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View Full Version : Dana 44 axle swap (with pics)



john00TJ
10-20-2007, 11:35 AM
well almost everything has arrived (brackets and mounts )..a little later than expected and one box destroyed in transit with a few small items missing :012: ...anyway heres the low down as of now and i`ll be adding pics as this progresses ..

starting with a 76 HP dana 44 from a F-150 ...got a stupid good deal on this axle and couldnt pass it up .it has teh weld on Cs ..i will be running this fullwidth at roughly 65in WMS-WMS ....gears and locker will be coming around the bend shortly ....http://www.imagestation.com/picture/sraid225/p268d8971f5ce2c6bb96f65e0fd341a44/e78c3273.jpg

JeepGeneral
10-20-2007, 11:41 AM
I'm interested to see how wide it ends up, I was looking to do the same swap. Where did you get the brackets from and how much (TnT has a sweet truss with the brackets built in that I've been eyeing up). What are you doing for a rear axle?

john00TJ
10-20-2007, 02:30 PM
some brackets came from Ruffstuff and the upper control mounts came from K.O.R.E 4x4 customs ..i think i spent around $160 on the brackets in the picture ...i have a 14b FF on deck for the rear but i am still unsure on the exact direction this project is going ...

i can either change everything over to 8 lug or change the rear 44 i have now to 5x5.5 and keep the front 5 bolt pattern .. .not sure yet i guess we will see

Xplodedin
10-20-2007, 02:35 PM
Better get some fender flares

john00TJ
10-20-2007, 02:46 PM
yeah thats the least of my worries now ...but i`ll have some tube fenders bent up with some flares once done ..

andrew2516
10-20-2007, 05:15 PM
Looks good...I've been thinking of putting full widths under mine for a while. I would like to still be able to get it to pass PA inspection though.

john00TJ
10-20-2007, 07:30 PM
not to worried about that ...my inspection guy will pass anything with a 30pk of coors lite on the front seat ...LOL

gonecheenin
10-21-2007, 08:53 PM
Looks good...I've been thinking of putting full widths under mine for a while. I would like to still be able to get it to pass PA inspection though.


You'd be surprised how little 5"s wider looks with some skinny wheels & tires

http://www.blwa.org/phpbb/viewtopic.php?t=2555

HeepH8erTy
10-21-2007, 10:52 PM
where are you going to be getting all your new parts from? i got a 44 that i plan to replace everything on. It sat outside on the grass for like 2 years and isnt in the best shape, but i got it for free. I plan to start re-building over thanksgiving and winter breaks, but dont know where a good place to get the parts from would be. I may end up getting everything from napa.

ezman
10-21-2007, 11:45 PM
if you are going full width i'd stick with 8lug... slap some h2 wheels on it and you won't be much wider than a stock axle with 12.5 wide tires on wheels with 3.75in of bs...

i think it's only about a 2-3 in difference...

john00TJ
10-23-2007, 05:36 PM
made some progress this week...axle is stripped and cleaned..cutting the radius mounts off sucked ..gotaa be careful not to cut the tubes...i am waiting on some lost in transit parts( my control arm mounts ) they must have fell outta my ripped box ...but the vendor was quite cool and reshipped no questions asked ..i`ll have some pics up soon ..

not sure i wanna do h2 wheels due to the price of 17in tires ..not sure yet ..

theclintcommander
10-23-2007, 06:03 PM
Looks good...I've been thinking of putting full widths under mine for a while. I would like to still be able to get it to pass PA inspection though.


If you want to pass inspection chances are you will need to cut the axle down. I'm running full width with 4.5" of BS and my 79' F250 D44 sticks out a good bit.

Brackets look good, too bad you don't have a jig to put them in.

http://photos-497.ll.facebook.com/photos-ll-sf2p/v141/130/65/501741497/n501741497_364655_9954.jpg

john00TJ
10-25-2007, 06:16 PM
got the whole axle stripped and cleaned ..i pressured washed the POS the hit it with a wire brush on the Dewalt ..Time to rip the jeep apart and start to mock this Bitch up http://www.imagestation.com/picture/sraid225/pbf3c3b4c6cb4b134bf9623ba94f2861e/e78700c3.jpghttp://www.imagestation.com/picture/sraid225/pc65a7bb9a2fc336c95de1bdd9b61b556/e78700c2.jpg

Stupid Radius arm brackets real PITA to cut off .....good Bye :098: http://www.imagestation.com/picture/sraid225/p463b311588137ae0aa846d3430f406ff/e78700c1.jpg

JeepGeneral
10-25-2007, 06:26 PM
Work faster!...I just dropped the idea of doing this like a week ago because I was afraid it was going to be too wide for my trailer. Now you have sparked my interest again. I'm interested to see how wide it is with tires on.

john00TJ
10-25-2007, 06:39 PM
LOL i wish i could get this done faster ..with a full time job ,a baby ,and i sold my garage and have to move a ton of stuff time is restricted ..LOL

i still dont know what wheels/tires i am running ..if i could find a set of H1 12 bolt beadlocks near PA that would seal the deal ..

i am tryin to keep it tight and dont wanna run a 4in backspace wheel ..i think it will be way too wide for PA .ummmm oh well too much thinking for me ...

andrew2516
10-25-2007, 07:14 PM
It's looking good

rangerman538
10-25-2007, 11:17 PM
im still thinkin the ranger will be done first

jeepxj3
10-26-2007, 12:58 AM
I love build threads where people actually take pictures!

MF Steve!
10-26-2007, 08:20 AM
I love build threads where people actually take pictures!

What's that supposed to mean??? I'll be takin plenty of pix within the next week!

jeepxj3
10-26-2007, 02:05 PM
What's that supposed to mean??? I'll be takin plenty of pix within the next week!

Im a picture whore what can I say? :030: POST UP THE PIXAHHH's makes it easy to follow if somone was to do the same thing.

john00TJ
10-27-2007, 01:24 PM
got some of the jeep tear down today ..hoping to start mocking in the new axle soon ..it almost makes me a tad sad to just start cutting it apart ..i`ll have some new pics up soon as soon and something exciting happens ..

john00TJ
10-30-2007, 07:02 PM
got the old axle out and slipped the new housing under to start mocking stuff up ...man this things is going to be wide ...the new housing is just as wide at the outers as the complete HP dana 30 WSM-WSM ...i should be tacking some mounts on tomorrow if i get a chance ,but Ruffstuff stiffed me on contorl arm mounts and hast resent them yet ...:062: ...lots of cutting and grinding coming my way ..

so far the trackbar bracket on the frame side is a problem with the front moved forward 2.5 inches ,and i am not sure about the steering yet .....i`ll get some pics up as soon as some noticable progress is made ..

jeepxj3
10-30-2007, 07:06 PM
got the old axle out and slipped the new housing under to start mocking stuff up ...man this things is going to be wide ...the new housing is just as wide at the outers as the complete HP dana 30 WSM-WSM ...i should be tacking some mounts on tomorrow if i get a chance ,but Ruffstuff stiffed me on contorl arm mounts and hast resent them yet ...:062: ...lots of cutting and grinding coming my way ..

so far the trackbar bracket on the frame side is a problem with the front moved forward 2.5 inches ,and i am not sure about the steering yet .....i`ll get some pics up as soon as some noticable progress is made ..

Why not just make your own? LCA mounts are probably the easiest thing to make.

john00TJ
10-30-2007, 07:39 PM
yeah most likley i will ,but i didnt want to cause of time and ease of just ordering them .time is slim with kids and such .but with this bullshit i`d already be done ..

jeepin ruby
10-30-2007, 08:15 PM
john, if ya need an extra set of hands im right down the road. let me know

john00TJ
12-23-2007, 12:35 PM
got the 14 bolt stripped down and cleaned ,its a SRW axle so i need to find some C&C hubs ..67 inchs seems way to wide so the other hubs will make it about 63inchs WMS-WMS ..after the Christmas i`ll be all over this getiing these axles burned in and setting up some gears :icon_super: ..i`ll have some more pcis when i actually have time .as of now what little tiem i have i am tryin to get shit done not snap pics ..

joe_and_jeep
12-24-2007, 11:09 AM
Why a 14 bolt? That axle is massive. Unless your running 42's I would run a 9in. And that I would even be happy with up to 40's.

john00TJ
12-24-2007, 02:01 PM
well its getting shaved so i am not worried about ground clearance that much .its also FF so broken axle changes are easy ....plus it costs next to nothing and i have spare shafts and factory detroit already ..i got the axle for $50 the only 9in i could find was $250 ,so the 14 bolt will be geared /shaved and locked for the same price then all i need is disc brake crap ...

jeepxj3
12-24-2007, 02:05 PM
I agree with your decission on the 14bff. You can shave it, toss disks on it, run some H2 Rimz and your set! Its not as wide as you think, that and the hubs dont stick out like somthing obserd like sterlings do.

joe_and_jeep
12-24-2007, 03:00 PM
well its getting shaved so i am not worried about ground clearance that much .its also FF so broken axle changes are easy ....plus it costs next to nothing and i have spare shafts and factory detroit already ..i got the axle for $50 the only 9in i could find was $250 ,so the 14 bolt will be geared /shaved and locked for the same price then all i need is disc brake crap ...


