CNC4x4 club build

BRUISER

silent.. but deadly
Moderator
Joined
Mar 17, 2005
Location
Raleigh
Every year CNC has wrenching days where we ask members to come together and help other member or new members either fix or add stuff to there rigs.

We have done cages, lifts, suspension, etc. pretty much almost every part that you can think off.

Well this year we are stepping up our game. We have a club member that would do anything for anyone so we are gonna give back to him.

We will be using my shop for the build with all others putting in time and muscle :)

Day 1 started yesterday Dec 10 2016. Jack and his dad showed up with a pile of parts and his jeep. His jeep is built very well but he wants to take it to the next level.

We have a deadline of April 1st 2017. Which is good cause that means I don't have to be in the garage every night :)

27ab91be8d895a40aeedfe432079ec4d.jpg


8a3a8c5053f8311562285c6cb67b1246.jpg


Shop ready to be filled with parts and the jeep.
5665e6bcee026639ab512b77aff3156e.jpg


ace6258fba6244544d89ee43d5ba5d5a.jpg


Crate of axles.
e1fef8f62d14e490df1150d46558afcb.jpg


Jeep full of parts
a7481350e58e0b3fc15e221de201e208.jpg
 
More parts

19d506cfc51061436368796733dc8b24.jpg


1115cb2fd1a2df7a11588a342c5164be.jpg


2974519035891b90befaa08aa7fe8aab.jpg


05185ff1450c5656306618e12ee09efb.jpg


Jack very excited to get started :)

a27b7b0e4582dc4fda4f9c522b052719.jpg


Put jeep on lift and pulled off the tires. Then we sprayed all bolts/nuts with WD and PB so when we do our tear down it will go smoothly.

d95ad7d5bcae7caa0d1e649e36e08cd5.jpg


It may not be the fastest build but it will be cool.
 
The list:

Dana 60's from dynatrac front and rear
All new suspension with ORI's
All new steering - and it steering with joy sticks
Gen right fuel tank
New fenders
And of course 40" tires
 
Awesome!!! I would love to lend a hand in this if time and travel permits!
 
Jack is one of those guys that when he's wheelin' there ain't no handicap. Heck, in general for that matter! If folks haven't seen the hoist and steering setup, it allows Jack to be one of the hardest rock crawlers in the club! And, one of the nicest most giving people you'll ever meet.

Nice Ken! He's gonna love it! :driver:
 
Today we had our official first wrench day

We took out the axles, all suspension parts, and gas tank.

Next we strip the frame and then we can get started.

c6058c7765b3c6d3b84a98c93945a29f.jpg


2167a166fe9a660ca4c125fa3f4dc28d.jpg


3c06b437897d47ad6c79d636a25df302.jpg


b9722e8a72419a8c8840a4c4c5608fdf.jpg


dfbcd836535dd00f67270e9b83213250.jpg


5f61e27c583045c7375440efe1b13fbc.jpg


fcb69616b7b35f336c40671f7cac9a92.jpg


b8d48187ea6eedcc1dec35580c76bba7.jpg


0fd04d409e12c6dad7c7048eb7e9c747.jpg


48bb8f30235947eae2b3119eb94717ba.jpg
 
Today we cut off all the old suspension brackets. Installed 1" Daystar body lift and a genright 23 gallon fuel tank and skid.

25c7c8231267d3ab1af8021b184f8299.jpg


b3ea4e9829209be99339699bf5623dad.jpg


578599aa91f331e02f91b9a988be0333.jpg


1716acada473622702cdbc5721cb101f.jpg


ff0d385f1e67e1ca92bdc8e02c1985da.jpg


3844cea33651b7f7a1eeea40b8f65895.jpg
 
because you cant ever have enough pics.. Here are some that Jack took sunday.. and a much better writeup then I do :)


Sunday, January 16, 2017


This was “officially” the second build day on the Jeep. Work started promptly at 9AM. The plan for the day was to remove all unnecessary suspension brackets and mounts, smooth out the frame, install the body lift, bolt in the new gas tank, and possibly remove the front fenders.


The first lesson of the day came early. As Ken was using the plasma cutter to remove old suspension parts, Jack Sr was using the air grinder to wire brush the frame. Well, the air compressor could not keep up with both tools at the same time. So, Jack Sr proceeded to remove the Anti-Rock sway bar.


Lucas showed up and took to smoothing the frame with the electric drill and sanding disks. The cutting and smoothing process took several hours. Next, we unpacked the SWAG weld-on body mounts. Since the build calls for a 1” body lift for the gas tank install, we decided to unbolt the body from the frame and insert the body lift blocks. The plan is to cut off the existing mounts one at a time and weld on the new mounts one inch higher. Lesson number two: it's easier to lift the body off the frame when you unbolt all the body mount bolts. We missed the two bolts on the rear crossmember. Lesson number three: the back half of a stripped down Jeep, on a frame style lift, is very light! Tie/strap the body down before lifting the body to insert the taller blocks.


