Thread: Family Wagon 1996 ZJ BUILD Cantilever Rear Suspension

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  1. #51 Re: Family Waggon 
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    rear truss

















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  2. #52 Re: Family Waggon 
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    rear cantilever.


    took 4 hours to get the geometry correct.


    full bump



    ride height



    full droop





    10" shocks. 14" of travel.
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  3. #53 Re: Family Waggon 
    Senior Member MallCrawlin Supporter biggoofy's Avatar
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    Great looking build man. Makes me miss my Zj.
    93 ZJ long arms, 35's, F/R Long arms, 4.56 gears, and a bunch more
    98 5.9 slate gray 4" lift with stuff (sold)
    96 ZJ Lift, Long arms, 35's and a bunch of other shit! (RIP)
    [ IRONMAN 4X4 FAB ] [ RACELINE WHEELS]
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  4. #54 Re: Family Waggon 
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    Tunrs out some material didn't arrive in time so i had a spot on the CNC mill.


    i got the cantilever pivots done. tomorrow mornign i will put the pockets in them for the shock eye's and the links that will connect it to the axle.

















    2" thick 6061 T6
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  5. #55 Re: Family Wagon 1996 ZJ BUILD 
    Senior Member SuicideTireZJ's Avatar
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    I'm really digging that setup and all the non-shadetree planning, design and engineering going into this project. I work for a 3D scanning/printing CAD/CAM company and if I were in the position to build from scratch again this is how I'd approach it.
    Poetry in commotion.
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  6. #56 Re: Family Wagon 1996 ZJ BUILD 
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    Awesome work! Solid Works + CNC mill + Sheet Metal Laser or Water Jet =

    I bet you will sell a bunch of your kits. Shall we expect you to be showing off your new rig at GSW 2015?
    WJ, 4.7, Clayton's Front, Double Triangulated Rear, 231HD, HP44, 8.8, ARBs, TR Bumpers, Hydro Assist, 35's, Cage
    Lambo Doors - tweaked unibody
    http://www.mallcrawlin.com/forum/showthread.php?t=8532
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  7. #57 Re: Family Wagon 1996 ZJ BUILD 
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    i really want to go to GSW 2015. but i'm not sure i will be making it. in May i am moving my rubber division into a new facility we are building next to my urethane plant (where my office and CNC equipment is). progress will be slow during the move

    more progress on the cantilever pivot arms.


    i got the pockets done and managed to turn up a few bushings with the inner sleeves.

















    the bushings are a moly filled nylon with an oil lubricant impregnated into it. the sleeves are just 1018 steel, they will go out for liquid nitrite coating when i finish the rod end bodies.
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  8. #58 Re: Family Wagon 1996 ZJ BUILD 
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    If I run into any guys at GSW 2015 from Florida, that are too afraid to drive their rental Wrangler, shall I say hi from you?

    I'm looking forward to seeing how your rear cantilever works, taking your design to functional mechanism. That's always the fun part!
    Last edited by JohnBoulderCO; 01-07-2015 at 12:09 AM.
    WJ, 4.7, Clayton's Front, Double Triangulated Rear, 231HD, HP44, 8.8, ARBs, TR Bumpers, Hydro Assist, 35's, Cage
    Lambo Doors - tweaked unibody
    http://www.mallcrawlin.com/forum/showthread.php?t=8532
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  9. #59 Re: Family Wagon 1996 ZJ BUILD 
    Member FOUR.GO's Avatar
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    Now I see why you were asking about the 37's at 4.5 your planning and detail is phenomenal man. Props to you.
    98 grand cherokee laredo rolled and rebuilt, 4.5 lift bald 37's, locked dana35/ dana 300 tcase and soon to be 8 lug 44 chevy front axle running 4:10's building a 3 linked chevy 44, and triangulated 4 link 14 bolt rear

    96 grand cherokee bone stock.. has death wobble #JEEPLIFE
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  10. #60 Re: Family Wagon 1996 ZJ BUILD 
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    i got some time today between helping the wife with laundry and some random things needing to be done around the house.


    i finished off the rear truss. it will needs some metal finishing on tubes for the bolt pockets. i need to get some small flap wheels for a die grinder.








    i will do a tie in to the dif cover or the housing (not sure yet) later on in the project.


    starting on the cantilever mounts



    i used some incorrectly cut peices for the truss to make a fixture so that each side was identical


    the start









    i'm getting super excited to see this come together. Shocks will probably be another 2 weeks. i want everything ready for them when they arrive
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  11. #61 Re: Family Wagon 1996 ZJ BUILD 
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    the axle is at ride height. the cantilever arm is at full droop.








    the cantilever arm at full bump (axle still at ride height)


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  12. #62 Family Wagon 1996 ZJ BUILD Cantilever Rear Suspension 
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    Loving the work here!
    Are you going to make a removable skid that attaches to the bars
    for the tank?
    "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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  13. #63 Re: Family Wagon 1996 ZJ BUILD Cantilever Rear Suspension 
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    Absolutely. Thinking about doing 1/8" plate with dimpled holes. Our uhmw. If I do the uhmw I can save a huge amount of weight.

