Burrellsjeep Project: Eugene

burrellsjeep

Breaking Stuff...
Joined
Nov 19, 2008
Location
Morganton NC
Specs:

97 TJ 2.5 liter AX5/231J
3.5 Inch Teraflex Springs
Custom 3 link Front,
Custom 4 link
Locked D30/ Locked 8.8
4.88 Gears

I build all my projects in my garage with a 110 volt weekend welder.

Current Progress Pic 7/5/2017

standalone


Plans

This build is going to be a work in progress, Or a slow build.

  1. Upgrade Steering - DOM Heims - Done!
  2. 3 link the front - Done!
  3. Build Track Bar - Done!
  4. Build a truss for the D30 - Done!
  5. Cut Fenders - Build tube fenders -Done!
  6. 4 link the rear - Done!
  7. Full Roll Cage - Done!
  8. Built Front Bumper - Done
  9. Rock Sliders - Done
I currently running 35s, and will stay there until I come across a front axle, Not really looking just if I happen to find one then I will address the D30, Until then I plan on trussing it and wheeling it. I plan to keep the 3.5 inch springs and just build a 3 link in the front and a rear 4 link.

This is another poor mans non hardcore build, and your input is welcome.

Links to some write ups of small projects on the jeep.

Second Skin Dead Liner Install
Cheapo Hand Throttle
 

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Ron

Dum Spiro Spero
Moderator
Joined
Apr 16, 2005
Location
Sharon, SC
That wasn't "backpack" Jason Hill helping with the liner install was it?
 

burrellsjeep

Breaking Stuff...
Joined
Nov 19, 2008
Location
Morganton NC
Steering Installation

So here is what I am currently working on. I am building my steering from of 1 3/4 3/8 wall DOM tubing (7 feet of it) and 3/4 Heims. Here is what I started out with.
Tubing
ai298.photobucket.com_albums_mm279_burrellsjeep_002_1.jpg_f2763a53e1248c2dc5558ff522478719.jpg

Heims
ai298.photobucket.com_albums_mm279_burrellsjeep_004.jpg_9e1c7f6cac084b968339e48d7982e428.jpg

Mocked together
ai298.photobucket.com_albums_mm279_burrellsjeep_006.jpg_0ee90812c1371038d55bdc0df8468a4e.jpg

I drilled my knuckles and pitman arm out to 5/8 (I got an Industrial grade 5/8 bit from a supply house well worth it) and I am using 5/8 bolts and 5/8 step down spacers at the knuckles and 5/8 high misalignments at the pitman arm.
Here was my first design welded up
awww_pirate4x4_com_forum_picture_php_0fa06e09058a376557f6d78329d7b7d0._.jpg

ai298.photobucket.com_albums_mm279_burrellsjeep_004_1.jpg_c094f8e032f5f1e4c32493bcb5436f7a.jpg

ai298.photobucket.com_albums_mm279_burrellsjeep_005_1.jpg_dab281d7df80b9210da18928c4d839a9.jpg
 

burrellsjeep

Breaking Stuff...
Joined
Nov 19, 2008
Location
Morganton NC
There was some roll in the steering do to heims, Very little but I wanted it tighter so I added a bushing.
ai298.photobucket.com_albums_mm279_burrellsjeep_002_2.jpg_ec724b95d92386a7d413f55265f783a6.jpg

After I got done with I just didn't like how the drag link ties into the tierod. I wanted a double sheer mount and I was concerned the two would bind. So I got some brackets and did it this way.
Here are Brackets courtesy of Ballistic Fab
ai298.photobucket.com_albums_mm279_burrellsjeep_003_1.jpg_e1068d922c9019af5861f539818afc1e.jpg

And here is how it is now.
ai298.photobucket.com_albums_mm279_burrellsjeep_008_1.jpg_dd4202a1a1529537a7899465b7e772f2.jpg

ai298.photobucket.com_albums_mm279_burrellsjeep_007_1.jpg_a0fb643be4914d9a95e3c7845870206f.jpg

ai298.photobucket.com_albums_mm279_burrellsjeep_009_1.jpg_288108fbe071eebd8ac8081e55880734.jpg
 

burrellsjeep

Breaking Stuff...
Joined
Nov 19, 2008
Location
Morganton NC
Track Bar

Since I got the steering done, I needed a solution for the track bar, I was able to get some more 1 3/4 tubing (Actually enough to 3 link the front also). So I decided to build it just like my steering arms. I had to relocated the axle bracket in order to clear the steering.
I ordered this bracket from Ruffstuffspecialties.com
IMG_0920.jpg

I moved it to the top of the axle and offset it 2.5 inches to match the factory offset. Here are some pictures of it tacked in place and mocked up.
ai298.photobucket.com_albums_mm279_burrellsjeep_011.jpg_c955f22aa099ceb462c2f5444d4c144e.jpg
ai298.photobucket.com_albums_mm279_burrellsjeep_012.jpg_4218b96a189b09429b8b4c0a2279abae.jpg

Looks like it will work well, I just have to burn it in and gusseted up. I am going to use these to gusseted it. There 1/4 thick and from DIY4X.com.
ai298.photobucket.com_albums_mm279_burrellsjeep_010_1.jpg_1101a08d55b64a3b4c0adc53ed33864f.jpg

I have some material for a truss for the top of the D30, I will post that up tonight, Along with my plans for the truss I am building.
 

braxton357

Robot
Joined
Apr 6, 2005
Location
Morganton
You didn't fawk around with that steering...I've seen monster trucks that don't have tierods that large. There's no binding anywhere with that diameter tubing?

