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Building a Bumper?Ruffstuff Axle Simple Swap Kit!~Artec JK 1 TON SWAP~

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Unread 04-13-2009, 06:54 PM   #1
blovingier
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Home-Brew Swaybar Disconnects - The Gritz Way

Ok, so I wanted to have some swaybar disconnects and I ran across this write-up. So that's what I modeled mine from. I know, it's a pretty good write-up, but I made some little changes to make them better (in my opinion). Here's my final parts list of what is actually on my Jeep:

2 - 1/2" x 2-1/2" Clevis Pins
4 - 1/2" Washers
2 - Hitch Pins (in the future these may become 3/16" lynch pins)


All in all with all my goof-ups and extras I had about thirty dollars in it all. The pieces listed above came out to about $11 total.

First thing that I decided to do differently was to weld a washer on the end of the clevis pin to keep it from ripping out like what happened in the article that I hyperlinked above. I first had to make a "jig" to make sure the clevis pin and the washer were flush. This ended up being a 1/2" hole drilled into my metal sawhorse.



Then I drilled out the washer so that it would fit right over the fat end of the Clevis pin. After that, I placed the washer over the clevis pin and ground them down flat with each other.



!!CAUTION!! !!DANGER!! !!HEALTH RISK WARNING!!

WELDING GALVANIZED METAL PRODUCES ZINC OXIDE FUMES AND CAN LEAD TO METAL FUME FEVER. I DO NOT ADVOCATE, OR RECOMMEND WELDING ON GALVANIZED STEEL. I AM A CERTIFIED WELDER AND HAVE BEEN GIVEN TRAINING ON HANDLING SUCH MATERIALS. PLEASE DO NOT INJURE YOURSELF.FOR MORE INFORMATION LOOK HERE.


I then welded the washer to the clevis pin.





And here's a picture of my little welder in my garage.



While I was letting the clevis pins cool, I went out to the Jeep and drilled out the swaybar end link bushing sleeve to fit the 1/2" pin instead of the 7/16". This only took off like 1/32 - 1/16". Be careful here too because the drill wanted to bind on me really bad.



Now this is where it got really dangerous for me. I had finished my drilling and was pulling the sway bar back down to get it lined back up into the bracket. Well, the swaybar got kind of stuck and I started pulling harder and it gave way really quickly. This caused me to smash my finger in between the end link and the bracket on the axle and my finger was actually pinned in there for a couple minutes until I slowly wiggled it out trying not to do anymore damage to the finger. All-in-all that part cost me 5 stitches ($648 bill) and now my finger isn't healed right, so I'm going to have to see a surgeon to get my finger back to normal again. Here's what it looked like that night.



And finally we have the finished product on the Jeep. No flex pics yet because I just haven't had a chance to take any. It wouldn't be impressive anyways with a BB. "Ooh look, that curb just got served."



Hope you enjoyed my little write-up and people can learn from all the mistakes I make and not do any repeats. I'll update when or if I change to lynch pins to show that if anybody cares to see.

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[B]99 Jeep Grand Cherokee Laredo[/B] - [COLOR="Red"][SIZE="4"]Totalled[/SIZE][/COLOR]
-3" lift w/Bilsteins - - - - - - - - - - - - - - - - - -30.5" Pirelli Scorpion ATRs
-[URL="http://www.jeepforum.com/forum/showthread.php?t=494045"]Clear Lenses[/URL] - - - - - - - - - - - - - - - - - - -[URL="http://www.jeepforum.com/forum/showthread.php?p=5229329#post5229329"]Cobra 75 CB w/Wilson 4' Antenna[/URL]
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Unread 04-13-2009, 06:59 PM   #2
WhiteOut
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Looks pretty good. I hate welding up some stuff and then feeling like crap after, the next time I'm gonna wear a mask I think.
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Unread 04-13-2009, 07:03 PM   #3
blovingier
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Quote:
Originally Posted by fraser1986brown View Post
Looks pretty good. I hate welding up some stuff and then feeling like crap after, the next time I'm gonna wear a mask I think.
I stay away from galvanized as much as possible. Some ******* that was in school with me was welding on galvanized pipe in the booth next to me (without my knowlege) and got himself, me and two other sick as a dog for a bit. I was so mad.
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[B]99 Jeep Grand Cherokee Laredo[/B] - [COLOR="Red"][SIZE="4"]Totalled[/SIZE][/COLOR]
-3" lift w/Bilsteins - - - - - - - - - - - - - - - - - -30.5" Pirelli Scorpion ATRs
-[URL="http://www.jeepforum.com/forum/showthread.php?t=494045"]Clear Lenses[/URL] - - - - - - - - - - - - - - - - - - -[URL="http://www.jeepforum.com/forum/showthread.php?p=5229329#post5229329"]Cobra 75 CB w/Wilson 4' Antenna[/URL]
-[URL="http://www.jeepforum.com/forum/showthread.php?p=7008250#post7008250"]Home-Brew Discos[/URL]- - - - - - - - - - - - - - - - - -[URL="http://www.jeepforum.com/forum/showthread.php?t=734768&highlight=diamond+plate+hitch+cover"]Diamond Plate Hitch Cover[/URL]

[B]07 Compass (wife's ride)[/B][COLOR="Red"][SIZE="4"]Sold[/SIZE][/COLOR]
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Unread 04-13-2009, 07:27 PM   #4
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Heh, I welded galvanized tin onto 1/4 plate for a year. Luckily the place I worked at had damned good ventilation...