Just before lunch, Ron joined the forces. After lunch – pizza from Salvio’s. Good stuff! We unpacked the new gas tank, which will allow the Dana 60 rear axle to be pushed back 5”, and installed fuel pump.


Lesson number four: what seems simple and straightforward isn't always so. The tank install appeared to be a direct bolt in. Not the case. The front mounting tabs required drilling the frame at the location of a crossmember. Drilling from the inside of the frame to the outside of the frame was not an option. First, we had to transfer the mark from the inside to the outside of the frame. Next, the challenge was to drill straight through the frame and hit the mark on the inside. Not so easy. The passenger side was slightly off the mark and took some time to lineup the holes. Lessons learned from the passenger side were applied to the driver side and we found success on the first try!


Holding the tank up and bolting it in place sounds easy; especially with four guys. Well, not so much, this took us the rest of the afternoon. The back of the tank lines up on the factory studs and the original nuts were used to secure the back of the tank, no problem. The next hour plus was spent devising ways to fish the supplied bolt through the newly drilled hole. Existing holes were used to assist in the process. Success was achieved by taping some welding wire to the bolt and pulling the bolt through the hole with the wire. Home free now, right? Wrong! We must have used every combination of tools in Ken’s toolbox. We had swivels, extensions, crows foot wrenches, off-set wrenches, shorty wrenches, and every other combination of ratchet and wrench we could think of. Finally, a combination that worked was discovered! The other side took ten minutes.

Lesson five: pay attention to hang wires and hoses. In hast to bolt the tank in place, we neglected to attach all of the electrical connections and hoses to the top of the tank. So, we had to partially unbolt the tank and drop it down. Luckily for us, Lucas has skinny arms. He was able to reach up over the tank and connect the unattended wires and hoses. We did have to spend some extra time on the one electrical connection. Over time, the plug has become brittle and the safety latch was broke on one side. The connection did not want to stay together. Ken used a zip tie to hold the latch in place. When then retighten all the bolts on the gas tank, put away tools, and called it a day.


File_000 (1).jpeg
File_000 (2).jpeg
File_000 (3).jpeg
File_000 (4).jpeg
File_000 (5).jpeg
File_000 (6).jpeg
File_000.jpeg
 
because you cant ever have enough pics.. Here are some that Jack took sunday.. and a much better writeup then I do :)


Sunday, January 16, 2017


This was “officially” the second build day on the Jeep. Work started promptly at 9AM. The plan for the day was to remove all unnecessary suspension brackets and mounts, smooth out the frame, install the body lift, bolt in the new gas tank, and possibly remove the front fenders.


The first lesson of the day came early. As Ken was using the plasma cutter to remove old suspension parts, Jack Sr was using the air grinder to wire brush the frame. Well, the air compressor could not keep up with both tools at the same time. So, Jack Sr proceeded to remove the Anti-Rock sway bar.


Lucas showed up and took to smoothing the frame with the electric drill and sanding disks. The cutting and smoothing process took several hours. Next, we unpacked the SWAG weld-on body mounts. Since the build calls for a 1” body lift for the gas tank install, we decided to unbolt the body from the frame and insert the body lift blocks. The plan is to cut off the existing mounts one at a time and weld on the new mounts one inch higher. Lesson number two: it's easier to lift the body off the frame when you unbolt all the body mount bolts. We missed the two bolts on the rear crossmember. Lesson number three: the back half of a stripped down Jeep, on a frame style lift, is very light! Tie/strap the body down before lifting the body to insert the taller blocks.


Just before lunch, Ron joined the forces. After lunch – pizza from Salvio’s. Good stuff! We unpacked the new gas tank, which will allow the Dana 60 rear axle to be pushed back 5”, and installed fuel pump.


Lesson number four: what seems simple and straightforward isn't always so. The tank install appeared to be a direct bolt in. Not the case. The front mounting tabs required drilling the frame at the location of a crossmember. Drilling from the inside of the frame to the outside of the frame was not an option. First, we had to transfer the mark from the inside to the outside of the frame. Next, the challenge was to drill straight through the frame and hit the mark on the inside. Not so easy. The passenger side was slightly off the mark and took some time to lineup the holes. Lessons learned from the passenger side were applied to the driver side and we found success on the first try!