Now you just have to worry about tearing the steering arm or balljoints off that cheesy d30 knuckle. :flipoff2:

Looks good though.
 

burrellsjeep

Breaking Stuff...
Joined
Nov 19, 2008
Location
Morganton NC
You didn't fawk around with that steering...I've seen monster trucks that don't have tierods that large. There's no binding anywhere with that diameter tubing?

Now you just have to worry about tearing the steering arm or balljoints off that cheesy d30 knuckle. :flipoff2:

Looks good though.

Hey don't hate on my D30 it's special :flipoff2:

I will put a larger axle in the front one day, When I can decide what I want.

I had to mount the tie rod under the knuckles due to the size, If I had put them on top they would bind like hell, Don't think I will have an issue with it getting bent being lower. Hey I got a great deal on DOM.

I think I might mount some recovery points on the tie rod. :lol:
 

burrellsjeep

Breaking Stuff...
Joined
Nov 19, 2008
Location
Morganton NC
D30 Truss

So here's my plan for the truss on the D30, I have some 1.75x2.75 1/4 inch wall square tubing, I am going to cut it on an angle. I plan on using it kinda like a large gusset to help with the tube flex the 30s are known for.

This gives you the idea.

ai298.photobucket.com_albums_mm279_burrellsjeep_Truss.jpg_0b5b2bc13c2ff11698a54175ae4d93ed.jpg


I am going to mock it up in card board and see how it going to fit.
 

burrellsjeep

Breaking Stuff...
Joined
Nov 19, 2008
Location
Morganton NC
My buddy Justin (Who works for a large machine shop) is helping me with this build. He is a much better welder and I trust him to do the welding on anything that is tied to safety. I hope to be posting up his build in the near future. His rig is one of the impressive rides I have seen ever.


Just wanted to give him his due.

Thanks again.:beer:
 

burrellsjeep

Breaking Stuff...
Joined
Nov 19, 2008
Location
Morganton NC
**Updates**

Well turns out I have a bad computer in the TJ, Been chasing that problem so I hadn't worked on much else until today.

Well I finished removing the 2 inch spacer lift, getting me back down to the ride height I am looking for.

Having it at ride height I can my measure for my rear driveshaft, It ended up 18.5 inches from Center of Cap to Center of Cap. I getting a ZJ CV shaft cut down.

I have it back to the stock wheel base maybe a inch or two longer. This will be where it stays.
 

burrellsjeep

Breaking Stuff...
Joined
Nov 19, 2008
Location
Morganton NC
Got my Driveshaft back from CCC Truck parts today,
They did an great job on it, Had them redo the whole thing, All new u joints, CV joint, shorten and rebalance. They even painted it. Paid like $170, Hell of allot better than $300 for a new one. Got the ZJ shaft free from my brother in law.

I dropped it off at eight and it was ready by noon. They kicked ass on it.

Great job thanks.

ai298.photobucket.com_albums_mm279_burrellsjeep_006_4.jpg_2b5382a6b00352e072acf1fa7f83a656.jpg
ai298.photobucket.com_albums_mm279_burrellsjeep_005_2.jpg_909e9e5f1d5ea63d12d1fb0ab0845586.jpg


Look them up if you need driveshaft or drive line work done.


CCC Truck Parts / Joint & Clutch Service
1112 1ST Avenue S W
Hickory, NC 28602
(828) 328-5705
 

burrellsjeep

Breaking Stuff...
Joined
Nov 19, 2008
Location
Morganton NC
Question

Do you guys see any issues with making my front links out of 1 3/4 3/8 walled DOM with 3/4 heims on the frame side and a ballistic joint on the axle end?

I have read other builds with guys using them, I figure with the weight of my TJ, 4 banger and all, I should be ok
 

burrellsjeep

Breaking Stuff...
Joined
Nov 19, 2008
Location
Morganton NC
So here is what I decided on the links for the front.

I building the lowers out of the 1 3/4 inch 3/8 walled DOM, I using a Ballistic Joint welded to the Axle end, And I went with a Creeper joint threaded in the frame end, I going to tap the DOM for the 1.25 threads.

Here are ends I just bought from "Indy Will" on Pirate.

2008-1576-600.jpg


On the upper link for the front I am going with a 3/4 heim on the Frame side and a poly bushing in the mount on the diff. I plan on using a summit joint in place of the bushing when the budget allows. But for now I will use the bushing. I haven't decided on the DOM for the upper, If I have left over of the 1 3/4 I will just use it, If not I may go with a 1.5 .250 DOM.
 

burrellsjeep

Breaking Stuff...
Joined
Nov 19, 2008
Location
Morganton NC
Truss

Starting on the truss for the D30.

I using this 2.5 X 1.75 .250 square tube
ai298.photobucket.com_albums_mm279_burrellsjeep_004_3.jpg_901bb6d5b38c586c2eac4c2431ec9be2.jpg


I made a card board template to help me get it closer to the shape, I still going to have to shape it to fit.
ai298.photobucket.com_albums_mm279_burrellsjeep_001_3.jpg_aa594b0225dbea15647f875d1d3969ea.jpg


Kids are in bed so I will have to cut in the morning.
 
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