$250 for a 9in? Out here they are a dime a dozen. I had probably 7 or 8. I was giving them away to some of the derby car guys around here. I think I still have 3 or 4. Probably, 5 front 44s. I scrapped a couple of the cast on wedge 44s. Anyhoo...

john00TJ
12-25-2007, 09:49 PM
$250 for a 9in? Out here they are a dime a dozen. I had probably 7 or 8. I was giving them away to some of the derby car guys around here. I think I still have 3 or 4. Probably, 5 front 44s. I scrapped a couple of the cast on wedge 44s. Anyhoo...

maybe my hook up sucks but not many 9ins around here for a fair price ..i did however just run across a deal on a front 60 ...too bad this 44 is cleaned and ready to mock up in there ..

john00TJ
01-12-2008, 02:32 PM
14 bolt got a shave job ..heres a few pics as its now ..tomorrow i`ll maybe get aroud to fabbing the long arms and mocking the front 44 in there ..i shaved around 2 inchs total off the bottom ..time to make a plate and weld her flat ...

http://i261.photobucket.com/albums/ii74/john02r600tj/Picture293.jpg



heres the bottom cut off http://i261.photobucket.com/albums/ii74/john02r600tj/Picture294.jpg


getting ready to be flat on the bottom ..http://i261.photobucket.com/albums/ii74/john02r600tj/Picture297.jpg

UPJ Wheeler
01-13-2008, 04:55 PM
sweetness!!! how did you cut it? Bandsaw? How are you gona go about welding the cast?

john00TJ
01-13-2008, 10:33 PM
started the cut with a 4in cutoff wheel on the lines marked and then finished with a long sawzall blad..my buddy is welding the plate on the bottom since he owns a welding/fab shop and deals with cast alot and i am a tad clueless ...the ring needs cut down to fit inside the new case so its off to the lathe for that ..

UPJ Wheeler
01-14-2008, 09:36 AM
cool shit! Try to get some pics of the lathing process, and some numbers of how much material was taken off. I think most guys just cut the housing to fit the ring gear. This is a kick ass twist to the build!

MF Steve!
01-14-2008, 09:59 AM
I was going to ask if you had to machine the ring gear. I've never seen anyone cut three bolt holes off of a 14b housing, and not have to shave the ring gear...

Krod
01-14-2008, 12:51 PM
Rather than machining the ring, would it be possible to machine a slot in the new bottom plate for clearance? (this would depend on the thickness of the plate you're using of course)

UPJ Wheeler
01-14-2008, 02:10 PM
Kinda like this guy did with his from D60 (from Pirate 4x4)

I like the idea of turning down the ring gear personally. Not to mention after a few years of draggin it over rocks thins out the bottom of your diffs too, just ask Trailer rails from BLWA. D60 ring gears are huge, and a little material wont effect strength enough to make a difference in your situation.

http://www.pirate4x4.com/forum/attachment.php?attachmentid=292894&stc=1&d=1173886886

john00TJ
01-14-2008, 09:41 PM
Rather than machining the ring, would it be possible to machine a slot in the new bottom plate for clearance? (this would depend on the thickness of the plate you're using of course)


yeah but why ..the bottom plate is only going to be 1/2 thick ..too thin to machine out and any thicker i may as well not shaved it ..

john00TJ
01-29-2008, 07:34 PM
well Ups showed up today with some yukon 5:13s and new carrier for the front and some install kits ...

the front radius arms are done ,the lowers measure 35in eye to eye and the upper is 18in eye to eye ...the lower links are 2x.25 Dom with bushing on one end and 1x1.25 johnny joints on the axle side ..upper is 1 in shanked johnny joint and a RE flex joint on the opposite end ..

wheel base is right and 97in as of now should be about 101 once the rear is set in there ..

The 14 bolt Ring gear is off to the machine shop to get a small trim job ..i am thinking around 1/4 off the outside Diameter should clear my shave job ..

i shuold have some new pics of all the progress up soon and the cutting of the sheet metal ..

john00TJ
01-30-2008, 06:42 PM
got the ring gear shaved 1/4 today..now i gotta bolt it to the carrier and check for clearance ..should be plenty of room now ..





http://i261.photobucket.com/albums/ii74/john02r600tj/101_1144.jpg

http://i261.photobucket.com/albums/ii74/john02r600tj/101_1145.jpg

gonecheenin
01-30-2008, 10:10 PM
Looks great!

What machine shop did you use?

john00TJ
01-30-2008, 10:40 PM
it was done at a big tool and die shop in my area ..i have a friend who works there so he had a machinist do it for me for free ..

MF Steve!
01-30-2008, 10:41 PM
Noice!!! Almost mirror like!

UPJ Wheeler
01-31-2008, 01:21 AM
are you gona have to trim the pinion a hair too?

ezman
01-31-2008, 08:03 PM
if you could get any pics of the plate being welded on, or at least the process you used that would be awesome... i know it's a pain in the ass to weld cast iron...

are you going to drill and tap a hole on the plate so you don't have to worry about it leaking...

john00TJ
01-31-2008, 10:19 PM
no i dont have to trim the pinion it will be fine ..

yeah i`ll go into a bit of detail when the rear gets welded up ..i`ll also have a bunch of pics i just been too busy to post them up ..

ummm dril and tap the a hole huh ?? well i honestly havent gave that any thought along with what i am going to do about a diff cover ..sounds like a good idea i`ll have to see how my cover is going to work and go from there ..

gonecheenin
02-01-2008, 04:46 AM
are you gona have to trim the pinion a hair too?

Why would you need to do that?

UPJ Wheeler
02-01-2008, 10:52 AM
I wasnt sure if trimming the ring gear would expose any amount of the larger end of the taper on the pinion gear. But now that Im thinking about it, the pinion wouldnt interfere with anything if the gear was slightly exposed...

ezman
02-01-2008, 06:18 PM
i like the idea of machining it down a bit... looking good man...
i'm curious to see how you do the diff cover too... keep up the good work...

Xplodedin
02-01-2008, 09:28 PM
if you could get any pics of the plate being welded on, or at least the process you used that would be awesome... i know it's a pain in the ass to weld cast iron..


You have to heat the cast iron up with a torch. Then weld it with nickel rods

MF Steve!
02-01-2008, 10:32 PM
Torch preheat is almost a must...wouldn't go over about 1200* though. I've done a few cast welds using Lincoln Electric Ferroweld, and Softweld 99Ni. We learned about this for a few hours when I took welding classes.

Edit: Also, don't let it cool rapidly. It will almost certainly crack if you try and quench it with water. If you can get the bottom of the diff. in some sand that would work perfect.

gonecheenin
02-02-2008, 04:27 PM
I've always just welded cast steel with high amperage 7018 rods with out any issues

No preheat, no post heat, no special cooling in anyway (just let it sit in the warm garage or warm weather & cool normally)

ANd everything I've ever welded has held up great


One fella on our board that build NP205 doublers for fullsize mud trucks hacks the output off the NP205, welds on a plate with 7018 rod, lets it crack, then goes over the welds again & has never had a problem


I know its far from right, but has always worked great (I think thats how YZEater did his shaved 14 bolt too)

john00TJ
02-16-2008, 06:39 PM
Control arms done and painted ..I notched the end for the bushing ,welded that and then strapped it with 1/4 ..The ends got drilled for grease fittings

http://i261.photobucket.com/albums/ii74/john02r600tj/Picture301.jpg

http://i261.photobucket.com/albums/ii74/john02r600tj/Picture302.jpg

Shock mounts are on the lowers due to the 3in front streach

http://i261.photobucket.com/albums/ii74/john02r600tj/Picture303.jpg

john00TJ
02-16-2008, 06:46 PM
Inner C cut off ,did i mention what a bitch this was ...It felt like i was grinding for a year ..Once you think the weld is ground off enough keep grinding ..If you keep hitting it with a hammer as you grind you`ll see a faint line develop all the way around ..Then find you biggest hammer and wack that sucker that your pissed at it ..After it came off i needed a nap ..LOL No really i cleaned it up with a 40g flapper disc so it would slide back on easier ..

http://i261.photobucket.com/albums/ii74/john02r600tj/Picture300.jpg


I rotated the Cs to 7 degrees and then tacked them in place with 4 small welds ..

http://i261.photobucket.com/albums/ii74/john02r600tj/Picture299.jpg

http://i261.photobucket.com/albums/ii74/john02r600tj/Picture305.jpg

Deadman 94 xj
02-17-2008, 03:44 AM
Those CA are sick! The pics don't do them justice.
Keep up the good work.

john00TJ
02-17-2008, 09:31 AM
Thanks man ,

I Got the frame brackets cleaned off and ready to tack in the links mounts today ..Now i`ll cycle the axle and check for clearance or binding ..and onto tackbar fab and shit

http://i261.photobucket.com/albums/ii74/john02r600tj/Picture304.jpg

UPJ Wheeler
02-17-2008, 03:57 PM
This build keeps gettn better and better

ezman
02-17-2008, 05:00 PM
nice jack stands... i've got the same ones...

looks good man...

john00TJ
02-20-2008, 10:31 PM
few more shots making some progress but its slow due to weather ..i shouldnt have sold my garage so soon ,i forgot how bad it sucks to wrench in the driveway ..

