Family Wagon 1996 ZJ BUILD Cantilever Rear Suspension

[Kraqa]

i'm been doing alot of design work on the subframe up to now for the suspension. And also machining components for the rod ends. I should have the subframe completed tonight in solid works.

I really want to get the axles under it before i even think about the design of the cantilever,

[Kraqa]

Here is where i'm at so far. Everything is parametric so i can change one dimension and it will update every part accordingly. All the brackets are tabbed or keyed into another so alignment during welding will be super easy.

I still have lots of work to do for holes and plug weld's. i also need to finish off the tranny X member. I may encorporate mounts for fuel lines into it if i get ambitious.











Although this will be just for me. it is designed in a way i would sell it as a DIY kit if i was ever asked. I'm going to be doing axle trusses and axle brackets in the same way.

[Kraqa]

one more

[BigDaveZJ]

Lookin' good!!

One of the issues I've run into with my Clayton's set up that is similar in bracketry to what you have there, is the unibody outside of that is still weak. My frame rails are buckling up against the rear control arm mounts. Are you going to tie your cage in to a full length frame stiffener of some sort? That's one of the issues I'm trying to figure out on my new build without the thing weighing more than Chad's pile of tube.

[Kraqa]

i had no plans to do anything other than whats here at this time. i didn't have any buckling with my old set-up. it was very similar but not as nicely finished.





geesus. Looking back those things were terrible. lol. The top plate may on the rear upper arms may have helped with any buckling issues though. it would be an easy feature to add to this set-up.

[Kraqa]

i just reread your post. this sub frame i am designing goes from the A pillar rocker support all the way to the C pillar rocker support. It is 52" long. so it will be spreading the load out ALOT>

[Stealth Crawler ZJ]

Need to keep this thread on hand for when I design the WJ setup (with some mods of course!).

[Kraqa]

the waterjet will be running tomorrow

[cwm]

well the suspense is killin me update time!!!!

[Kraqa]

So I got the rod end balls back from the liquid nitrite





Beadlock rings in the automated sandblast booth



Suspension brackets in the automated blast booth





2 min later all the brackets are blasted








I got all the weld washers pressed into the brackets and the back. I TIG’d the inside of them and will sand them smooth. I needed filler rod to TIG the outside of them.

[Kraqa]

i finished tiging the weld washers in place on the brackets. that took a while. i'm not the greatest at tig welding





got the stiffeners together





hmm sexy





then pieces started to fall together like Lego




















i will let it cool over night so it doesn't banana on me then finish the top side welding and flip to do the mounts for the upper arms.

[CRJEeP_wj]

Looks good man, real good. Im jealous of your skills and tools.

[Kraqa]

go to it yesterday.


unibody sanded.





subframe in place





all welded up.














i got all the factory rear lower CA brackets cut off.

[Kraqa]

more progress today





i plan on using the factory tranny x member. i just need to sand blast it and trim it to the new length

[FortCollinsZJ]

Looks awesome Kris. Glad to see you building a ZJ again, as cool as the buggy is, I love a a good ZJ build.

Think you'd share/sell the DXF file for those link mount pieces? I kinda wanna do the same thing on my second ZJ. I'm considering this or trying a mid arm setup alternatively. Don't really need
long arms for what I'm going for.

[polar_jeep_04]

Who's rear CA brackets are you using on the frame side or did you make them?

[Kraqa]

Who's rear CA brackets are you using on the frame side or did you make them?

i made everything.

i will be selling this as a DIY weld together kit when i am done.

[Kraqa]

Looks awesome Kris. Glad to see you building a ZJ again, as cool as the buggy is, I love a a good ZJ build.

Think you'd share/sell the DXF file for those link mount pieces? I kinda wanna do the same thing on my second ZJ. I'm considering this or trying a mid arm setup alternatively. Don't really need
long arms for what I'm going for.

I'd probably just give you the DXF file for free. we go way back.

[polar_jeep_04]

i made everything.

i will be selling this as a DIY weld together kit when i am done.

Eta on that? I was going to buy clayton's bracket after the holidays and build my own CAs.

[Kraqa]

i will have final pricing and final modifications made for Jan 5th.

i have a few other orders pending for this.

[Kraqa]

i will also be doing a full skid plate, and fabricated tranny x member as an option. The system is set-up right now to be able to use the factory cross member by cutting it to length and adding the bolting plates to the end of it.

[Kraqa]

Waiting for the Waterjet to slow down at work I kept goign on the skid design and rear dif brackets.


drop out skid



rear link mounts






drop out tranny x member








the skid is just shown as a flat plate. i need to get the tranny x member in place to check clearances for the t-case then i will add dimpled holes and stiffeners.


mounting






section view of the mounting rail for the skid. there will be tube inserts around the bolt holes to keep the structure and not allow it to dent as easy




for the guys who wanted Kit pricing. your goign to have to wait a bit longer. i want to get EVERYTHING sorted out before i start cutting these.

[Kraqa]

just a bit more..


i got the links all figured out



ride height



full bump



full droop

[polar_jeep_04]

Looks amazing! I want that "subframe"

[Kraqa]

tranny x member fabed and installed.





before someone says something about the bolts. all of this is coming back out for powdercoating.

and I got the lower link mounts welded on the rear housing.