Nice discos. Hopefully the ones I'm buying off a fellow board member are as good.
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Unread 04-13-2009, 07:30 PM   #5
blovingier
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Well, hopefully these hold up. I forgot to mention that the reason why I went with the 1/2" pins instaed of the 7/16" pins is because after I made the ones from 7/16" and puth them on, they were clicking and clanking and driving me crazy. The 1/2" with the end link drilled out doesn't hardly clank at all. I have to really hit something hard.
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[B]99 Jeep Grand Cherokee Laredo[/B] - [COLOR="Red"][SIZE="4"]Totalled[/SIZE][/COLOR]
-3" lift w/Bilsteins - - - - - - - - - - - - - - - - - -30.5" Pirelli Scorpion ATRs
-[URL="http://www.jeepforum.com/forum/showthread.php?t=494045"]Clear Lenses[/URL] - - - - - - - - - - - - - - - - - - -[URL="http://www.jeepforum.com/forum/showthread.php?p=5229329#post5229329"]Cobra 75 CB w/Wilson 4' Antenna[/URL]
-[URL="http://www.jeepforum.com/forum/showthread.php?p=7008250#post7008250"]Home-Brew Discos[/URL]- - - - - - - - - - - - - - - - - -[URL="http://www.jeepforum.com/forum/showthread.php?t=734768&highlight=diamond+plate+hitch+cover"]Diamond Plate Hitch Cover[/URL]

[B]07 Compass (wife's ride)[/B][COLOR="Red"][SIZE="4"]Sold[/SIZE][/COLOR]
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Unread 04-13-2009, 08:49 PM   #6
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I torched out one of those galvanized exhaust nipple adapters one time and got a whiff of the smoke and I instantly began to hack violently and could hardly breathe
I went to the ER and they gave ma a pill that would choke a horse... ever since I wear a mask when cutting exhaust
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Unread 04-13-2009, 09:08 PM   #7
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LOL, I guess the 20+ years of smoking made me almost immune to it. It never really bothered me unless it got up in behind the helmet and got in my eyes. But I was also welding above my head for the most part, so the smoke pretty much went up and away from me. The slag was what used to do me in...
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Unread 04-14-2009, 05:11 AM   #8
blovingier
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Quote:
Originally Posted by Mickey_D View Post
LOL, I guess the 20+ years of smoking made me almost immune to it. It never really bothered me unless it got up in behind the helmet and got in my eyes. But I was also welding above my head for the most part, so the smoke pretty much went up and away from me. The slag was what used to do me in...
I've got a nice scar on my arm from when I was doing a certification on overhead 1". A chunk of slag found a hole somewhere and made a hole in me.
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[B][FONT="Arial"][SIZE="4"][COLOR="Blue"]"GRITZ"[/COLOR][/SIZE][/FONT][/B]

[B]99 Jeep Grand Cherokee Laredo[/B] - [COLOR="Red"][SIZE="4"]Totalled[/SIZE][/COLOR]
-3" lift w/Bilsteins - - - - - - - - - - - - - - - - - -30.5" Pirelli Scorpion ATRs
-[URL="http://www.jeepforum.com/forum/showthread.php?t=494045"]Clear Lenses[/URL] - - - - - - - - - - - - - - - - - - -[URL="http://www.jeepforum.com/forum/showthread.php?p=5229329#post5229329"]Cobra 75 CB w/Wilson 4' Antenna[/URL]
-[URL="http://www.jeepforum.com/forum/showthread.php?p=7008250#post7008250"]Home-Brew Discos[/URL]- - - - - - - - - - - - - - - - - -[URL="http://www.jeepforum.com/forum/showthread.php?t=734768&highlight=diamond+plate+hitch+cover"]Diamond Plate Hitch Cover[/URL]

[B]07 Compass (wife's ride)[/B][COLOR="Red"][SIZE="4"]Sold[/SIZE][/COLOR]
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Unread 04-14-2009, 07:49 AM   #9
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Do they rattle at all ? (when you drive)
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03' Jeep Grand Cherokee Laredo, (wifes Jeep) 99k, 4.7 5 speed auto, K&N, KYB shocks, drilled-slotted rotors, All the toys.
2000' Ford Superduty, F250, 7.3, 198K, 37's, too much to list.