Everything cycles fine without binding and is tacked in place
http://i261.photobucket.com/albums/ii74/john02r600tj/Picture308.jpg

http://i261.photobucket.com/albums/ii74/john02r600tj/Picture314.jpg

http://i261.photobucket.com/albums/ii74/john02r600tj/Picture307.jpg

john00TJ
02-20-2008, 10:36 PM
test fit the shaved 5:13s in the housing and see i still have some more clearance so i decided to shave the housing some more .
http://i261.photobucket.com/albums/ii74/john02r600tj/Picture310.jpg

http://i261.photobucket.com/albums/ii74/john02r600tj/Picture311.jpg

getting closer maybe shave another 1/8 off and it`ll be good ...damn this sucks
http://i261.photobucket.com/albums/ii74/john02r600tj/Picture313.jpg

ezman
02-20-2008, 11:18 PM
just wondering why you mounted your shocks with the bolt parallel to the axle instead of perpindicular...

looking good man...

jeepxj3
02-20-2008, 11:33 PM
just wondering why you mounted your shocks with the bolt parallel to the axle instead of perpindicular...

looking good man...

I agree, thats gonna cause binding and premature bushing wear. :icon_frown:

john00TJ
02-20-2008, 11:48 PM
just wondering why you mounted your shocks with the bolt parallel to the axle instead of perpindicular...

looking good man...


cause i over looked when i welded it up ,guess i was in a hurry ..it will get changed around eventually before finally assembely :088:

john00TJ
02-20-2008, 11:50 PM
I agree, thats gonna cause binding and premature bushing wear. :icon_frown:


it actually doesnt bind as tested but will most likley eat bushings ..either way it will get changed

MF Steve!
02-20-2008, 11:52 PM
Looks great man!

OverkillZJ
02-21-2008, 09:35 AM
cause i over looked when i welded it up ,guess i was in a hurry ..it will get changed around eventually before finally assembely :088:

Make sure you do it before you flex it out: the eyes tear off of shocks when you screw up and mount them wrong, ask me how I know! :043:

gonecheenin
02-22-2008, 12:23 AM
Noice

You sure are being anal about the diff clearance though, I mean dude-an 1/8 on an inch :icon_eyes:

john00TJ
02-22-2008, 06:00 PM
Noice

You sure are being anal about the diff clearance though, I mean dude-an 1/8 on an inch :icon_eyes:

another 1/8 means around 1/4 total ..once the 1/2 plate is welded to the bottom i`ll be around 2 -3/4 gain in GC ..might be anal sure ,but i am only doing it once

john00TJ
03-13-2008, 07:45 PM
The 14bolt is shaved and plated ..turned out pretty nice ..heres whats going down with the diff cover ..i bought a 14b kit from Dan at ruff stuff ..it comes 2 pieces the bolt flange then the cover ...i`ll modify the flange to fit the new housing then welder up ..yeah seems simple ..

i also got the rear spring hangers tacked in and the leafs hanging in the rear ..looks like a ton of streach and the gas tank is for sure in the way ..guess i gotta order a fuel cell ..i might have to move the front spring mounts forward a bit i think its going to be longer than planed for if i dont ..

alot of parts came in so i`ll be making progress this weekend and maybe get it on some roller wheels ..i also have to hit the parts store for balls and stupid stu ..pics will be up later ...:kyle:

90LiftedYJ
03-13-2008, 08:11 PM
looking real good man.

Barillms
03-13-2008, 09:03 PM
Looks good, nice shock mounts.
Everything looks good.

Peccavi18
03-13-2008, 11:30 PM
I'm really watching this build, I'm headed for almost the exact same stretch up front but with a D60. Are you going hysteer arms? and are you moving the steering box up/forward or working from stock location?

In the rear how much stretch are you going for? And are you gonna keep it street legal with the fuelcell outside the cab? I really like the shave on the ring idea and the plating of the poly bushings.

john00TJ
03-14-2008, 07:34 AM
yes i`ll be using highsteer , the steering box will be moving forward also and clocked flat ..i was shooting for around 5 inches in the rear but i think i have more right now ..i might have to change a few things ..fuel cell will be behind the rear seat and boxed in ..

JeepGeneral
03-14-2008, 09:20 AM
What leafs are you using in the rear, have any pictures of that setup?

jeepxj3
03-14-2008, 10:08 AM
it actually doesnt bind as tested but will most likley eat bushings ..either way it will get changed

I guess if you keep it pin style on the top of the shock you wont have much of an issue, but if you plan to change this I would seriously thing about reworking those lower shock mounts.

john00TJ
03-14-2008, 06:32 PM
What leafs are you using in the rear, have any pictures of that setup?


Flipped around XJ springs so the long side is forward .mounted in the stock control arm mounts and Ruff stuff way back shackle hangers ..i do have a few pics of them but i cant get Photobucket to upload them now ..

JeepGeneral
03-14-2008, 07:12 PM
hmmm I always wondered if you could use the old LCA mounts, I'll have to look into the way back shackle hangers, did you cut out the stock crossmember and weld in a new one?

john00TJ
03-14-2008, 07:34 PM
yeah the stock LCA location seems to be too far back ..i may cut them and move everything forward 1-2 inches ,but i`ll make the decsion once its on some wheels ..what cross member are you talking about ??you mean the rear cross member ..if so the no my shackle mounts are welded to the face on the rear bumper ...man i wish the pics would up-load

john00TJ
03-14-2008, 07:56 PM
leafs mounted in factory LCA mounts ..heres a shot ,not sure it will stay the same or not

http://img170.imageshack.us/img170/122/dsc01463kq8.jpg

Rear shackle hanger ,sorry its a crappy pic but you get the idea

http://img170.imageshack.us/img170/967/dsc01465yt4.jpg

john00TJ
03-14-2008, 07:58 PM
heres the final product on the 14B shave job and the diff mounting flange i`ll cut to make fit ..

http://img221.imageshack.us/img221/2875/dsc01458wt2.jpg


http://img170.imageshack.us/img170/8158/dsc01459lq5.jpg

2 piece diff cover ,from Ruff Stuff for $89 ..cant go wrong for this deal ..it should easily be altered for my shave job and look good ..


http://img170.imageshack.us/img170/3299/dsc01461se9.jpg

JeepGeneral
03-15-2008, 09:12 AM
Is your rear bumper bolted or welded on?

john00TJ
03-15-2008, 09:34 AM
its 3/16 box bolt to all factory locations ,there will be a plate welded to the top on the bumper and ran under the 2 rear body mounts also

john00TJ
03-15-2008, 08:15 PM
rear axle is mocked in there ..wheel base is 108 inches ..damn its long and wide i might be moving the rear axle forward a few inches ..time for some serious sheet metal cutting :106:
http://img150.imageshack.us/img150/79/dsc01472jj8.jpg

http://img291.imageshack.us/img291/6154/dsc01474jq8.jpg


http://img213.imageshack.us/img213/7995/dsc01475kb7.jpg

MF Steve!
03-15-2008, 10:15 PM
Looks great John. Is it possible to turn the rear XJ springs around, and will that shorten up the wheelbase a little? IIRC, the pin is not exactly centered on those springs.

we3jeepers
03-15-2008, 11:40 PM
good thing you dont have neighborhood punks that could make up a new game called Jeep Tippin

john00TJ
03-16-2008, 09:45 AM
Looks great John. Is it possible to turn the rear XJ springs around, and will that shorten up the wheelbase a little? IIRC, the pin is not exactly centered on those springs.

thanks man
yeah i could flip them but it shortens it too much . i guess if i want to do it i`ll have to cut the mounts off and move stuff forward ,.i am going to leave it at 108 right now and get some wheels on it and see how crazy it looks up close then decied



good thing you dont have neighborhood punks that could make up a new game called Jeep Tippin

LOL i am the crazy neighbor ,hell the kids dont even come to the house to sell candy and crap ..

john00TJ
03-17-2008, 10:01 PM
Made some more progress today i got the rear sitting on some roller wheels ...i have crazy clearance issues with the gas tank so thats next to come out ..the rear is able to move forward about 4 inchs and that will leave me at 104 inch wheelbase so thats what its going to be ..it seems to be sitting kind of high i might have to french in the front leaf mounts i`ll see once the axle doesnt hit the gas tank what will work best ..

the front got some ball joints pressed into the milled ,drilled and taped chevy highsteer knuckles and the spindles and crap installed .i am running chevy big bearing spindles and crap to match the rear 8 lug .i am hoping to have it sitting on its on weight this week to measure for some driveshafts ,then tear down for axle assembley ,prep and paint ..

if it needs to come down which i think it will ,i would consider trading someone coils ..i have 4 pretty new 4in procomps that id trade so something smaller like a 3.5 or so ...the 4in procomps gave me alot more that 4in of lift ..i`ll know by this weekend for sure

UPJ Wheeler
03-18-2008, 01:27 AM
The springs will settle some once they have been sitting under the load of the Jeep for a couple weeks..... I wouldnt be too hasty to swap coils just yet. Give it a little time and see how she sits after a while. my $0.02

ezman
03-18-2008, 07:25 PM
i never thought about recessing the frame end spring mounts... that's a good idea to keep it lower... plus less shit to get hung up on...

sweet build man... my plan is damn near the same... just not set on the leaf springs... let me know what you do for the front steering box...

john00TJ
03-18-2008, 08:40 PM
The springs will settle some once they have been sitting under the load of the Jeep for a couple weeks..... I wouldnt be too hasty to swap coils just yet. Give it a little time and see how she sits after a while. my $0.02

the springs are about 9 months old ,they are from the previous build they are pretty much settled ,still seems a bit too high for my liking ,i guess i`ll see soon


i never thought about recessing the frame end spring mounts... that's a good idea to keep it lower... plus less shit to get hung up on...

sweet build man... my plan is damn near the same... just not set on the leaf springs... let me know what you do for the front steering box...

thanks man ,this thing is breaking the bank ,i would have linked the rear but i`ll be poor ..the leafs seemed more stable off camber and cheaper than linking it ,if it sucks then i`ll link it later ..

