CJ5 Jevy

Are these extensions going to support the new suspension you will be adding to the jeep? If so I'd reccomend having someone else do it. That's one hellava learning curve right.
 
Good Grief! I looked at this thread after you called me, I think that CJ5 tub came from Yankee Land the way it's ate up.
 
I told you the thing was a peice! The pics don't even do the rustyness full justice :rolleyes:

When i say slightly larger and overlap I mean the existing frame fits right into the square tubing perfectly and I will slide it in about 1/2" of overlap b4 welding

Yes The frame extensions will be supporting the rear suspension, I have been practicing welding alot over the last couple of days on scrap metal and feel pretty confident about it now.
 
jrraw23 said:
Yes The frame extensions will be supporting the rear suspension, I have been practicing welding alot over the last couple of days on scrap metal and feel pretty confident about it now.
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If it's going to be supporting the rear suspension remember it's going to be seeing heavy cyclical loading, make absolutely sure you're getting adequate PENETRATION. I'm sure you know just b/c the two pieces stick together doesn't mean they're welded sufficiently. Be carefull and take your time. Good luck!
 
jrraw23 said:
I have been practicing welding alot over the last couple of days on scrap metal and feel pretty confident about it now.
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Take a piece you have welded and first cut in half with a band saw, you can better examine the weld's penetration.. then chuck it up in the vise and beat the high holy hell out of it, and report back what failed.

Seriously.
 
sounds like a great plan... just a vertical weld huh? simple as that? seriously, do everyone else on the road and trail a favor and to a little more research into that extension before executing it.
 
Practicing on some scrap metal is a good start to welding....But a home brew frame stretch is hardly the logical second step. Im not ganna say have some body else do it because if I were you Id want to do it myself too...But I would highly recomaned getting somebody you know that can weld (maybe somebody from this site?) to help with your design and give you some pointers with the welds. Just sliding a peice of pipe over the frame and globbing weld over it is not going to last long on the trail.
 
Yea my buddy Adam is the head of the NC State Baja Buggy team and that man can weld like crazy so he has been telling me what I should be looking for and how to weld as far as quality and safety. I def did the beat the crap out of the metal after welding like he told me to and all of my welds held fine. The metal bent but no broken welds. As far as penetration, I think I need a little more practice on that but I'm getting close. I'll have to look into the frame ext design, cause yea i was just gonna slide it over and weld it on by the strait edges of the tube but that sounds like its wrong. I started thinking about it thou and remember reading that diamond shape is the strongest shape to weld so maybe I should weld it on with kinda half diamond shape ends???? Ideas? Pics of your setup or others would be sweet.
Thanks.
 
Ricky. I would slide it up on the frame at least 6 or 8 inches. 1/2 an inch isn't enough for the stress it will be prone to. Some plug welds would be good too. The more area you have to lay bead, the better. I did a simular extension on my Heep, except I used heavy channel.

You can get an idea of how much I over lapped the frame from this pic. Also after this a cross member was also added on each of the additions. So far, over a year of beating it, and no issues.
 

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I will try to post some pics of mine tonight. i couldnt find tubing that fit my frame perfect so I had the machine shop bend some 3/16 plate into angles that i welded together to form the piece of tubing. I had to use a bfh to get them to fit over my frame rails. Cut angles into the tubing that slides onto the frame also. I had 6" of the tubing onto the original frame.
 
You're correct. Try to avoid vertical or horizontal welds on a frame.
 
More Progress, did a 21 to 23 spine input shaft swap on my np231 mon night/tues morn then got the drivetrain in place teus afternoon, i was able to modify the old crossmember to fit the new tranny. Since then done a bunch of random stuff including runnin errands to get what I needed for the frame extensions. Ended up having to get Nitro Manufacturing to bend me some 1/4" flat steel into angle iron to fit over my frame cause Stock Car Steel didn't have the right size. Gonna extend exactly 11.25" almost got the it all ready to go 4 the extending, probably finish up tom then start the extending.


during the input swap

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Drivetrain In Place

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Finnaly got the frame extensions in place, was a pain measuring, leveling, remeasuring, etc. etc. Found out in the process the frame it self is slightly bent in two places: the rear is twisted and the front right side is curved in a bit, oh well, at least I know my frame extensions are bang on. Anyway here's pics, just got it tacked in place, unfortunatly ran out of thanksgiving break so it will be a couple weeks b4 I can work on it again over christmas break.

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it took you all of break to get that done? at that rate you wont be finished for a year.
 
That looks really good man, way better than just stickin pipe on the end of the frame. While you got it all pulled apart you aughta go ahead and box the frame, especially considering that it has already been bent in the past.
 
are you using a camera phone for all of these pics?
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Yea, Don't have a real digital camera, so got to use the camera phone, lol.

That looks really good man, way better than just stickin pipe on the end of the frame. While you got it all pulled apart you aughta go ahead and box the frame, especially considering that it has already been bent in the past.
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Thanks man, Def gonna box in the frame, and add two crossmembers, but yea I was looking and i saw that if i just extended the rear then not only would it not look as clean but also where the frame curves up for the rear axle would have been way off for the new 95 YJ body and I would have had to use huge spacers in the front body mounts to accomidate for the curve being in the wrong spot but now it all lines up pretty well

it took you all of break to get that done? at that rate you wont be finished for a year.
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Well I had other thing to do as well, It wasn't like I was always workin on it everyday, plus it's not like I'm in too much of a hurry anyway I'm running out of $ again and can't really do much w/o that.
 
For future reference, cutting the stock frame at an angle would have been a better idea.
 
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