The Never Tight TJ Build

[NickMaul]

Long time no update, the more and more I work on other peoples stuff the more my junk gets neglected. It's basically been untouched since I changed the rear ring and pinion out. Did ghetto fix the leaks on the power steering resi, lets just say jb weld was involved but it doesn't leak any more.

Past weekend not 15 ft into the second trail the cross pin decided to check out on me At least my dad got to drive it through the Honey Hole before it broke. It may have been on the limiter when I broke it

View attachment 328044

Tried to weld it but couldn't really weld the passenger side back solid due to the ring gear being in the way.

On the 2nd or so send the passenger side weld broke which basically let go. I could go back and re-weld it or put a spool but I despise these rcvs so much I'm selling the axle as is.

Which means as soon as I get room in the shop here in a few weeks it'll be One Ton time finally. I'm not going to be like other build threads around here and post a bunch of pics of cad or shit I'm going to buy because I don't have time for that. However my basic bitch TJ plans are as follows:

• 05 SD 60 Front (Spool, 5.38s, Stock shafts for now, has 1480 shafts may nab the 1550 shafts but we'll see.)
• 4 link front, 14" 2.0 Radflo Coilovers (not sure how well it will package but guess I'll find out) cheap poly bumps and limit straps
• 99-06 AAM 10.5 Rear (Spool/welded/Detroit (yo @D2320M you know you want to sell me the Detroit out of that 14b)) TMR shave
• 4 link rear, similar to what I'm running now just going to smooth the belly and triangulate the lowers some, 16" 2.0 Radflo air shocks, cheap poly bumps and limit straps
• Wheelbase Viagra from 106" to 113-116"
• SMOOTH Belly, tired of hanging up on my link mounts. Going to weld weld some 2x2x.188 to the bottom of the frame and run 1.75x.188 dom across for the lower link mounts. Trans is already on it's on mount but it'll have to be redo since it's a Savvy
• Front frame chop, still undecided on how but I'm probably going to cut the frame at the first tub body mount, drink a Busch Latte and throw some tube and hot welding wire at it
• 17" Raceline's and 40" sticky Treps (I would go 42 and will eventually but not enough horsepressures or chromoly in the planed driveline to push them)

Why not run the sterling 10.5 rear if you are talking of welding the rear anyways? Are you converting your d60 to 8 on 6.5 pattern?


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[Bebop]

14 bolt buddy.

Anything other than that will bite you in the long run.

I'm glad you get to upgrade your rig

 

[Chris_Keziah]

Why not run the sterling 10.5 rear if you are talking of welding the rear anyways? Are you converting your d60 to 8 on 6.5 pattern?


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Just going to redrill the front, cost wise even with a shave I'll be ahead of a sterling plus still have 8x6.5 pattern. That and the aftermarket is much stronger for the 14b than the sterling.

 

[paradisePWoffrd]

Id just go 13 bolt, and bypass the shave. A number of folks have complained about housing flex after the shave, causing part failures.

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[Chris_Keziah]

Id just go 13 bolt, and bypass the shave. A number of folks have complained about housing flex after the shave, causing part failures.

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Already have the shave kit, plus this year 14 bolt has a drain plug in the bottom so it's pretty much a must to shave. Haven't ever heard of issues after a shave, only issues I've heard of are leaks.

 

[Chris_Keziah]

Seems to be a thing around here to post cad screenshots

Bored at work and figured I'd try and get my idea into digital form. All the dimensions are pure guess at the moment. Likely going to have to move the front crossmember forward. Planning to cut the front of the frame off just forward of the first tub body mount. The rear link crossmember should be roughly in the right spot but need to lay under the shitbox with a tape measure, note pad and pencil and pretend like I know what I'm doing wavy the tape measure around and writing down numbers.

The whole reason for this is all my lower frame brackets are fucked, imagine what unboxed brackets look like after 30+ wheeling trips of driving by braile. That and I'm tired of catching the lower link brackets on shit and want that smooth(er) transition from the skid to link. Square tube will be 2x2x.188 (likely end up being .25 since I can get it more easily) round tube will be 1.75x.188 DOM.

 

[paradisePWoffrd]

I know the transmission mount is likely above that area, but you will want to brace that tubing behind the lower mounts. The .188 wall will hold up well to rocks, but doesnt hold up to much bouncing on the rear axle.

 

[Chris_Keziah]

I know the transmission mount is likely above that area, but you will want to brace that tubing behind the lower mounts. The .188 wall will hold up well to rocks, but doesnt hold up to much bouncing on the rear axle.

Oh yeah it'll have a tube gusset from the back of the link mount back to the side of the frame. The trans cross will be above all the lower structure. Just going to do a simple one for now since eventually it'll have a different power plant.

 

[ncsutj]

Seems to be a thing around here to post cad screenshots

Bored at work and figured I'd try and get my idea into digital form. All the dimensions are pure guess at the moment. Likely going to have to move the front crossmember forward. Planning to cut the front of the frame off just forward of the first tub body mount. The rear link crossmember should be roughly in the right spot but need to lay under the shitbox with a tape measure, note pad and pencil and pretend like I know what I'm doing wavy the tape measure around and writing down numbers.