The steering box will be a durango box .the front round crossmember is getting cut out and the box will move forward 3 inchs ..the factoy mount is getting cut off and the box will get clocked flat using a stock TJ pitman arm

ezman
03-19-2008, 06:28 AM
what are you going to do about a bolt on the bottom flange of your diff...

i know you'd loose some ground clearence... but what about welding a nut/sleeve to the bottom of the plate...

john00TJ
03-19-2008, 08:09 AM
i thought about what your saying and also thought about drilling and tapping a small hole but i think i`ll do nothing for now ..the bolt flange is pretty thick and the other bolts should hold it tight with some RTV (RightSTuff)..i might bend a small 3/16 lip guard over the edge of the cover so nothing can directly hit the edge and make it leak

ezman
03-19-2008, 11:41 PM
that's not a bad idea... i dig the build man... it's gonna be pretty sick when it's done...

have you mocked up your steering shaft... i'd like to see how that worked out for you... i've been reading different things about cutting and not cutting... just drilling out the little retainer and collapsing the rod a bit...

or is your box going to be moved up far enough you won't have to mess with it...

Peccavi18
03-20-2008, 12:25 AM
The only problem I have read about when moving the steering box forward and flat clocking is hitting the bottom of the grill with the shaft which just requires abit of trimming of the grill.
What are you planning on running up front to stiffen the front end up? I am looking at making my own "bumper" basically like the M.O.R.E. stubby but welded to the frame and cut out where needed for the steering box and access

john00TJ
03-20-2008, 07:57 AM
The only problem I have read about when moving the steering box forward and flat clocking is hitting the bottom of the grill with the shaft which just requires abit of trimming of the grill.
What are you planning on running up front to stiffen the front end up? I am looking at making my own "bumper" basically like the M.O.R.E. stubby but welded to the frame and cut out where needed for the steering box and access


Basically the way around cutting the grill would be a 1in BL .thats whats i am doing it will also help with clearance with the flat belly skid (i wont have to cut my floor)..between the 3/8 thick Winch mount thats going to get welded on and the whatever front bumper i fab and weld on will be pleant to strengthing up the front

john00TJ
04-06-2008, 08:47 PM
5:13s setup ended up with this gear pattern and .006 backlash ..

http://i261.photobucket.com/albums/ii74/john02r600tj/DSC01487.jpg


Also figured out the rear diff cover ...i took a piece of 3/8s and welded it in bottom of the mounting flange ..then i bolted it up and drew a line with a sharpie and wacked it off ..pretty easy and the actual cover still fits nicely ..just needs some final welding

http://i261.photobucket.com/albums/ii74/john02r600tj/DSC01480.jpg

john00TJ
06-11-2008, 07:12 PM
made some progress after a long break ...I hacked up some rear sheet metal ,i was considering comp cut but figured id have a tough time with the Police man ..rear axle is hanging again and is going to move forward a bit , gas tank is out now the 14 BOLT has a ton of room ..

going to hopefully have my springs for the front this weekend and hang the front under for some steering fab ..and still need to fab a track bar but i have heims and J-joints so that should be a breeze ..

john00TJ
08-04-2008, 06:59 PM
got it rollin on some wheels and sanpped a few pics ...wheel base is at about 102 inchs ..i am going to work on setting up the steering and front trac bar ..i have a few parts ordered that should be here this week .rear flares are removed and trimmed a bit for now ..more cutting and chopping to come

http://i261.photobucket.com/albums/ii74/john02r600tj/DSC01492.jpg


http://i261.photobucket.com/albums/ii74/john02r600tj/DSC01493.jpg

jeepin ruby
08-04-2008, 10:24 PM
Looks good man! Did you score some wheels yet? I think I already asked you but what size tires are ya gonna run?


.... And yeah, you are so gettin pulled over first time out :040:

jeepxj3
08-04-2008, 11:12 PM
in the words of Bill " That Jeep is so illegal "

john00TJ
08-05-2008, 06:16 PM
Looks good man! Did you score some wheels yet? I think I already asked you but what size tires are ya gonna run?


.... And yeah, you are so gettin pulled over first time out :040:

no i didnt get wheels yet ,they will be H1 beadlocks wrapped with 38.5 TSLs..it should be close to legal ...LMAO ..who cares :102:

john00TJ
08-05-2008, 08:14 PM
i order a durango steering box from a local yard ,i was able to find one with 23kmiles and great shape ..i should have that on thursday ..i am probably going to have to fab some mounts due to the front streach but i`ll see .

steering is going to be 1.5 x.25 Dom with tube inserts from Ken at K.O.R.E and high steer arms from Scott and Rock stomper with some chevy 7/8 shanked tie rod ends ..

Rock stomper makes high steer arms that will clear 7in back spaced wheels like the H1 /humvees use so there will be no clearance issues with the tie rod ends and the back of the wheel ..these should be able to tuck my 38s in to the wheel wells with some minor tube flare mods and be somewhat on the legal side

http://rockstomper.netfirms.com/shoppingcart/nfoscomm/catalog/images/d44arms.jpg

john00TJ
08-26-2008, 08:07 PM
durango box is on but the pitman arm is directly over the diff cover ..plans are to chop off the steering mount along with the front frame section and stretch everything with some box tubing ..i am going to clock the steering box flat and move it forward ..grill has to come off and get notched for the steering shaft to clear ..Pic will follow this weekend

mxg342
08-26-2008, 08:23 PM
What shafts are you going to run in the 44? Will it be locked? Hydro assist? What Tcase?

john00TJ
08-26-2008, 09:22 PM
What shafts are you going to run in the 44? Will it be locked? Hydro assist? What Tcase?

Stock shafts for now ,i need to get this rolling and dont have funds for shafts ..Detroit locker up front ..Hydro assist is last on the list right now ,id like it, but wont get to it untill this moves under its own power ..stock case as of now ,thats still up in the air ., i have been considering a clocked 300 twin stick with 4:1

UPJ Wheeler
08-27-2008, 02:00 AM
I recommend the 4:1 300 clocked :nod:

mxg342
08-27-2008, 07:15 AM
I'm not trying to downgrade your build at all but I wanted to let you know what I'm going through right now with mine.

36" Iroks on D44's front and rear. ARB in the front. Twin sticked Tcase

I added Hydro assist last summer. I was running stock shafts. I lost a ujoint in March at the BeaveRun dirt days. I had the caps welded and they still broke the welds and threw a cap. I replaced with my spare shaft. Made it through a weekend at Harlan, KY. Found another inner shaft failure. It cracked the Ujoint cap but I didn't loose it. Instead it pulled and twisted the ears on the yoke.

I bought Yukon Alloy shafts from Dutchman. Inners and outers with Yukon super joints. I installed them in early June. At Jeepfest I noticed that they did the same thing as the shaft I broke at Harlan. It spread and twisted the yoke end of the inner shaft.

Dutchman has been wishy washy about the warranty so far. I need to send them the shafts and they'll tell me if they are warranted or not.

I know at least two other people who are running the same setup as me (front 44 with arb and dutchman shafts) Now the only thing I have on both of them is the hydro assist steering and the ability to front dig.

Like I said before. I'm not talking shit on your build. I'm just trying to let you know what to look for. I'd carry spare shafts for sure.

john00TJ
08-27-2008, 10:46 AM
thanks for the opinion ,i kind of figured it could be a problem when i started the build ..i do plan on swappping out the shafts for alloys later but funds dont allow it now at this point in the build ..if it breaks a bunch i`ll ditch the 44 but at the time this 44 was dirt cheap ..i guess i`ll see how it goes ..and yes i`ll have spare shafts with me ..LOL

How did yours hold up before Hydro assist ??Think they are breaking cause its locked up fully turned and getting on it ??

mxg342
08-27-2008, 10:54 AM
That is my best guess right now. I think I had one Ujoint fail before I did the hydro assist. I think the hydro assist is causing some sort of oversteer condition. I really need to take a look at that. I'm going to adjust my steering stops out some more to see what I come up with.