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Parts for sale d30 and d35 parts http://www.jeepforum.com/forum/f126/...-parts-1004499
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Unread 04-14-2009, 08:05 AM   #10
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I have home brew discos, Made mine from lowes, they are tight..no rattling at all! No cutting at all.
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Unread 04-14-2009, 08:50 AM   #11
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My grandpa was a welder and he always told me drink milk after welding galvanized. Something in the milk, cant remember. He swore buy it. He live to be 89 years old. Must've worked.
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Unread 04-14-2009, 08:56 AM   #12
blovingier
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Originally Posted by rugermack View Post
Do they rattle at all ? (when you drive)
Mine don't too bad, just when I hit something really hard you can hear some clicking, but it may be my shocks doing some of the clanking. For the most part, they are pretty well mannered. I'll report back after driving on them a little longer to let you know how they are holding.
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[B][FONT="Arial"][SIZE="4"][COLOR="Blue"]"GRITZ"[/COLOR][/SIZE][/FONT][/B]

[B]99 Jeep Grand Cherokee Laredo[/B] - [COLOR="Red"][SIZE="4"]Totalled[/SIZE][/COLOR]
-3" lift w/Bilsteins - - - - - - - - - - - - - - - - - -30.5" Pirelli Scorpion ATRs
-[URL="http://www.jeepforum.com/forum/showthread.php?t=494045"]Clear Lenses[/URL] - - - - - - - - - - - - - - - - - - -[URL="http://www.jeepforum.com/forum/showthread.php?p=5229329#post5229329"]Cobra 75 CB w/Wilson 4' Antenna[/URL]
-[URL="http://www.jeepforum.com/forum/showthread.php?p=7008250#post7008250"]Home-Brew Discos[/URL]- - - - - - - - - - - - - - - - - -[URL="http://www.jeepforum.com/forum/showthread.php?t=734768&highlight=diamond+plate+hitch+cover"]Diamond Plate Hitch Cover[/URL]

[B]07 Compass (wife's ride)[/B][COLOR="Red"][SIZE="4"]Sold[/SIZE][/COLOR]
-Stock
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Unread 04-14-2009, 10:56 AM   #13
rugermack
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Thanks, I'd hate to do it and have it rattle.
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95' Jeep Grand Cherokee Laredo, 148k, 5.2, NP242, 46RH, 4" RC lift, all new adjustable ca's(2 IRO front uppers and the rest RC adjustables), nitro shocks, JKS TB's, Jet Chip, Dynamax cat back, Magnaflow cat, GTP hood vents. 31" Pro Comps with Rock Krawler "D"s. Westin brush/grill guard with Hella 500s, 411's, Solid diff covers, detroit locker rear, power lock in front, SYE and Tom Wood's front/rear shafts, RE discos, BPE's, d-rings front and back, factory tc and rad skid, hitch, Sliders next.
03' Jeep Grand Cherokee Laredo, (wifes Jeep) 99k, 4.7 5 speed auto, K&N, KYB shocks, drilled-slotted rotors, All the toys.
2000' Ford Superduty, F250, 7.3, 198K, 37's, too much to list.

Built Not Bought #257

Parts for sale d30 and d35 parts http://www.jeepforum.com/forum/f126/...-parts-1004499
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Unread 04-15-2009, 04:05 PM   #14
blovingier
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Originally Posted by rugermack View Post
Thanks, I'd hate to do it and have it rattle.
Even the other 7/16" pins didn't rattle too bad, but it was enough to make it annying on a long trip or something.
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[B][FONT="Arial"][SIZE="4"][COLOR="Blue"]"GRITZ"[/COLOR][/SIZE][/FONT][/B]

[B]99 Jeep Grand Cherokee Laredo[/B] - [COLOR="Red"][SIZE="4"]Totalled[/SIZE][/COLOR]
-3" lift w/Bilsteins - - - - - - - - - - - - - - - - - -30.5" Pirelli Scorpion ATRs
-[URL="http://www.jeepforum.com/forum/showthread.php?t=494045"]Clear Lenses[/URL] - - - - - - - - - - - - - - - - - - -[URL="http://www.jeepforum.com/forum/showthread.php?p=5229329#post5229329"]Cobra 75 CB w/Wilson 4' Antenna[/URL]
-[URL="http://www.jeepforum.com/forum/showthread.php?p=7008250#post7008250"]Home-Brew Discos[/URL]- - - - - - - - - - - - - - - - - -[URL="http://www.jeepforum.com/forum/showthread.php?t=734768&highlight=diamond+plate+hitch+cover"]Diamond Plate Hitch Cover[/URL]

[B]07 Compass (wife's ride)[/B][COLOR="Red"][SIZE="4"]Sold[/SIZE][/COLOR]
-Stock
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Unread 05-16-2009, 08:26 PM   #15
surfsup887
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do you think that adding a couple thick rubber washers would help out with the rattle using the 7/16" pins?
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