Family Wagon 1996 ZJ BUILD Cantilever Rear Suspension

[Kraqa]

No Prob. 2.5" bodies. 2" travel. These bodies are shorter than most bumps since they are only 2" travel. Most companies make 4" units then limit then to 2" or 3" travel.

Some assembly




Still need to make the piston wear surface

[Kraqa]

some pathetic progress.


got the front passenger fender trimmed, opened up and a 1" lip folded into it.





i got the front axle out. turned the knuckles...again.....and started to look at the steering.

[bentwrench]

Cricket cricket.....




This is why i mainly just update my pirate thread... Looks good

[egg]

I said it earlier in this thread, it's really nice re-reading a thread like this with so much good tech without having to read all the extra fluff that fills out a thread

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[Kraqa]

had these spun up out of brass








adapters for to go from a 2000 F350 booster to the ZJ brake petal.


and made some progress on the front bumper. i managed to fit a winch in there with the AC condenser

[pitbull78133]

Its looking great! What M/C are you running with the F350 booster?

[Kraqa]

f350 master as well. the axles are also f350 so the brakes are all matching.

[pitbull78133]

makes sense! Keep us posted, Id like to know how she stops

[Kraqa]

makes sense! Keep us posted, Id like to know how she stops

i've run this booster/master set-up before with ford front calipers and the chevy 1/2 ton in the rear. Full body ZJ on 38's stopped on a dime. I then buggied the ZJ and put it on 40's and same performance.

this will be the first tim ei will have ford calipers front and rear. i expect that it shoudl work exceptionaly well since they are all matched together and designed to stop a 12,000lb truck towing a trailer.

[egg]

Nice job on the bumper, I wish I did mine down low like that so I didn't have to cut up my grill.

Keep up the great work !!

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[pitbull78133]

What year model F350 did you use?

[Kraqa]

2000

[Kraqa]

i got the bumper all welded up. and some side supports on it. Left enough room for some 6" rigid LED bars on the sides.











i still need to cut and weld the tabs for the 6" LED bars, do a smapp hoop and mount for a 20" bar on the top and a top skin to hide the winch.


then its onto the frame stiffening in the front, a lower rad support and tow points....then i will get the front dif up under there to finish off the links.

[Kraqa]

light bars mounted!!











and the powder coater was running white so i sent the first of many parts out for coating....yup the brakes. like i said before. all of the difs will be coated white. it will look SUUUPER douche bag.

[Stealth Crawler ZJ]

Bitchin build man! Love that bumper!

[ELLLLLIOTTTTT]

This is your best build yet.

[cwm]

Did you have to disassemble the calipers prior to powder coating or are they up to the heat?

[Kraqa]

Thanks guys. I'm having fun with this one.

Ya I pulled the callipers apart to powder coat them. I need to drill and tap the brake line port on the calipers to NPT anyways. I always take them apart to get the shavings out of the piston when I do that.

[Brad S]

What winch do you have in there? I've been contemplating doing something similar on mine for a while now. I have an XRC8 which is pretty small, but curious on the size you are using.

[Kraqa]

this is the smitty built 8000lb winch. nothing special really.

[ogdak]

Haven't been on here for a while, lol.
As always great build, I dig the family thing.
Keep it coming.

[Kraqa]

Thanks Ogdak, I always enjoyed your build. very detail oriented.

finally getting some time to assemble the bumps.











PTFE wear band for the piston





you can see the snap ring seat is tapered so that the more pressure against the snap ring the more it pushes the ring into the groove in the body. the OD of the aluminum pieces is also 0.010" smaller than the ID of the snap ring when installed so that there is no possible way the ring back back its way out and have the bump fall apart.





snap ring in place the bottom shaft support pushed in.





the bottom shaft support pulled up to the snap ring. you can see how tight the fit is.





then the locking ring to keep it against the snap ring.

[Stealth Crawler ZJ]

Just freaking amazing!

[Kraqa]

started to tackle the lower radiator support.


make 2 of these:






bolted up to the frame. acts as a bumper mount support as well as a rad support








with the bumper installed.








i still need to add the lower piece. its about 1.5" more ground clearance than the stock support. its way stronger and it add 2 tow points.








because its angled in i think it helps break up the boxiness of the front end a bit.

[Kraqa]

i got some time in the garage


i got the upper control arm and track bar mount done on the front dif.














i got the links all fabbed..at this point i needed to assemble my joints.





then.....its under the truck. such a good feeling.











i thought i was going to have to modify the oil pan to clear the track bar. i pulled the pan off and did the rear main oil seal then quickly realized there is no room to gain. the bottom of the pan is about 1/2" from the crank. so i will have to do a bend track bar.





this is how she sits till i get the track bar fabbed.