Holding the tank up and bolting it in place sounds easy; especially with four guys. Well, not so much, this took us the rest of the afternoon. The back of the tank lines up on the factory studs and the original nuts were used to secure the back of the tank, no problem. The next hour plus was spent devising ways to fish the supplied bolt through the newly drilled hole. Existing holes were used to assist in the process. Success was achieved by taping some welding wire to the bolt and pulling the bolt through the hole with the wire. Home free now, right? Wrong! We must have used every combination of tools in Ken’s toolbox. We had swivels, extensions, crows foot wrenches, off-set wrenches, shorty wrenches, and every other combination of ratchet and wrench we could think of. Finally, a combination that worked was discovered! The other side took ten minutes.

Lesson five: pay attention to hang wires and hoses. In hast to bolt the tank in place, we neglected to attach all of the electrical connections and hoses to the top of the tank. So, we had to partially unbolt the tank and drop it down. Luckily for us, Lucas has skinny arms. He was able to reach up over the tank and connect the unattended wires and hoses. We did have to spend some extra time on the one electrical connection. Over time, the plug has become brittle and the safety latch was broke on one side. The connection did not want to stay together. Ken used a zip tie to hold the latch in place. When then retighten all the bolts on the gas tank, put away tools, and called it a day.


View attachment 240271 View attachment 240272 View attachment 240273 View attachment 240274 View attachment 240275 View attachment 240276 View attachment 240277

Love it! Glad you're enjoying the process Jack!


Sent from my iPhone using Tapatalk
 
work is moving along slowly and will be ramping up quickly now that we are back from KOH.

we replaced the motor mounts with new 1" lifted one, took the old fenders off and installed new gen right battery boxes and started prep for new fenders. we also installed a new PSC steering box with a poison spyder steering box skid.

next I will be working on cleaning more of the old stuff off the frame and prepping for new 4 link mounting brackets. we also unboxed everything which was a lot of fun and felt like Christmas.

@livetorun
IMG_2954.JPG

IMG_2955.JPG

IMG_2956.JPG
 
Another night in the shop. Cut a bunch more off. And then added two swag body mount. 4 more to go.

bb0ea416d427a056b6948e2c31bdc17a.jpg
 
Progress. All body mounts done. Entire frame clean, axles in place.

Thanks to Dave,Ron,Randal and the Kacks for helping today

9eb60c83eefcd16f1235aebf0e82f863.jpg


62d745c1ab4bf18cfc08baa4765009c9.jpg


c5edd890dcf7c61c8ccce6bb355846de.jpg


e126e670c1340871215ea6a207507b3e.jpg


a50549718796f1c23e15462ae36e04f8.jpg


bb8fe494eb4f3c4451a9349ea0efc9a2.jpg


14f11205940066953e7d45abe36ebef9.jpg


2c9b140b6da0d9315dbe606771d74123.jpg


af99d1ea6b90428a5823cdaeb3ac3b86.jpg


401307c9d73bb1763d27855c42eb36af.jpg


ade180f0baa70cb9f638e0e264622dfa.jpg


97a2a7ef5bbded8a3a7af27e758fb855.jpg


26b6089e9387fd5da2c0d463366f8de1.jpg


1efba8cb50200956300864f30992bc5e.jpg
 
Might want to cover those side windows up when you grind the driver side fender. The sparks will melt the plastic.
 
Worked on jeep again. Front axle in place. Front frame mounts in place. Made temp links and temp steering. We are making progress

20143fcd52017b85b4cbb215c4171b2f.jpg


404b9aa056afdda38fd0962b4c54a4e5.jpg


8962758193ca7a5b8ccb28429ad3aebf.jpg


eaf548ac7a141e48c0049ddf1e0780a2.jpg


da2daa4f9c033d2c9907a8dde9619116.jpg


97b7597a406774759e66330b51b74161.jpg
 
Made more progress today. Thanks to all the helpers

My helper and myself.
151b53565163b18a6b1a1220b6a8b372.jpg


310edb3250f2440f34d5a9974e9b22b0.jpg


Mr. safety
d9173c771b4ceed80bc0a145baee16be.jpg


485668aa58e7a166cb51102c526cfc88.jpg


Setting pinion angle
7f735d908d1dbcbcd4a38029d7ed2e7c.jpg


bbc7005f93e67669ae8eed34b5dfe3fa.jpg


f0e3b4e90617d1344c30c36585267d8e.jpg


26351f498b92480609c285477a787579.jpg


9ed3e4fc5478542bc6a9b7a6eb65d20d.jpg


830f787b325dde8ad772fa154c460bc4.jpg


241f3ff4d582500150e2a38e451c58f4.jpg


8ea1e3eb72e206488d66e88a254edabd.jpg


039c57c6bab04014fabad9cfaa812fd9.jpg


cecc0ee8f9b2808b008a0b96c4198efc.jpg


e6431bfb3301cd51dedbd8487fda6b10.jpg


b0009cae64aeca1f716d4dae5ae086b2.jpg
 
Back
Top