Thread: Family Wagon 1996 ZJ BUILD Cantilever Rear Suspension

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  1. #351 Re: Family Wagon 1996 ZJ BUILD Cantilever Rear Suspension 
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    so i'm going crazy here not being able to drive the jeep i got complete 1 project and start another.


    i got my steel racks up.



    and i started to adapt the factory ebrake handles to some CNC cutting brakes for a new center console i will be building.











    i still need to sort out a bracket to hold everything. i want this to look factory and be able to use the ratcheting mechanism to hold the cutting brake. i'm hoping if i get pulled over the cops wont know any better when they ask me to pull the ebrake. i do plan on leaving all the factory cables under the car in place so it also looks like i have a mechanical brake.
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  2. #352 Re: Family Wagon 1996 ZJ BUILD Cantilever Rear Suspension 
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    the start of the console build.








    its 1/2" aluminum round bar.
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  3. #353 Re: Family Wagon 1996 ZJ BUILD Cantilever Rear Suspension 
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    so i made some more progress on the cutting brakes.





    folded and tig welded.




    center punch for the new mounting hole on the factory ebrake handle



    i machined a 1/4" spacer from aluminum to go between the ebrake handle and the cutting brake mount.


    and here it is.








    i still have to adjust the linkages. they aren't perfect yet. Also as you can see i had to drill a second hole for the ball socket heim i had the pivot point wrong and it wouldn't allow for full travel.





    and roughly mocked up in the jeep. If i was smart i would have made the base mount to the factory locations. 2 of the 4 spots are only within 1/2" of the factory mounting holes.





    and the entire point of this project was to be ale to do this.



    i also kept the factory Ebrake indicator switch too. i'm pumped how factory this will look then complete.
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  4. #354 Re: Family Wagon 1996 ZJ BUILD Cantilever Rear Suspension 
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    Of all the impressive shit you've done on this Jeep, this blew my mind possibly the most. Cantilevered suspension is up there lol

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  5. #355 Re: Family Wagon 1996 ZJ BUILD Cantilever Rear Suspension 
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    Quote Originally Posted by egg View Post
    Of all the impressive shit you've done on this Jeep, this blew my mind possibly the most. Cantilevered suspension is up there lol

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    thanks Bruh.
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  6. #356 Re: Family Wagon 1996 ZJ BUILD Cantilever Rear Suspension 
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    Very nice work as always.
    I'm watching this closely as a console upgrade is one of the items on the list for my project.
    '96 ZJ slightly modded with more in the works (5.3L HP44 and SF 14b)
    '03 WJ Limited 4.7HO - just starting the journey
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  7. #357 Re: Family Wagon 1996 ZJ BUILD Cantilever Rear Suspension 
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    Quote Originally Posted by Varkyl View Post
    Very nice work as always.
    I'm watching this closely as a console upgrade is one of the items on the list for my project.
    Thanks. Its been on my list for a while. I finally got out of bed today (chemo really kicks ur ass) and went to the shop to work on the console. I ended up organizing my tools, i built a few holders for things with the new little metal bender i have and then managed to get the cutting brake mount to pick up 1 of the factory e brake mounting holes. I found a way to get it to pick up one of the other factory holes too. Im heading out to get a riv nut tool cause im going to be mounting the console and remaining cutting brake mounts with riv nuts. More pics will follow.
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  8. #358 Re: Family Wagon 1996 ZJ BUILD Cantilever Rear Suspension 
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    I'm really sorry to hear that you're going through chemo. Hang in there!!

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  9. #359 Re: Family Wagon 1996 ZJ BUILD Cantilever Rear Suspension 
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    Quote Originally Posted by egg View Post
    I'm really sorry to hear that you're going through chemo. Hang in there!!

    Sent from my Pixel XL using Tapatalk
    X2. Cancer is the suck, I've seen too much of it on my wife's side of the family. Best wishes on a full recovery.

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  10. #360 Re: Family Wagon 1996 ZJ BUILD Cantilever Rear Suspension 
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    thanks guy's i'm pushing through the treatments.

    moar progress.


    i added another mount to the cutting brakes to pick up another factory mount.






    i also decided that i didn't need to remake the front of the console since i'm not changing anything, so i'm going to make a hybrid using the front portion of the factory unit.



    which means i'm modifying my original aluminum frame





    I cut it here and added this new piece





    then onto more fab work














    this is a full 3" wider then stock. it fills the gaps between the seats nicely.











    i think it blended into the factory front quite nice.











    i am looking forward to the cardboard part of this doing all the templates for the skins.


