Thread: Family Wagon 1996 ZJ BUILD Cantilever Rear Suspension

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  1. #151 Re: Family Wagon 1996 ZJ BUILD Cantilever Rear Suspension 
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    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













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  2. #152 Re: Family Wagon 1996 ZJ BUILD Cantilever Rear Suspension 
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    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.


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  3. #153 Re: Family Wagon 1996 ZJ BUILD Cantilever Rear Suspension 
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    Cricket cricket.....




    This is why i mainly just update my pirate thread... Looks good
    93zj build. 4.0 aw4, 231, 60s, and 37s. Some cutting and some welding.
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  4. #154 Re: Family Wagon 1996 ZJ BUILD Cantilever Rear Suspension 
    Senior Member egg's Avatar
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    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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    4.5" front custom 3-link, dual triangulated 4 link, 35s, custom front bumper. upcoming: custom belly skid, rear bumper, rocker cutout/boatsides, half doors
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  5. #155 Re: Family Wagon 1996 ZJ BUILD Cantilever Rear Suspension 
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    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














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  6. #156 Re: Family Wagon 1996 ZJ BUILD Cantilever Rear Suspension 
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    Its looking great! What M/C are you running with the F350 booster?
    93 ZJ 3.5" RE Superflex kit, KOR Stealth Rear bumper with carrier, Nates 4x4 Front Stinger bumper, Surco Safari Rack, HP D30 , Ford 8.8 Locked, Trimmed out on both ends with 33" Toyo Open Country M/T's
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  7. #157 Re: Family Wagon 1996 ZJ BUILD Cantilever Rear Suspension 
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    f350 master as well. the axles are also f350 so the brakes are all matching.
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  8. #158 Re: Family Wagon 1996 ZJ BUILD Cantilever Rear Suspension 
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    makes sense! Keep us posted, Id like to know how she stops
    93 ZJ 3.5" RE Superflex kit, KOR Stealth Rear bumper with carrier, Nates 4x4 Front Stinger bumper, Surco Safari Rack, HP D30 , Ford 8.8 Locked, Trimmed out on both ends with 33" Toyo Open Country M/T's
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  9. #159 Re: Family Wagon 1996 ZJ BUILD Cantilever Rear Suspension 
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    Quote Originally Posted by pitbull78133 View Post
    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.
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  10. #160 Re: Family Wagon 1996 ZJ BUILD Cantilever Rear Suspension 
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    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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  11. #161 Re: Family Wagon 1996 ZJ BUILD Cantilever Rear Suspension 
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    What year model F350 did you use?
    93 ZJ 3.5" RE Superflex kit, KOR Stealth Rear bumper with carrier, Nates 4x4 Front Stinger bumper, Surco Safari Rack, HP D30 , Ford 8.8 Locked, Trimmed out on both ends with 33" Toyo Open Country M/T's
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  12. #162 Re: Family Wagon 1996 ZJ BUILD Cantilever Rear Suspension 
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  13. #163 Re: Family Wagon 1996 ZJ BUILD Cantilever Rear Suspension 
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    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.
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  14. #164 Re: Family Wagon 1996 ZJ BUILD Cantilever Rear Suspension 
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    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.


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  15. #165 Re: Family Wagon 1996 ZJ BUILD Cantilever Rear Suspension 
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    Bitchin build man! Love that bumper!
    "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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  16. #166 Re: Family Wagon 1996 ZJ BUILD Cantilever Rear Suspension 
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    This is your best build yet.
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  17. #167 Re: Family Wagon 1996 ZJ BUILD Cantilever Rear Suspension 
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    Did you have to disassemble the calipers prior to powder coating or are they up to the heat?
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  18. #168 Re: Family Wagon 1996 ZJ BUILD Cantilever Rear Suspension 
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    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.
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  19. #169 Re: Family Wagon 1996 ZJ BUILD Cantilever Rear Suspension 
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    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.
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  20. #170 Re: Family Wagon 1996 ZJ BUILD Cantilever Rear Suspension 
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    this is the smitty built 8000lb winch. nothing special really.
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  21. #171 Re: Family Wagon 1996 ZJ BUILD Cantilever Rear Suspension 
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    Haven't been on here for a while, lol.
    As always great build, I dig the family thing.
    Keep it coming.
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  22. #172 Re: Family Wagon 1996 ZJ BUILD Cantilever Rear Suspension 
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    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.


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  23. #173 Family Wagon 1996 ZJ BUILD Cantilever Rear Suspension 
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    Just freaking amazing!
    "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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  24. #174 Re: Family Wagon 1996 ZJ BUILD Cantilever Rear Suspension 
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    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.
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  25. #175 Re: Family Wagon 1996 ZJ BUILD Cantilever Rear Suspension 
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    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.


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