Thread: Family Wagon 1996 ZJ BUILD Cantilever Rear Suspension

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  1. #26 Re: Family Waggon 
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    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,
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  2. #27 Re: Family Waggon 
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    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.
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  3. #28 Re: Family Waggon 
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    one more

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  4. #29 Re: Family Waggon 
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    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.
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  5. #30 Re: Family Waggon 
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    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.
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  6. #31 Re: Family Waggon 
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    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>
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  7. #32 Re: Family Waggon 
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    Need to keep this thread on hand for when I design the WJ setup (with some mods of course!).
    "ZJ's were designed with the intention to take 1 really good hit, and fold up. As long as the occupants walked away, it was a success. In the wheeling world, we expect our vehicles to take multiple really good hits, drive out of it, and run the obstacle again!"
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  8. #33 Re: Family Waggon 
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    the waterjet will be running tomorrow

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  9. #34 Re: Family Waggon 
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    well the suspense is killin me update time!!!!
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  10. #35 Re: Family Waggon 
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    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.


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  11. #36 Re: Family Waggon 
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    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.
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  12. #37 Re: Family Waggon 
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    Looks good man, real good. Im jealous of your skills and tools.
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  13. #38 Re: Family Waggon 
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    go to it yesterday.


    unibody sanded.





    subframe in place





    all welded up.














    i got all the factory rear lower CA brackets cut off.
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  14. #39 Re: Family Waggon 
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    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



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  15. #40 Re: Family Waggon 
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    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.
    Neil R.

    93 318 ZJ, HP30, 8.8, 4.56, 35"s, tube.

    Quote Originally Posted by SirFuego View Post
    WTF? A unibody won? Did they build a mall at the finish line or something?


    Funniest thread on MC
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  16. #41 Re: Family Waggon 
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    Who's rear CA brackets are you using on the frame side or did you make them?
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  17. #42 Re: Family Waggon 
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    Quote Originally Posted by polar_jeep_04 View Post
    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.
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  18. #43 Re: Family Waggon 
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    Quote Originally Posted by FortCollinsZJ View Post
    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.
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  19. #44 Re: Family Waggon 
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    Quote Originally Posted by Kraqa View Post
    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.
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  20. #45 Re: Family Waggon 
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    i will have final pricing and final modifications made for Jan 5th.

    i have a few other orders pending for this.
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  21. #46 Re: Family Waggon 
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    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.
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  22. #47 Re: Family Waggon 
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    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.
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  23. #48 Re: Family Waggon 
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    just a bit more..


    i got the links all figured out



    ride height



    full bump



    full droop
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  24. #49 Re: Family Waggon 
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    Looks amazing! I want that "subframe"
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  25. #50 Re: Family Waggon 
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    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.



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