/DSCF2772.JPG

On the one highest level the line lock came to use. Left front wheel slipped,
Applied brakes, locked left line lock, released brake, got the revs up a little and crawled on to the highest level.
http://www.ogdak.eu/images/2006-10/DSCF2773.JPG

http://www.ogdak.eu/images/2006-10/DSCF2775.JPG

http://www.ogdak.eu/images/2006-10/DSCF2776.JPG

aresridingflat
10-29-2006, 05:23 PM
This is a great build thread. Awesome to see it on the trail finally. I bet it feels good after all that work...

Props.

Will

ogdak
10-29-2006, 06:08 PM
This is a great build thread. Awesome to see it on the trail finally. I bet it feels good after all that work...

Props.

Will

thnx, I'll start uplaoding the pic's from the start again pretty soon.


More detailted pic's, cause I can not get enough off it.
The coil won't fall out.
http://www.ogdak.eu/images/2006-10/DSCF2774.JPG

http://www.ogdak.eu/images/2006-10/DSCF2777.JPG

http://www.ogdak.eu/images/2006-10/DSCF2778.JPG

http://www.ogdak.eu/images/2006-10/DSCF2779.JPG

Limiting strap doing wat it was ment for.
http://www.ogdak.eu/images/2006-10/DSCF2780.JPG

http://www.ogdak.eu/images/2006-10/DSCF2781.JPG

In another spot, Mudmiep and Jeepee thanx for taking pic's
http://www.ogdak.eu/images/2006-10/ogdak12R.jpg

http://www.ogdak.eu/images/2006-10/ogdak13R.jpg

http://www.ogdak.eu/images/2006-10/ogdak14R.jpg

http://www.ogdak.eu/images/2006-10/ogdak16R.jpg

Trouble with the whinch, ground was not mounted properly.
http://www.ogdak.eu/images/2006-10/ogdak17R.jpg

Mudmiep taking it for a spin
http://www.ogdak.eu/images/2006-10/ogdak20R.jpg

Fun?
http://www.ogdak.eu/images/2006-10/DSCF2788.JPG

Not according to Dennis, by the looks off his face.
http://www.ogdak.eu/images/2006-10/DSCF2789.JPG

http://www.ogdak.eu/images/2006-10/ogdak29R.jpg

http://www.ogdak.eu/images/2006-10/ogdak31R.jpg

Eventually problems with the steering again.
But no oilleak this time
Fortunatly it is monday and we have had a excelent weekend.
http://www.ogdak.eu/images/2006-10/ogdak11R.jpg

Meanwhile at home again, checked the steering.
Broken pump shaft, coloured blue so maybe run a little to long without enough oil.
http://www.ogdak.eu/images/2006-10/DSCF2805.JPG

http://www.ogdak.eu/images/2006-10/DSCF2808.JPG

http://www.ogdak.eu/images/2006-10/DSCF2809.JPG

For de rest no real issue's except lenghtning bumptops and brakelines.

RiPPiNiTuP7
10-29-2006, 10:05 PM
i'd call that a pretty good turnout after doing so many changes to the jeep and taking it out for the first time. it came out great.

ILikeMud
10-29-2006, 10:45 PM
That's AWESOME man.

EMTimZJ
10-29-2006, 10:46 PM
Looking great! Awesome to see it moving and wheeling!

-Tim

ogdak
10-30-2006, 02:05 AM
thnx guys, it was awesome to wheel it again. It came out better then expected.

Cue-Ball
10-30-2006, 10:38 AM
AWESOME Man, totally awesome.

Dirk

ogdak
10-30-2006, 02:22 PM
AWESOME Man, totally awesome.

Dirk

thnx Dirk

ogdak
11-09-2006, 03:11 PM
Hi

Just recieved an email from Kelvin at http://www.pscmotorsports.com/ telling me the parts for my p/s pump will be shipped tomorrow.