The whole reason for this is all my lower frame brackets are fucked, imagine what unboxed brackets look like after 30+ wheeling trips of driving by braile. That and I'm tired of catching the lower link brackets on shit and want that smooth(er) transition from the skid to link. Square tube will be 2x2x.188 (likely end up being .25 since I can get it more easily) round tube will be 1.75x.188 DOM.

View attachment 328323

Where'd you get the model of the frame?

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[Chris_Keziah]

Where'd you get the model of the frame?

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Got from @adamk pretty sure it came off the fb page for offroad cad stuff. Want me to send it to you?

 

[adamk]

Where'd you get the model of the frame?

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like Chris said, there’s a FB group for sharing CAD files. Some are crap and some are good. It’s up to the user to verify accuracy

 

[CasterTroy]

Your viruses may vary

 

[ncsutj]

Got from @adamk pretty sure it came off the fb page for offroad cad stuff. Want me to send it to you?

Nah, just curious. Didnt know how bored you were.

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[paradisePWoffrd]

Oh yeah it'll have a tube gusset from the back of the link mount back to the side of the frame. The trans cross will be above all the lower structure. Just going to do a simple one for now since eventually it'll have a different power plant.

Theres a piece of 2x6 .250 wall that wasnt braced and failed from a rockwelled TJ beatdown. If I find it I will take a pic. Was impressive for sure.

I have always liked the mounts that hang the trans & tcase from above. Might be something to consider on the next drivetrain.

 

[Chris_Keziah]

It's definitely Monday and I'm avoiding doing work today. Not sure how I'm going to do the front half but I remember a cool build on Pirate that duder made plates to slide into the frame and the tube went through those plates. Between that or just notching the frame vertically.

 

[NickMaul]

What’s stopping you from just building a new tube chassis? Seems like the original frame will just be a flat parallel section.


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[Chris_Keziah]

What’s stopping you from just building a new tube chassis? Seems like the original frame will just be a flat parallel section.


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Time, space, and money. If I went the full chassis route the rig would be down for way to long and I'd spend a lot on the unforseen. This way the tub stay mostly untouched from the firewall to where the B pillar will live. I'm basically working with the tools and skills I have currently. A chassis will come but not until after I move to a bigger shop so I can have a chassis table.

In the long run a chassis makes sense but none of what we do makes sense.

 

[paradisePWoffrd]

Time, space, and money. If I went the full chassis route the rig would be down for way to long and I'd spend a lot on the unforseen. This way the tub stay mostly untouched from the firewall to where the B pillar will live. I'm basically working with the tools and skills I have currently. A chassis will come but not until after I move to a bigger shop so I can have a chassis table.

In the long run a chassis makes sense but none of what we do makes sense.

I agree with this statement 100%, but after doing this, I have told myself the next time I will just build a new frame, as there are always tradeoffs.

With that being said, I have done this approach on 3 rigs, and am contemplating this route with my 4th.

For me, keeping the existing together as is, and building the new frame/suspension/axles and just swapping the tub at the end, seems like a much better plan for allowing me to ride as much as I can... but space, tools, and building at a turtle's pace have basically been the hurdle I havent gotten past.

 

[Chris_Keziah]

Super Sad Jeep!

Also after looking at everything I'm just going to do the Motobilt front half kit for time reasons. Should be ordering all the gear stuff this week from ECGS, need to get the 14 bolt tore apart so I can get it on the mill table at work for skecthy after hours projects.

 

[NickMaul]

Super Sad Jeep!

Also after looking at everything I'm just going to do the Motobilt front half kit for time reasons. Should be ordering all the gear stuff this week from ECGS, need to get the 14 bolt tore apart so I can get it on the mill table at work for skecthy after hours projects.

When are we going to see the 4 wheel drive burn out videos?


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[Chris_Keziah]

When are we going to see the 4 wheel drive burn out videos?


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Oh there will be a shop burnout before it's tore down, only 2wd though.

 

[XJsavage]

It's quite refreshing to see some building going on. Everyone around me either quit, found a gf, or something irrelevant.

 

[WARRIORWELDING]

Super Sad Jeep!

Also after looking at everything I'm just going to do the Motobilt front half kit for time reasons. Should be ordering all the gear stuff this week from ECGS, need to get the 14 bolt tore apart so I can get it on the mill table at work for skecthy after hours projects.

Mill? Shave I assume? It cuts like butta' I've done porta band, cut off rocks, and a sawzal. Never spoiled myself with a mill!

 

[Chris_Keziah]

It's quite refreshing to see some building going on. Everyone around me either quit, found a gf, or something irrelevant.

Mill? Shave I assume? It cuts like butta' I've done porta band, cut off rocks, and a sawzal. Never spoiled myself with a mill!

Yeah for the shave. Figured since I have access I'll at least make it easy on myself.

 

[Chris_Keziah]

It's quite refreshing to see some building going on. Everyone around me either quit, found a gf, or something irrelevant.

Thanks man. Seems the amount of build threads across all forums has dwindled and most have sXs. Half the fun is building them.