UPJ Wheeler
08-27-2008, 11:00 AM
I went with a True Trac in the front 44 of my heep to keep from breaking stuff!!! Granted that its not the traction of a locker, but its better than an open diff, and it will slip in high stress situations rather than break shit

john00TJ
08-27-2008, 08:29 PM
front frame section and factory steering box mount ..GONE

New frame will be mocked up tomorrow with box relocated ..god i love the sawzall

http://i261.photobucket.com/albums/ii74/john02r600tj/Picture321.jpg

john00TJ
08-30-2008, 07:08 PM
Front frame chopped and stretched 3in to move the steering box forward ..Box also has been clocked flat ..i robbed the factory frame for the bolt sleeves to remount the box they just need a little grinding to clean the up ..everything is just tacked up as of now ..

http://i261.photobucket.com/albums/ii74/john02r600tj/Picture327.jpg


The way the steering box is now i need to mount the winch about 2in off the frame rails ..i am still trying to figure out the best way to do this ..while i am standing around scratching my ass trying to figure this out i should be cutting some fish plates for the frame rails ..i am considering making a 2in riser that would plate the top of the frame rails and cover the uper steering box bolt ..this is how high the winch needs to sit to clear the box screw
http://i261.photobucket.com/albums/ii74/john02r600tj/Picture326.jpg

john00TJ
08-30-2008, 07:14 PM
i used a Ruff stuff inside mount trac bar bracket but had to modify it a bit ..i cut it down the center and opened it up a bit to fit a Johnny Joint and had to cut some angle on it to fit the frame nicely ..its just tack and chilling so far ..trac bar is 1.5 x.25 wall DOM with a heim on the axle end and a joint on the frame side ..yeah yeah dont laugh at the bolts ..they were laying around and fit it the holes (sort of ) ..they will be fitted with the correct hardware
http://i261.photobucket.com/albums/ii74/john02r600tj/Picture323.jpg

http://i261.photobucket.com/albums/ii74/john02r600tj/Picture322.jpg

http://i261.photobucket.com/albums/ii74/john02r600tj/Picture324.jpg

john00TJ
09-01-2008, 05:42 PM
Ryan wanted to know if my steering was going to hit my tracbar mount ...UMmmmmm thats a good question so i went and bout a few TRE and made some steering ..TREs are chevy units with the 7/8-18 threads ..part #s Es2027 pitman arm side ...Es2233l this has a hole for steering stabilizer that needs re tapered to fit TRE ..and 2x -Es2234r for the newly tapered hole and the driver side

http://i261.photobucket.com/albums/ii74/john02r600tj/courtney006.jpg
Picture makes the clearance look less ..it makes it by about 3/8 of a in ..hope i dont bend this sucker it will rub like a bitch
http://i261.photobucket.com/albums/ii74/john02r600tj/courtney008.jpg

Peccavi18
09-01-2008, 06:45 PM
Pic does make it look tight. Hows it look when you cycle it?

Where did you pick the ends up at? and how much they run you?
Are you planning on running a steering stabilizer or just going hydro assist? I can't remember if you mentioned that?

john00TJ
09-01-2008, 09:01 PM
thats full turn to the right at the tightest point of the whole cycle ..everything else has tons of room and cycles without problems so far ..i need to get a reamer to hit that pitman arm and ream the hole on the passanger TRE to attach the drag link ..

Es2027 was 34.99
Es2233l was 34.99
and Es 2234r was 28.99 all are TRW parts and sourced from Advanced Auto ..however not alot of stock on these so call ahead .

No stabilizer for me ,i`ll be running hydro assist just gotta source some parts that fit my budget ..

mxg342
09-01-2008, 09:16 PM
No stabilizer for me ,i`ll be running hydro assist just gotta source some parts that fit my budget ..


http://forums.hrja.org/showthread.php?t=7088&highlight=hydro

john00TJ
09-01-2008, 09:21 PM
your the man ..thanks

Peccavi18
09-01-2008, 11:24 PM
Thanks I needed to readd that to my favorites list as well

mxg342
09-02-2008, 07:35 AM
A couple more links from guys who I helped. They got the idea from me but made a few changes.

http://forums.hrja.org/showthread.php?t=8143&highlight=hydro

http://forums.hrja.org/showthread.php?t=8365&highlight=hydro

oros35
09-02-2008, 09:44 AM
Yep, got my ideas off of him. Mine's on a TJ with a HP44 in it, stretched foward about 4", Tapped Durango box.

I have around 15K miles on it now, works great. Only problem I had was ripping the brackets off of the axle, which was my fault for underestimating the force that thing puts out. Plus it's hard on ball joints.

Got any questions shoot them my way.

http://i16.photobucket.com/albums/b31/oros35/JeepHydroassistfall2007009.jpg
http://i16.photobucket.com/albums/b31/oros35/Jeepsteeringandrearsuspensionfal-2.jpg
http://i16.photobucket.com/albums/b31/oros35/JeepHydroassistfall2007027.jpg

mxg342
09-02-2008, 11:50 AM
Yeah I couldn't find your posts Brad.

Peccavi18
09-28-2008, 11:15 PM
Get to work its so close...
I sent you a Pm about those crusher corners.

And another question did you tap the tube for your Tie rod or was it inserts. I can't remember I am ordering inserts already and figured if I needed tie rod inserts I would throw them in my order too. I was thinking you had heavy walled pipe but can't remember.

john00TJ
09-29-2008, 08:00 AM
its alot further along now i just havent updated this ..LOL..

i used inserts from Ballistic ,the toobing is 1.5x.25 wall DOM ..

I`ll make a call this morning about the cornors

mxg342
09-29-2008, 10:08 AM
Don't use pipe. Use DOM for steering.

Peccavi18
09-29-2008, 02:21 PM
Yeah my bad I ment tube.


lets see som e updates then:popcorn2:

john00TJ
09-29-2008, 09:10 PM
No time , i`ll try and get some pics soon

john00TJ
10-01-2008, 10:44 PM
ok heres whats going on ,i switched over to highsteer got a deal on the arms from KOZ offroad $40 each drilled with a 5/8 hole that needed reamed for TREs ..then hardware kits whole deal with conical washers ,studs and bolts $145 ..not bad i just hope they dont break ..

http://i261.photobucket.com/albums/ii74/john02r600tj/courtney050.jpg

Trac bar and drag link are within 1/2 of each other in length and both run at 5 degrees ,i guess thats as close to parallel as i can get
Frame was welded up and fish plated
http://i261.photobucket.com/albums/ii74/john02r600tj/courtney049.jpg

http://i261.photobucket.com/albums/ii74/john02r600tj/courtney047.jpg

john00TJ
10-01-2008, 10:49 PM
http://i261.photobucket.com/albums/ii74/john02r600tj/courtney044.jpg







Not much steering box hanging down now ..

http://i261.photobucket.com/albums/ii74/john02r600tj/courtney045.jpg

Peccavi18
10-02-2008, 12:10 AM
Are you running the Koz studs too?
And what are the "tabs" hanging off the sides of the end of the tube out front?

john00TJ
10-02-2008, 07:51 AM
yeah studs are from KOZ ,the tabs are part of my bumper system to be pictured later

john00TJ
10-18-2008, 05:38 PM
heres ya go Ryan some new 38x12.50x16.5 TSLs for ya ..the should fit with some trimming ..Oh yah by the way IT HAS A HEMI ...LOL

http://i261.photobucket.com/albums/ii74/john02r600tj/courtney105.jpg

http://i261.photobucket.com/albums/ii74/john02r600tj/courtney112.jpg

http://i261.photobucket.com/albums/ii74/john02r600tj/courtney106.jpg

Peccavi18
10-19-2008, 12:59 AM
Dude they are huge, what's the true measurment of them? Looks like you need to do some "minor" trimming to make them fit:icon_super: That front end is really up there. Steve has the same springs I do, the RK 5.5" ones. They lowered my Jeep about 2 inches...but they were still fairly new. Once they broke in it might have been more.


And looking at your steering pics, first thing I noticed was the draglink to tie rod connecter(ex. steering stabilizer hole) I wouln't have that so I will need another 4-5" of tube. figure we said 58"? (will have to reask steve I can't remember)-4" so 54". Give me a few days b4 you cut it though now that I have the tre measurements I will double check everything. We were kicking around the idea of going astro van up front even if we only do 4-5" forward it would make it hella easier.

btw your top is full of water:hijacked:

john00TJ
10-19-2008, 08:51 AM
I`ll have them mounted on the H1s this week and i`ll see what the really measure ..trimming ,Hell i think i`ll be cutting ..LOL..jeep is way to high for my tastes so alot more sheet metal will be removed this week during mock up of ride hight ..not sure what i am doing for springs yet .i may cut these a bit and see what i come up with or just..


BTW my top has had water on it for like a year now ..


why astro van box ,dont you plan on clocking that box flat anyway and moving it forward ?? i dont see how it would be easier unless you were leaving it in the stock location ..

john00TJ
10-25-2008, 06:51 PM
got my H1s on Wed..went down to a buddies today and sand blasted them in a cabinet since Ryan is hogging my blaster ..

Rings all primed and ready to spray
http://i261.photobucket.com/albums/ii74/john02r600tj/courtney113.jpg

The weapon of choice for this job
http://i261.photobucket.com/albums/ii74/john02r600tj/courtney114.jpg

..i sprayed some Sherwin Williams basecoat that was left over for the jeep and then layed out 2 coats of PPG clear .the center of the rim is Gun metal gray metallic i had layin around also .
http://i261.photobucket.com/albums/ii74/john02r600tj/courtney116.jpg

john00TJ
10-25-2008, 06:52 PM
teaser shot of the front on ..bottom of the bumper sits 30in

http://i261.photobucket.com/albums/ii74/john02r600tj/courtney124.jpg

96greenxjjeep
10-25-2008, 07:46 PM
need a front end shot

john00TJ
10-25-2008, 09:14 PM
yeah i know ,i didnt have all the tires mounted up ..maybe if i get some time tomorrow

96greenxjjeep
10-25-2008, 09:15 PM
o ok kool looks good keep em coming

john00TJ
10-25-2008, 10:07 PM
it will start coming togther fast now ,gotta mock ride height now that i have wheels and tires and check clearance on everything then tear down and finish installing gears and start finalizing shit

Peccavi18
10-26-2008, 01:32 AM
I'll get it back to ya soon. I may have to buy one, it's been to damn useful.