Upon first contact, He asked me to send in the pump so it good be fixed at no cost to me. Then later on he offerd to send the parts to be replaced by myself, so it would be cheaper concerning shipping cost.

Excellent customer service, thnx Kelvin.

ogdak
11-15-2006, 06:07 PM
Sorry for the red X'ses,
this is why http://www.mallcrawlin.com/forum/showthread.php?p=118700#post118700

ogdak
12-08-2006, 12:41 PM
I'd like to edit my own posts because off the broken links for the pic's.
But I do not have an edit button anymore.
I doubt you want me to quote all my posts.

I also want to edit the psc topic title cuase there service aint that great afterall,
have not seen anything yet and the are refusing to answer my emails.

EMTimZJ
12-08-2006, 02:15 PM
Double click on your thread title in the "Jeep journals and members rides" forum view, you should be able to edit the title using this method...

ogdak
12-08-2006, 02:37 PM
Double click on your thread title in the "Jeep journals and members rides" forum view, you should be able to edit the title using this method...

Well is does turn bleu, but before I can do anything it opens the thread.
Doesn't matter wether I use IE or FF

Popsicle
12-08-2006, 03:16 PM
your ZJ amazes me. Ive been following this thread from when i first got my jeep. And honestly, it seems as tho im making the same progress as you! Keep up the great work. this is definately one of the best threads on the site!

ogdak
12-08-2006, 03:52 PM
Thnx Paolo

ogdak
12-09-2006, 07:11 AM
Double click on your thread title in the "Jeep journals and members rides" forum view, you should be able to edit the title using this method...

It did work afterall, being very fast at the keyboard with Cut/Paste and a double "enter"
Thnx

ogdak
12-09-2006, 09:56 AM
Have not been up to a lot lately, some minor things I did do are,
A modification for the bracket where the hydro cylinder attach to the tie rod
Since the stroke of the assist cylinder(8") is bigger than the lateral movement off the tie rod
approx. 5"(did not take exact meas.) from left full lock to right.
So the previous bracket slided over the tie rod
The idea is to fab 2 large rings to put around the tie rod on both sides off the existing bracket.
The rings would prevent the bracket from sliding, same time I'll still be able to adjust toe-in
So took some solid axle, drilled a hole in it.
http://www.ogdak.eu/images/2006-11/DSCF2820.JPG

The bench did the rest.
http://www.ogdak.eu/images/2006-11/DSCF2821.JPG

result
http://www.ogdak.eu/images/2006-11/DSCF2822.JPG

Drilled some M10 holes for welding them on to the tie rod.
http://www.ogdak.eu/images/2006-11/DSCF2823.JPG

So eventualy it will look like this.
http://www.ogdak.eu/images/2006-11/DSCF2824.JPG

So still hopping from one to another subject.
The broken P/S pump for which I still did not get the replacement parts.
So I'll make an attempt to fix it.
De pump axle is broken at the point where it is splined to fit in the pump rotor.
So drilled a hole in the axle and through the broken piece, and tapped a M8 thread in it.
http://www.ogdak.eu/images/2006-11/DSCF2825.JPG

Put it together with an allen bolt,
already having doubts weather this will hold.
http://www.ogdak.eu/images/2006-11/DSCF2826.JPG

http://www.ogdak.eu/images/2006-11/DSCF2827.JPG

But how knows, piece off M8 thread and a lot off loc-tite
http://www.ogdak.eu/images/2006-11/DSCF2828.JPG