    i also haven't sorted out the lid yet.
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  11. #361 Re: Family Wagon 1996 ZJ BUILD Cantilever Rear Suspension 
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    Looks incredible so far. I really am looking forward to seeing the finished part.
    Ken L
    '96 ZJ with stuff
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  12. #362 Re: Family Wagon 1996 ZJ BUILD Cantilever Rear Suspension 
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    Quote Originally Posted by Ken L View Post
    Looks incredible so far. I really am looking forward to seeing the finished part.
    thanks. its been work...but still really fun. I can't wait to redo half of this when i finally buy an atlas t-case
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  13. #363 Re: Family Wagon 1996 ZJ BUILD Cantilever Rear Suspension 
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    Great work as always Kris. Do me a favor, and kick cancer in the nuts!
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  14. #364 Re: Family Wagon 1996 ZJ BUILD Cantilever Rear Suspension 
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    I will dave. Im almost through it. !!

    I got to play with some poster board today.

    Cup holders will fit a yeti 8ball they will also be super deep so the drinks dont fall over like the stock one.

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  15. #365 Re: Family Wagon 1996 ZJ BUILD Cantilever Rear Suspension 
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    0.063 aluminum


    not looking forward to cutting this out by hand.


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  16. #366 Re: Family Wagon 1996 ZJ BUILD Cantilever Rear Suspension 
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    My fingers hurt just looking at that!
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  17. #367 Re: Family Wagon 1996 ZJ BUILD Cantilever Rear Suspension 
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    Quote Originally Posted by OverkillZJ View Post
    My fingers hurt just looking at that!
    it actually wasnt that bad.

    i got to the assembly today.























    it wasn't as bad as i thought to weld the 1/2" and 3/8" round bar to the .063" aluminum. no burn through yet.
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  18. #368 Re: Family Wagon 1996 ZJ BUILD Cantilever Rear Suspension 
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    i started to weld and rad out of rod. Wasn't too bad welding .063" to 1/2" round bar.


    i need to go get some sanding pads to properly dress the welds and blend everything smooth.








    i am by no means a good or even decent tig welder, but i can definitely see an improvement from when i started this to now.


    on a side note, Some 24' lengths showed up. 1.9" Handrail tube. this will be for rockers and fender bars.


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  19. #369 Re: Family Wagon 1996 ZJ BUILD Cantilever Rear Suspension 
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    Will you leave it raw aluminum or finish it in some way? I'm thinking it'll look too nice to paint when it's done.
    Ken L
    '96 ZJ with stuff
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  20. #370 Re: Family Wagon 1996 ZJ BUILD Cantilever Rear Suspension 
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    Quote Originally Posted by Ken L View Post
    Will you leave it raw aluminum or finish it in some way? I'm thinking it'll look too nice to paint when it's done.
    i'm going to get it powder coated. I'm planning on trying to match the factory interior colour and texture. we will see how well that works.

    i had some time today before i went out to get more filler rod to convert some random lengths of extra winch rope to some soft shackles.








    not sure what style i like better. the left or the right. the left seams to be the most popular with the winch rope companies.








    takes about 5 min per shackle. i don't know why i didn't to this before.
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  21. #371 Re: Family Wagon 1996 ZJ BUILD Cantilever Rear Suspension 
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    i got to smash a few filler rods while my 2 year old naps.














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  22. #372 Re: Family Wagon 1996 ZJ BUILD Cantilever Rear Suspension 
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    Man this build has really come along way. Hope your treatment is going great!

    Got a few questions:
    1) Can you show how you mounted the window shelf thing? I'd love to make one for my WJ
    2) How did you separate the clear plastic in the taillights? Heat up in the oven?
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  23. #373 Re: Family Wagon 1996 ZJ BUILD Cantilever Rear Suspension 
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    some more progress, ran out of gas today.








    I'm pretty hapy how my tig welding has come along in this project.








    Heres a shot to show panel fitment prior to welding














    This has inspired me to make a few dollies for my vise.
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  24. #374 Re: Family Wagon 1996 ZJ BUILD Cantilever Rear Suspension 
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    Quote Originally Posted by Tuzmaster View Post
    Man this build has really come along way. Hope your treatment is going great!

    Got a few questions:
    1) Can you show how you mounted the window shelf thing? I'd love to make one for my WJ
    2) How did you separate the clear plastic in the taillights? Heat up in the oven?
    thanks!! treatment is going ok.

    1. the shelf is just bolted to the molle window guard. I'm certain i posted mountint pics but if i didnt post enough info let me know.

    2. the rear tail lights were just heated up in a kitchen oven at 265 F for 15 min. then they just pull appart.
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  25. #375 Re: Family Wagon 1996 ZJ BUILD Cantilever Rear Suspension 
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    1) I looked through your thread yesterday and did not see any pics on how you mounted them. Would you mind posting them again?
    2) also, how did you glue them back so neatly. If i try it, Ill wind up having glue all over the inside of the lens
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