Those springs really don't look that huge once you get real tires under there. I have a set of Skyjacker 8" shocks for the rear if you need them and am hoping the fronts will be off soon as well. Looks good now get to the gearing and brakes, that's the fun $$$ shit.:overkill:

john00TJ
10-26-2008, 09:44 AM
i have no need for it now and with a few friends that own body shops i can just go there so take your time ..

The springs look like i`ll have about 9.5in up travel i am thinking about cutting a coil out or so and lowering it some .

Once its back on the road i am going to start gathering some extra cash for coilovers anyway ,they just dont fit the budget now ..ya know

i still have more than gear and brakes unfortunley:022:

Peccavi18
10-26-2008, 10:33 AM
The boat trailer is about half blasted and painted, I just haven't been up there recently for any amount of time to work on it. I'm getting to where I'm gonna have to sling the boat up out to finish it.

What coilovers are you looking at? Chris from FOA has the new 2" bodied ones and reviews of his 2.5" ones seem to be good so I am really considering those although...I had a ebay seller saved on my comp before it died I believe Dirtcheapshocks was their name. They had Foxes, 14" with resivors for $3000ish not positive on that name or price though, but they were really cheap with a positive rating.

And I know what you mean the big stuff looks cool and makes it seem like it's coming together but the small details and pieces are where the money and time all dissappear.

john00TJ
10-26-2008, 05:49 PM
heres a few more on all fours ..still need to trim and make some clearance .steering is tight so i`ll need some wheel spacers

http://i261.photobucket.com/albums/ii74/john02r600tj/Picture328.jpg

http://i261.photobucket.com/albums/ii74/john02r600tj/Picture331-1.jpg

http://i261.photobucket.com/albums/ii74/john02r600tj/Picture330.jpg

96greenxjjeep
10-26-2008, 06:27 PM
i may have missed it but what axle is in the rear

john00TJ
10-26-2008, 08:03 PM
yeah you missed it ..its a shaved 14b ff SRW

http://img221.imageshack.us/img221/2875/dsc01458wt2.jpg

96greenxjjeep
10-26-2008, 08:17 PM
Oh nice looks very good i cant wait till i can do this to my jeep

Peccavi18
10-29-2008, 12:23 AM
was wondering if you had had a chance to pull a tape yet and get a true height on the tires, would also like to know where you are at height wise on either the rocker or frame rail, I know you are cutting a coil up front so do the back side, just trying to get some rough references to compare against.

village_idiot
10-29-2008, 01:07 AM
Looks bad ass on the TSL's, it does need lowered about an inch or 2

Deadman 94 xj
10-29-2008, 01:50 AM
Wow, the approach angle on that thing is sick!!

Are you going to comp cut the rear or tube it after you trim some more?

john00TJ
10-29-2008, 08:09 AM
was wondering if you had had a chance to pull a tape yet and get a true height on the tires, would also like to know where you are at height wise on either the rocker or frame rail, I know you are cutting a coil up front so do the back side, just trying to get some rough references to compare against.

nope didnt measure the tires , i probably make wont it over there untill later this week ..front frame rail is 29in right now .i plan on dropping it about 3in as of now so i`ll be around 26 done ..


Wow, the approach angle on that thing is sick!!

Are you going to comp cut the rear or tube it after you trim some more?

most likley tube it ,i still wanna drive on the street

john00TJ
12-04-2008, 09:14 PM
well some more parts are rolling in ,like Eldorado calipers and shit so the axles will be yanked and finally assembled real soon ..i havent been doing crap on it latley but some updates are coming

anyone have a 30 spline dana 44 locker for sale ??

highlandercj-7
12-04-2008, 09:35 PM
Nice work. Did you do the 14 bolt trimmin yourself?

john00TJ
12-04-2008, 09:42 PM
Nice work. Did you do the 14 bolt trimmin yourself?


yeah but i sent the gears out to get cut

Peccavi18
01-10-2009, 06:19 PM
Bumping this back from the dead with some spy pics and a few updates on his progress, maybe it will motivate him to finish it.

6" flares would cover it
http://i196.photobucket.com/albums/aa223/peccavi18/004-1-1.jpg

http://i196.photobucket.com/albums/aa223/peccavi18/006.jpg

No room for shocks between the frame and tire
http://i196.photobucket.com/albums/aa223/peccavi18/007.jpg

Front end
http://i196.photobucket.com/albums/aa223/peccavi18/009.jpg

cut coil
http://i196.photobucket.com/albums/aa223/peccavi18/008-2.jpg

Normal steering arms had to be cut to fit behind the hummer rims , and the current highsteer arms didn't clear either
http://i196.photobucket.com/albums/aa223/peccavi18/011-1.jpg

http://i196.photobucket.com/albums/aa223/peccavi18/010.jpg

john00TJ
01-10-2009, 07:51 PM
wow i look at those pics and gringe at how much work is left

jeepin ruby
01-18-2009, 05:19 PM
Someday John, someday... :icon_madu:

Lookin good though. Im suprised. Youll be able to cover MOST of the tire with a flare. Guess those wheels did the trick :023:

gearhead313
01-19-2009, 10:40 AM
Looks like you'll need a couple washers for that axle side track bar bolt :D

john00TJ
01-20-2009, 08:49 PM
think its long enough ??

john00TJ
02-07-2009, 04:32 PM
well i figured id update this since a bunch of parts are on there way and i am back to tinkering with this project ..

rear frame is cleaned and got a nice coat of chasis black ..i also cleaned up the rear leafs nd coated them ..fitted the Eldorado calipers up and painted them also .. the master Install is on its way for the 14 bolt so i can button this baby up this week maybe ..

http://i261.photobucket.com/albums/ii74/john02r600tj/DSC01442.jpg


rear traction device is a welded up set of spider gears ..yeah baby always locked ..this should drive nice on the road

http://i261.photobucket.com/albums/ii74/john02r600tj/DSC01437-1.jpg

bought a Sye kit off a guy on ebay ..it came with no directions since it was straight from the manufacturer but it was $150 ..

http://i261.photobucket.com/albums/ii74/john02r600tj/DSC01437.jpg

john00TJ
02-07-2009, 04:34 PM
i have 12in of GC at the diff sitting on its own weight on the 38s ..

http://i261.photobucket.com/albums/ii74/john02r600tj/DSC01439.jpg

i stripped off the tail lights and crap to get ready for the armour ..

http://i261.photobucket.com/albums/ii74/john02r600tj/DSC01441.jpg

96greenxjjeep
02-07-2009, 05:12 PM
what srpings did you use for the rear

john00TJ
02-07-2009, 09:44 PM
i used stock xj springs in the rear

slade
02-15-2009, 08:37 PM
I like your build. Ill be continuing to keep an eye on it.

Interested in seeing how you like the ride of the stock leaf pack. You will probly find you'll want to beef it up a litle bit. I used a Wagoneer rear main leaf and cut it down and inserted it under the xj main. I picked up a new set of stock leaves, but am unsure about running them without the Waggy main. There is no way around a traction bar on this setup.

john00TJ
02-16-2009, 05:57 PM
I like your build. Ill be continuing to keep an eye on it.

Interested in seeing how you like the ride of the stock leaf pack. You will probly find you'll want to beef it up a litle bit. I used a Wagoneer rear main leaf and cut it down and inserted it under the xj main. I picked up a new set of stock leaves, but am unsure about running them without the Waggy main. There is no way around a traction bar on this setup.

Thanks i go a few more things getting finished up this week sometime so i`ll update ..;.;the rear will have a extra main added and a military wrap .

john00TJ
02-20-2009, 08:44 PM
got the new Highsteer arms from rock stomper ..i had to shorten the previously made tie rod by 5-1/2 in.to fit the new super offset arms ..the old steering arms wouldnt clear the rims this set-up will have no problems ..i`ll have some pics up soon

also have the rear master install so i`ll be finishing up the rear and hoping my shaved diff cover doesnt leak ..

cut the front drive shaft from 2x.120 DOM and used a CV from the front a jeep Xj with new HD joints on the t-case side and the slip shaft from a 3/4 ton chevy truck .

also the stuff from Balistic fabs came in to make my new tranny crossmember so i`ll have to get some pics of this crap to update this tread ..

all and all alot is coming together now just wish i had more time

john00TJ
02-21-2009, 04:42 PM
heres the driveshaft build ...i cut the welds off the donor shafts being carefull not to cut too deep to allow allow it so all just slip apart ..the CV got new HD joints installed ..i`ll post up so pics on how to finish the shaft in a few days



http://i261.photobucket.com/albums/ii74/john02r600tj/DSC01444-1.jpg

http://i261.photobucket.com/albums/ii74/john02r600tj/DSC01446-1.jpg

http://i261.photobucket.com/albums/ii74/john02r600tj/DSC01445.jpg

http://i261.photobucket.com/albums/ii74/john02r600tj/DSC01447-1.jpg

john00TJ
02-21-2009, 04:46 PM
new high steer arms clearing like crazy without wheel spacers ..noice the factory TRE mount was cut ..and my too insert is loose..LOL

http://i261.photobucket.com/albums/ii74/john02r600tj/DSC01439-1.jpg


http://i261.photobucket.com/albums/ii74/john02r600tj/DSC01443.jpg

john00TJ
02-21-2009, 04:48 PM
few things for the tranny mount http://i261.photobucket.com/albums/ii74/john02r600tj/DSC01449-2.jpg

john00TJ
02-22-2009, 11:55 AM
Got a few things to work out on the front end ..at full turn to the left my steering hits my trackbar bracket cause of these crazy highsteer arms :102:..no big deal i guess that why they say tack everything beacuse as soon as you weld it ,this happens..