The "fixed" result,
http://www.ogdak.eu/images/2006-11/DSCF2829.JPG

in the rotor.
http://www.ogdak.eu/images/2006-11/DSCF2830.JPG

http://www.ogdak.eu/images/2006-11/DSCF2831.JPG

pump housing,
http://www.ogdak.eu/images/2006-11/DSCF2832.JPG

everything back together.
http://www.ogdak.eu/images/2006-11/DSCF2833.JPG

On to another subject.
Got myself a spare V8 with a little work.
It was diagnosed with a stuck or broken oil ring on piston nr 6
http://www.ogdak.eu/images/2006-11/DSCF2837.JPG

http://www.ogdak.eu/images/2006-11/DSCF2838.JPG

Took the right cylinder head cover off,
http://www.ogdak.eu/images/2006-11/DSCF2839.JPG

http://www.ogdak.eu/images/2006-11/DSCF2840.JPG

followed by the one on the left.
http://www.ogdak.eu/images/2006-11/DSCF2841.JPG

http://www.ogdak.eu/images/2006-11/DSCF2842.JPG

Right side exhaust manifold removed
http://www.ogdak.eu/images/2006-11/DSCF2843.JPG

The difference between cylinders 4 and 6
http://www.ogdak.eu/images/2006-11/DSCF2844.JPG

Nr: 8 does not look to good either.
http://www.ogdak.eu/images/2006-11/DSCF2845.JPG

The ones on the left are looking much better.
http://www.ogdak.eu/images/2006-11/DSCF2847.JPG

rocker-arms and pushrods removed.
http://www.ogdak.eu/images/2006-11/DSCF2849.JPG

a part dismanteld right cylinder head,
http://www.ogdak.eu/images/2006-11/DSCF2850.JPG

and left
http://www.ogdak.eu/images/2006-11/DSCF2851.JPG

Bottom view off the intake manifold, all that black stuff you see in most off these pic's.
Is caused, I was told by several people now, by random use off both mineral and synthetic engine oil.
Besides that this engine was treated with Forte Flush, an engine oil additief to clean the engine internally
This may have caused solid pieces to come loose and travel throuhg the engine and clocking oil ways.
Conclusion, this engine needs a rebuilt.
http://www.ogdak.eu/images/2006-11/DSCF2852.JPG

http://www.ogdak.eu/images/2006-11/DSCF2853.JPG

http://www.ogdak.eu/images/2006-11/DSCF2854.JPG

The right cylinder head removed, obvious cylinders 6 and 8 have had the biggest problems
http://www.ogdak.eu/images/2006-11/DSCF2856.JPG

http://www.ogdak.eu/images/2006-11/DSCF2857.JPG

The left cylinder head removed also.
http://www.ogdak.eu/images/2006-11/DSCF2858.JPG

Detail on the black stuff, it also smells real bad.
http://www.ogdak.eu/images/2006-11/DSCF2860.JPG

http://www.ogdak.eu/images/2006-11/DSCF2861.JPG

Finally the gear driven driveshaft which on the top side turns the distributor,
and on the downside the oil pump.
http://www.ogdak.eu/images/2006-11/DSCF2862.JPG

Well that covered what has happened lately.
SU.

Skyline
12-09-2006, 10:11 AM
Boy that's one nasty looking motor inside! I would think about getting all the larger components commercially cleaned once you get it all apart, otherwise they might have to send the haz-mat team to your house with all the solvent and rags you'd have to use! Any engine machine shop should be able to do that, or send you to someplace that can.

ogdak
12-09-2006, 10:27 AM
That sure is an option.
Right now I already poored several liters off diesel oil into the engine and let it soak for a while. Depending on that I'll see what to do next

EMTimZJ
12-10-2006, 01:54 PM
Yikes, that plenum gasket is probably shot as well. Here is some info on it that may help when it comes time to rebuilding!
http://www.jeepforum.com/forum/showthread.php?t=233448

-Tim

ogdak
12-10-2006, 02:50 PM
Yikes, that plenum gasket is probably shot as well. Here is some info on it that may help when it comes time to rebuilding!
http://www.jeepforum.com/forum/showthread.php?t=233448

-Tim

Thnx, got some reading ahead.

ogdak
12-13-2006, 05:33 PM
So just finished fixing broken links.
Approx. 750 pic's visible again.;)
No jeep update, still waiting on part's:(