    Quote Originally Posted by Stealth Crawler ZJ View Post
    Loving the work here!
    Are you going to make a removable skid that attaches to the bars
    for the tank?
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  14. #64 Re: Family Wagon 1996 ZJ BUILD Cantilever Rear Suspension 
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    Absolutely amazed at how quickly you work! It takes me a day just to do axle seals and bearings...Keep it up!
    04 Dub -- Longarms, JK44, 9" ARB's etc.
    68 Super Wagoneer - Resto Project
    93 ZJ: longarms, 231D, 35's, 44/Hi 9", ARB's, etc. -- Sold
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  15. #65 Re: Family Wagon 1996 ZJ BUILD Cantilever Rear Suspension 
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    This makes the stuff most of us made a decade ago when we thought we were hot stuff, a complete joke.
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  16. #66 Re: Family Wagon 1996 ZJ BUILD Cantilever Rear Suspension 
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    Quote Originally Posted by OverkillZJ View Post
    This makes the stuff most of us made a decade ago when we thought we were hot stuff, a complete joke.

    the motivation behind this build is to have a ZJ with no compromise. I want it to drive good, wheel good and have all the creature comforts with no squeaks and rattles. the front suspension will not be as elaborate. I really didn't want the shocks to be mounted into the passenger compartment in the rear. I plan on sleeping back there when i'm camping.
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  17. #67 Re: Family Wagon 1996 ZJ BUILD Cantilever Rear Suspension 
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    I think it'll be interesting to see what we both come up with. We both are wanting the same thing it sounds like in the end, but you're taking it much farther than I am! It is nice to build a rig at a point in life where you are able to afford to not cut some corners like we all have done in the past.
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  18. #68 Re: Family Wagon 1996 ZJ BUILD Cantilever Rear Suspension 
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    Quote Originally Posted by jsteves View Post
    Absolutely amazed at how quickly you work! It takes me a day just to do axle seals and bearings...Keep it up!
    Seriously. This is an amazing build.
    Ban Cowboy63b Fan Club Member #1
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  19. #69 Re: Family Wagon 1996 ZJ BUILD Cantilever Rear Suspension 
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    Got started on the rod end bodies. 4140 Chromoly

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  20. #70 Re: Family Wagon 1996 ZJ BUILD Cantilever Rear Suspension 
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    Godzuka came over to help get the tires mounted. The tires are off the ground 1" and the ride height is 2" too high.

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  21. #71 Re: Family Wagon 1996 ZJ BUILD Cantilever Rear Suspension 
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    Quote Originally Posted by OverkillZJ View Post
    This makes the stuff most of us made a decade ago when we thought we were hot stuff, a complete joke.
    For sure next level work !
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  22. #72 Re: Family Wagon 1996 ZJ BUILD Cantilever Rear Suspension 
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    so Godzuka came over to help with some body work. I take no credit for any of this work. he did it all.


    decided to go to to the upper next body line on the fenders. Which means you need to modify the doors.








    folded over and tack welded the outer door skin





    added some 2" x 1/8" fat bar for an edge and some strength








    for comparison





    ride height


    3.5" lift approx. with a 37" tire that measures a true 37"



    Last edited by Kraqa; 01-25-2015 at 07:03 PM.
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  23. #73 Re: Family Wagon 1996 ZJ BUILD Cantilever Rear Suspension 
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    Inspirational. Im contemplating weather i should cut into my door or move my axle/gas tank back when I lower mine. How much work was involved in getting the door trimmed and folded that smooth? I love the stance, can't wait to see this on all 4s.
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  24. #74 Re: Family Wagon 1996 ZJ BUILD Cantilever Rear Suspension 
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    What did you do with the inner layer of the rear fender?
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  25. #75 Re: Family Wagon 1996 ZJ BUILD Cantilever Rear Suspension 
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    The inner sheet metal was stretched and welded to the folded over outer skin. I will take a pic.
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