I also have to move the frame side mount about a 1/2in so the tierod wont hit it al full compression ,

looks like ill have to notch the frame to get the steering shaft back in since its hitting pretty good

john00TJ
03-20-2009, 07:28 PM
OK enough of this long ass build that i keep adding onto ..Its time to wrap this biatch up ..I am plain tired of not beating my junk in the woods ..

Got the 14b stuffed with the shaved ring gear and the new lincoln locker ... cleaned and repacked the rear bearings everything looked in good shape so i am running it ..rear Eldorado calipers and brakes are done and installed ,i`ll be buttoning up the rear this weekend and dumping some fossil lube it her and hope that shaved cover dont leak :022:

a RCI fuel cell is in route and the braided line and summit fitting arrived yesterday ..i got the Russel fitting thats plug directely into my stock fuel line and fuel pump ..so no need for ghetto hose clamps ..LOL

crusher cornors are back from getting bent 3/16 ,i need to Plasma out the new wheel well and figure out the rear flares and smash some LED in in there

Pics to follow tomorrow :fu:

96greenxjjeep
03-20-2009, 08:08 PM
awesome

OverkillZJ
03-20-2009, 08:10 PM
rear traction device is a welded up set of spider gears ..yeah baby always locked ..this should drive nice on the road



Weld that baby up some more!

LordAthens
03-20-2009, 09:10 PM
*sigh*

Does that mean the drivetrain isn't coming out?

Looks awesome man.

john00TJ
03-21-2009, 08:09 AM
No man not just yet ,i need to play with my toy for a little ,plus it needs outta the garage its in now since thats house is up for sale ..

john00TJ
05-14-2009, 08:27 PM
got the gears in and the diff sealed up ..
http://i261.photobucket.com/albums/ii74/john02r600tj/DSC01496.jpg
crush cornors bent out of 3/16 and waiting for the plasma cutter
http://i261.photobucket.com/albums/ii74/john02r600tj/DSC01495-1.jpg

all plasmaed out ,used the stock flares with a bunch of trimming for now ..guess it looks ok for now ..
http://i261.photobucket.com/albums/ii74/john02r600tj/DSC01501.jpg

john00TJ
05-14-2009, 08:31 PM
RCI 2161A mounted up and fuel pump installed ..need a few more fittings to wrap this up ..

http://i261.photobucket.com/albums/ii74/john02r600tj/DSC01503.jpg

shot of the rear ,starting to come together
http://i261.photobucket.com/albums/ii74/john02r600tj/DSC01502.jpg

almost covered ..hope the cops like it ..LOL

http://i261.photobucket.com/albums/ii74/john02r600tj/DSC01504.jpg

john00TJ
05-14-2009, 08:33 PM
http://i261.photobucket.com/albums/ii74/john02r600tj/DSC01507.jpg

http://i261.photobucket.com/albums/ii74/john02r600tj/DSC01506.jpg

UPJ Wheeler
05-14-2009, 08:36 PM
lookn good! where/how did you bend the steel for the corners?

john00TJ
05-14-2009, 09:17 PM
lookn good! where/how did you bend the steel for the corners?

my buddy did them ..they did a series of small bends on a break all the way around the radius ..it turned out good and fits well

Deadman 94 xj
05-14-2009, 10:13 PM
Bad Ass John!!!

Deadman 94 xj
05-14-2009, 10:20 PM
Did you have the wheels re-centered?

john00TJ
05-14-2009, 10:26 PM
thanks for the props man ..

no i didnt have them recentered they are stock Humvee wheels

Deadman 94 xj
05-14-2009, 10:39 PM
I thought the hubs would have stuck out further. Very nice. I hope you plan on taking this thing out local. By local I mean Rock Run and BDS OOAP. I want to check it out.

Nice work.

john00TJ
05-15-2009, 07:26 AM
yeah i`ll be around everywhere ,you could always come down this way and wheel the local spots if you want also ..

john00TJ
05-23-2009, 01:23 PM
i went ahead and coated the cornors with some Chassis saver on both side using a small foam padded roller ....

i also scuffed sanded the sides of the jeep down with a red scoth bright pad so the paint would stick..

after 3 good coats on both ,i used Fusor`s seam sealer and stuck the cornors on using some carriage bolts ..i ran a bead of seam sealer all around the outside edge till it squeezed out ..i cleaned up the extra seam sealer with some paint reducer and a rag

.then masking it all off and spraying some duplicolor truck bed on them finished product ..what ya think with the stock flares cut and mounted


http://i261.photobucket.com/albums/ii74/john02r600tj/DSC01508.jpg

john00TJ
05-23-2009, 01:26 PM
i drilled a few holes to re-mount the license plate on there in somewhat of the stock location ..i plan to add a small LED for the plate light

http://i261.photobucket.com/albums/ii74/john02r600tj/DSC01510.jpg

http://i261.photobucket.com/albums/ii74/john02r600tj/DSC01509.jpg

MF Steve!
05-23-2009, 02:05 PM
Tittays!

Peccavi18
06-08-2009, 03:13 AM
Did you get the other taillight drilled and in?

john00TJ
08-09-2009, 10:19 AM
Did you get the other taillight drilled and in?


nope drilling the 3/16 was a pain so i opted to skip it for now .lol.i do however have the whole front axle assembled ..i just need brake lines and lock outs and thats all done ..still have shocks to mounts and a few odd and ends ..the a ton of clean up and paint

i actually drove it out under its own power without brakes the other day

Peccavi18
08-09-2009, 03:03 PM
I have some spare 24" lengths of the 3/16" bendable hard line laying around if you need them. Where are these spy pics you keep texting me about? :)

john00TJ
08-09-2009, 03:51 PM
LOL pics are over rated ..i`ll get some soon as i find batteries ..LMAO

guy
08-10-2009, 12:21 AM
nice lookin rig man hope to see u out on the trail soon and check it out in person.

john00TJ
08-22-2009, 04:41 PM
nice lookin rig man hope to see u out on the trail soon and check it out in person.

hopefully soon ..i never have time to just get down and get some work done on it ..

made some progress got the rear frame notched since shocks wouldnt fit anywhere else .
http://i261.photobucket.com/albums/ii74/john02r600tj/101_2883.jpg


bent a little tubing for the upper mount .its 1.5x.250 wall dom
http://i261.photobucket.com/albums/ii74/john02r600tj/101_2882.jpg

http://i261.photobucket.com/albums/ii74/john02r600tj/101_2885.jpg

Peccavi18
08-23-2009, 12:48 AM
Getting your workout bending some of that heavy shit? When does the lighter stuff come in?

john00TJ
08-23-2009, 08:37 AM
workout ..lol..i am just warming up ..

i just gotta go pick up the 1.5x.120 ..had a guy at work quit so things are busy i need a minute to run over and load it ..u need some some flares ??

Peccavi18
08-23-2009, 04:54 PM
Flares, harness bar, grab handles and a few other misc items whenever you get a chance. I think I have all the parts ordered for my just gotta get them installed so I can beat on it.

john00TJ
08-25-2009, 06:11 PM
LMK i can grab more tubing if needed ..just lmk when your ready

john00TJ
09-27-2009, 06:27 PM
you know usually hang ups .. broke the mig gun and couldnt weld ,then ran outta gas nothing ever goes smooth ..the rear is finally welded and everything got prepped for paint ..after 2 coats of chassis black the wheel wells got 2 coats of duplicolor truck bed liner .. now for the edelbrock shocks i scored a few mouths back for $6 ea from summit racing
http://i261.photobucket.com/albums/ii74/john02r600tj/101_3009.jpg

my little guy is still amazed the tires are bigger than him

http://i261.photobucket.com/albums/ii74/john02r600tj/101_3011.jpg

ridgerunner97
09-27-2009, 06:34 PM
I love that color and the way it all just looks. BTW your kid looks happier than a pig in shit :biggrin:

96greenxjjeep
09-27-2009, 11:09 PM
i remember you saying that you were goin to use the rear control arm mount for the front spring hanger did you still use them

john00TJ
09-28-2009, 08:12 AM
i remember you saying that you were goin to use the rear control arm mount for the front spring hanger did you still use them


nope they wouldnt work right ..i hacked them and used a pair of ruff stuff brackets

Christopher
09-28-2009, 09:03 AM
Nice:thumbsup:

96greenxjjeep
09-29-2009, 06:12 PM
thanks

john00TJ
11-08-2009, 09:13 AM
busted some butt yesterday and made a ton of progress ..even got some TRE holes reamed for Ryan`s build
,i`ll have this wrapped up real soon ..i cant wait to beat it ,seems i never have time to work on it ..anyway some pics to follow later today

john00TJ
11-13-2009, 08:08 PM
as it sits now

http://i261.photobucket.com/albums/ii74/john02r600tj/101_3170.jpg

limegreentj
11-13-2009, 08:22 PM
nice man!!! your getting there!

Peccavi18
11-14-2009, 12:10 AM
Did you get your drive shafts and drive it out there or push it out? :biggrin: how's the hub search going, find what your looking for yet? I keep watching but haven't seen any.

edited to say hub instead of gun

john00TJ
11-14-2009, 12:47 AM
drove ...with brakes ..hahah

Peccavi18
11-14-2009, 02:41 AM
The unlimited e-brake cables work? looking like a no with it up against the 6x6. Hows it ride, any test runs for it yet?

