Build thread: Steering Brace and WJ sway bar mount on ZJ - JeepForum.com
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post #1 of 120 Old 12-05-2015, 11:55 PM Thread Starter
paulsheer
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Build thread: Steering Brace and WJ sway bar mount on ZJ

Many people have installed a WJ sway bar according to this thread

http://thespeedfreaks.net/showthread...pgrade-for-ZJs

The WJ sway bar gives the ZJ fantastic handling, better wheel clearance, more travel, and has a better end-link design. The WJ bar can be used with stock height, lifted, or lowered ZJs. (See for instance http://www.google.com/search?q=rough...+1131+sway-bar ).

...but there are three problems with WJ bar that this brace will to solve:

1. the sway bar crushes the lower radiator hose. (the frame shape does not allow for a simple spacer.)
2. you can't mount your skid plate back on.
3. the better steering box brace solution won't mount.

The solution is a custom made steering box brace that uses this part: http://www.boostwerksengineering.com...Kit-_p_23.html

Here is my fabrication so far:

First I got the boostwerks bearing:

20151122_135128.jpg

here it the core bolted on. notice in the background my WJ bar is temporarily unbolted for measuring. (Also notice the weird lower radiator hose solution which I plan to remove and replace with a stock lower radiator hose.)

20151122_134934.jpg

Then some 1/8" balsa wood and fabric pins -

20151122_135343.jpg

mock the whole thing up and check that it fits:

20151201_182533.jpg

here you can see where WJ bar will bolt on. (Note that I've ordered allen head bolts so that you can tighten them through the holes in the plates) ---

20151201_182636.jpg

pins removed for measuring. there are 26 pieces:

20151202_215442.jpg

i plan to get this laser cut / waterjet jut. engineering drawing using emachineshop.com software (this took hours *yawn*)

20151206_000528.jpg

in 3D:

20151206_000712.jpg

But now a a question for YOU --

the emachineshop software is quoting me $270 inclusive of shipping. If I do 10 it comes down.

Who is in, and who wants an "ultimate" steering brace and sway bar solution?

Some of the features:

1. 1/8" 1008/1018 super strong steel.
2. Recessed nut's welded along the side rail so you can bolt on anything. (especially your skid plate.)
3. Holes under the cross bar so no water can accumulate.
4. highly sought after i-have-a-better-sway-bar-plus-steering-brace-solution-than-you bragging rights

any takers?


93 ZJ 5.2, 3.58 stroked. HS 1.7. 242 swap. Shift kit. 3" cat back. 16x10 rims. 31" tires. 2.5" lift. Vanco 16" brakes. Alum rad + Flex-a-lite 180KS. 180tstat. Mopar Perf. PCM P5249518. WJ sway bar.
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post #2 of 120 Old 12-06-2015, 12:05 AM
riot1987
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Damn boooyyee


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Build thread^^
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post #3 of 120 Old 12-06-2015, 02:13 AM
kg6mov
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Quote:
Originally Posted by paulsheer View Post
The WJ sway bar gives the ZJ fantastic handling. But there are three problems with it:

1. the sway bar crushes the lower radiator hose.
2. you can't mount your skid plate back on.
3. the better steering box brace solution won't mount.
1) So use spacers.
2) Good.
3) If you're running tires big enough to need a box brace you should be running hydro assist anyway.


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1984 F250, 460 BB, T19, work truck/future tow pig
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post #4 of 120 Old 12-06-2015, 02:34 AM
PolkaPower
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ADDCO bolts right in.
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post #5 of 120 Old 12-06-2015, 09:05 AM
riot1987
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Haters^^ I like it.