BTW the RockKrawler 5.5" lift coils I are 22.85" long uncompressed, I forgot to get a compressed measurement, but if you need it I can call and have it for you in a few.

john00TJ
11-14-2009, 09:47 AM
didnt get the cables yet ,still waiting ..no real test runs just moved it around ...that coil is a inch or so long than what i am using now

john00TJ
03-13-2010, 01:57 PM
Whoa bring one from the archive ..sitting back in the garage since i have some time ..got some tubework going on and finishing all kinds of little odds and ends ..i`ll update as i roll

Deadman 94 xj
03-13-2010, 02:02 PM
Sweet!! Love this freakin jeep.

Sycotik Skier
03-13-2010, 02:03 PM
I was wondering what was going on with this jeep. I really like it.

john00TJ
03-13-2010, 02:21 PM
thanks guys i am happy with how its turning out .justtaking way too long .
its been buried under snow and i have ben working 11hr days ..it kind of got tossed on the back burner..i`ll have some updates for sure

Peccavi18
03-14-2010, 02:27 AM
I tried calling you yesterday, Did you go disk or drum style for the e-brake cables? I have been wrenching on my shit the last few days. Getting pretty close to drivable myself. Hit me up when you have time.

john00TJ
03-14-2010, 09:50 AM
i`ll call you later ryan ..the ebrake cables i got were for disc brakes but the caliper end will need some modification ..i am heading down the shop to work on this in a it..i`ll fill ya in when i am done

john00TJ
03-14-2010, 09:37 PM
lots of grinding and welding , swapped out alot of bolts i was using for mock up today ..final welded a bunch of stuff ..fabbed a new winch plate with a body mount for the grill ..threw a stinger on it (should have added the stinger onto the bumper but :flipoff2:) should have the winch and stuff mounted and a grill hoop bent this week ..

got the brakes all working using master cylinder from a dodge 3500 and bled out.. thats all working real well ..

teaser
http://i261.photobucket.com/albums/ii74/john02r600tj/DSC01516.jpg

limegreentj
03-14-2010, 09:57 PM
BOIY-YOYOYOYOY-YOING!


nice!

Sycotik Skier
03-15-2010, 12:12 AM
sick, just plain sick. It's funny how your tsl's stick out about as much as my boggers do and you're on full widths.

john00TJ
03-15-2010, 12:41 PM
yeah the H1s really keep the tires tucked ..i am happy with the overall outcome so far

john00TJ
04-04-2010, 06:50 PM
the grill hoop and stinger are done and painted ..the winch is mounted and the Ebrakes are all hooked up .bent up a new tranny cross member and figuring out the skid plates now ..also working on a drop down tailgate ..gotta get some pics up i guess

Deadman 94 xj
04-04-2010, 09:00 PM
Yes, pics!

john00TJ
04-18-2010, 02:46 PM
http://i261.photobucket.com/albums/ii74/john02r600tj/001.jpg

john00TJ
05-20-2010, 06:51 PM
well its been hanging out back sitting like that for a bit ..but i just ordered a pair of driveshafts from Highangle driveline ..finished the crossmember and tranny mount ,pissed with the ebrake and Led wiring .drilled out some 5/8 holes for the trackbar and swapped all harware for NEW grade 8 shit .looking like 2 weeks till the shafts arrive hoping to have this DONE and waiting for the new shafts ..

john00TJ
06-13-2010, 09:12 AM
back at it last week heres some updates ..tailgate on and done ..lights wired but some weird shit is going on need to go back over them
http://i261.photobucket.com/albums/ii74/john02r600tj/038.jpg

drive shafts in and crossmember done
http://i261.photobucket.com/albums/ii74/john02r600tj/041.jpg

john00TJ
06-13-2010, 09:14 AM
http://i261.photobucket.com/albums/ii74/john02r600tj/042.jpg

http://i261.photobucket.com/albums/ii74/john02r600tj/044.jpg

john00TJ
06-13-2010, 09:15 AM
http://i261.photobucket.com/albums/ii74/john02r600tj/045.jpg

http://i261.photobucket.com/albums/ii74/john02r600tj/043.jpg

JeepGeneral
06-13-2010, 10:36 AM
Not adding a skid for the transfer case?

john00TJ
06-13-2010, 10:47 AM
Not adding a skid for the transfer case?


yeah shooting for fabbing one up this week if my time allows ..still have some stuff to do but it did feel good to drive it some

Deadman 94 xj
06-13-2010, 09:23 PM
Looking good John.

Krod
06-13-2010, 09:38 PM
Well you can't just post pics without telling us how it drives! haha

Looking good.

john00TJ
06-14-2010, 10:15 PM
.i had to throw new plugs in it and tossed a K&N filter it was stumbling a bit ..then adjust the drag link a bit and get that steering wheel nice and straight
.the leds had to be the worst part of this project it took forever to get them working i had to wire in diodes and resistors with a trico LED flasher and still a pain in the ass ..got that stuff straightened out took it for a nice long drive ..
i might have to take the master cylinder off and readjust that little push rod in a bit it seems my brakes are dragging and the pedal is real tight ..the rest seems real tight and super stable even without a sway bar ..

rear spring even with a added main are real soft and need a traction bar bad ..that should really help the axle wrap on launches ..few more bugs and i`ll be ready

2002wranglerX
06-14-2010, 10:41 PM
wellsville saturday? what! lol

XJchris98
06-14-2010, 11:19 PM
.the leds had to be the worst part of this project it took forever to get them working i had to wire in diodes and resistors with a trico LED flasher and still a pain in the ass ..


I know you got the LED's worked out, but there's a really easy way to wire in Stop/Tail/Turn lights and have them blink correctly if you want to eliminate the diodes and resistors. Wish I would've seen this earlier before you went through all the trouble of diodes and resistors

john00TJ
06-15-2010, 05:45 PM
I know you got the LED's worked out, but there's a really easy way to wire in Stop/Tail/Turn lights and have them blink correctly if you want to eliminate the diodes and resistors. Wish I would've seen this earlier before you went through all the trouble of diodes and resistors

i am always down for some tech !!!!!!! post up it could save me trouble on the next build

XJchris98
06-15-2010, 10:10 PM
i am always down for some tech !!!!!!! post up it could save me trouble on the next build


When I wired up the Stop/Tail/Turn LED lights in my XJ, I used a taillight converter for trailer LED lights. From what I found, the TowReady brand converter is the ONLY one that works. Im not sure why this is, but alot of people have tried the Curt brand, Reese, etc converters found at Napa, Autozone, Advance, Walmart and none of them work.

Basically, you just tie the converter box into the factory wiring with the input going to the factory Jeep harness and the output leads going to the LED's. Alot of the XJ guys just skip trying to figure it out and use 2 lights. 1 for the stop/tail lights and the other for turn signals. I figured if I was spending $$$$ on good LED lights, they were going to work the way they were intended.

If you wire in LED's and you get a "fast blinker", you also need to replace your thermal flasher with an electric one. The flashers in Jeeps are thermal ones and dont work right on the minimal loads LED lights pull. Im not sure what year Jeep stopped using the thermal flashers, but I think anything before 2000-2001 should still use the thermal flasher. The flasher (in XJ's) is found under the dash on the drivers side above the hood latch. Any autoparts store should have these and they're roughly $8 (Look like a big relay). Im pretty sure you can wire in diodes/resistors to eliminate the fast blinker, but I figured just replacing the flasher module would be easier and neater (wiring wise).


Heres a link to the taillight converter:
http://www.towready.com/product/details.asp?ProdID=119130&cat=1545
If you keep an eye on Ebay, you can usually find these pretty cheap (Less than $20).

If you go this route, you only need ONE converter. The loose green wirein the picture below is the signal wire for the other taillight. Simply run that signal wire to the other light and use the 12V source and ground from that side of the vehicle to complete the wiring. Since the converter plugs into the factory harness, it gets the input for brake, running, and turn lights for BOTH sides.


Heres some pics from a writeup on NAXJA
http://i246.photobucket.com/albums/gg83/HD97XJ/P1105061.jpg

The RED group of wires is the stop lamp, the YELLOW is for the turn, and the WHITE is for the reverse. Again this is for an XJ, so it may be different for a TJ/YJ/ZJ/etc.
http://i246.photobucket.com/albums/gg83/HD97XJ/P1105067.jpg

http://i246.photobucket.com/albums/gg83/HD97XJ/P1105068.jpg

http://i246.photobucket.com/albums/gg83/HD97XJ/P1105069.jpg

Maybe this will save someone a headache in the future!:icon_jook:

john00TJ
06-16-2010, 07:39 AM
sweet ..thanks man

fathersnsons
06-19-2010, 06:22 AM
Sorry to crash this thread.

John00TJ

I tried to reply to your other for sale thread by PM, but your MAIL BOX seems to be full.

john00TJ
06-19-2010, 08:46 AM
cleaned out my PMs ..hit me back ..thanks

john00TJ
06-21-2010, 11:32 PM
must have had some air bubbles in the brake system or some shit ..after the brakes heated up the would drag ..pressure bleed that out and all is better now ...still having some lighting issues seems like maybe its the switch in the column .i have to keep screwing with the lever to get the indicator to flash ..ummm its never ending ..

right now i am pretty leary about street driving because of tire coverage ,i am begging for a ticket ..so it seems my best interest is some tube flares to cover these up ..i hope to get it done before i piss off the local Law ..LOL