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post #6 of 120 Old 12-06-2015, 09:56 AM Thread Starter
paulsheer
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thanks riot

also trying to get others to sign on -- so that i can make a run bigger than 1

are you in riot?

people should note the WJ sway has -

1. better wheel clearance
2. more travel
3. much better end-links

see for instance http://www.google.com/search?q=rough...+1131+sway-bar

Paul

93 ZJ 5.2, 3.58 stroked. HS 1.7. 242 swap. Shift kit. 3" cat back. 16x10 rims. 31" tires. 2.5" lift. Vanco 16" brakes. Alum rad + Flex-a-lite 180KS. 180tstat. Mopar Perf. PCM P5249518. WJ sway bar.
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post #7 of 120 Old 12-06-2015, 03:44 PM
riot1987
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Na, Id made one myself. Yours is way fancier though. I appreciate the effort and attention to detail. Nice work my friend


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post #8 of 120 Old 12-08-2015, 12:32 PM Thread Starter
paulsheer
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trying to get waterjet estimates locally...

93 ZJ 5.2, 3.58 stroked. HS 1.7. 242 swap. Shift kit. 3" cat back. 16x10 rims. 31" tires. 2.5" lift. Vanco 16" brakes. Alum rad + Flex-a-lite 180KS. 180tstat. Mopar Perf. PCM P5249518. WJ sway bar.
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post #9 of 120 Old 12-08-2015, 01:39 PM
Bodybuilder21
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Well done, way to go outta the norm! Can't wait to see the finished product

98' 5.9- racejeep build (boosted 408 dreamin')
96' 4.0- 5.5"- currently torn down for 4.7 stroker
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post #10 of 120 Old 12-08-2015, 02:14 PM Thread Starter
paulsheer
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Quote:
Originally Posted by Bodybuilder21 View Post
Well done, way to go outta the norm! Can't wait to see the finished product
you and me both LOL

93 ZJ 5.2, 3.58 stroked. HS 1.7. 242 swap. Shift kit. 3" cat back. 16x10 rims. 31" tires. 2.5" lift. Vanco 16" brakes. Alum rad + Flex-a-lite 180KS. 180tstat. Mopar Perf. PCM P5249518. WJ sway bar.
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post #11 of 120 Old 12-08-2015, 07:09 PM
riot1987
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The stub coming off the pump is a really good idea.


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post #12 of 120 Old 12-08-2015, 11:26 PM Thread Starter
paulsheer
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update: two companies in dallas are getting back to me with a quote from the DXF file. Autocad DXF rules.

Quote:
Originally Posted by riot1987 View Post
The stub coming off the pump is a really good idea.
stub? pump? you mean the special nut-column-thing on the steering box? Yes, it should take a lot of stress off the box internals. Boostwerks has a number of other nifty inventions. I have yet to make the special socket I need to properly torque it.

93 ZJ 5.2, 3.58 stroked. HS 1.7. 242 swap. Shift kit. 3" cat back. 16x10 rims. 31" tires. 2.5" lift. Vanco 16" brakes. Alum rad + Flex-a-lite 180KS. 180tstat. Mopar Perf. PCM P5249518. WJ sway bar.
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post #13 of 120 Old 12-10-2015, 06:25 AM
riot1987
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^^yes, thats what I meant


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post #14 of 120 Old 12-14-2015, 07:44 PM Thread Starter
paulsheer
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Update:

Ok, it seems the emachineshop software exports something awful into DXF file. I loaded into QCad and deleted the artifacts it had added. No wonder most of the shops were not getting back to me :-( They probably loaded the file and went "huh?".

bigbluesaw.com accepts the DXF file and quotes $200 inclusive of tax and shipping.

It's still a bit pricy but I've placed the order.

93 ZJ 5.2, 3.58 stroked. HS 1.7. 242 swap. Shift kit. 3" cat back. 16x10 rims. 31" tires. 2.5" lift. Vanco 16" brakes. Alum rad + Flex-a-lite 180KS. 180tstat. Mopar Perf. PCM P5249518. WJ sway bar.
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post #15 of 120 Old 12-14-2015, 08:38 PM
riot1987
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