AP's 5 Speed WJ Build - Page 2 - JeepForum.com

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post #16 of 1162 Old 04-16-2009, 10:05 AM
BLACKzj52
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1996 ZJ 
 
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couple things
- you said you were 17 when you first bought it, how old are you now? just wondering
- that front axle looks like its been a PITA for you
- how much were those TREs?
- nice wj

edit: forgot to mention
- nice welds
- you lucky bastard, you know how to set up gears!


- John - 23 and learning <-- ORIGINAL
- 1996 Black ZJ Limited: 5.9 swap, LA's, axles, absolutely built to hell
- 1998 Platinum 5.9 Limited: DD with some lighter modifications
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post #17 of 1162 Old 04-16-2009, 11:05 AM Thread Starter
AgitatedPancake
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Location: Sac, California
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I was 17 when I got it, I'm 21 now. I actually got it as a hand-me-down from my dad, beaten and abused with about 160k on it.

The front axle...yeah...although now the mounts and steering can hold up to quite a beating (and have).

I actually ended up going slightly different than that pic for the TRE's. The very top TRE is an ES2027L. It has the same taper as the others, but slightly larger diameter which I found out my arms had been drilled for. I returned the other 3, and got another 2027 and to ES2026R's to match it. The 2027 and 2026 are high angle TRE's, and actually have more metal attatching the stud part to the knuckle, so I figured stronger. I think they are supposed to be like 40 apeice, but I know people and got em for around 20 apeice.

Thanks about the welds, took a class at my local community college a few years ago, and just been getting more experience as I build =D.

The gears in the 44 was my first attempt at gearing ever, if you take your time and don't skimp they arent hard, it can just be VERY tedious....I'm not sure I'd do it again in anything besides like a ford 9" or yota 8" lol.

Thanks for all the comments guys, i appreciate it!

To contact me, email Greg@Frobotfab.com
Frobot Fabrication Facebook
01 WJ 5 Speed Claytons LA's, 36" Iroks, 35 spline 9" rear, Custom Ruffstuff 60-9" front axle.
Build Thread: http://www.mallcrawlin.com/forum//showthread.php?t=7387
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post #18 of 1162 Old 04-16-2009, 02:08 PM
JacksonsHole
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Love the front license plate.

Oh and those bumpers ain't bad either!!
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post #19 of 1162 Old 04-16-2009, 09:34 PM
Redstarlover
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2001 WJ 
 
Join Date: Nov 2006
Location: Ventura Ca
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Great photo's
I want a 44 up front and I'm going to get one now, thanks for the picts
The rear upper shock mount look good, are they holding up, also I like the lower brackets much better design
Thanks for all of your hard work on your WJ, I'm going to steal some of your ideas
Matt

2001 GC With Mods
4.0, Clayton's, JK axles, TR front bumper.
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post #20 of 1162 Old 04-17-2009, 01:42 AM
sadass
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1998 ZJ 
 
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Location: Hopeless Juction, NY
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Well, We all make mistakes. , You my friend, defiantly have some skill's, I am going to keep my eye on you. I could learn a thing. or two from you! or 3,4,5,6

5NineZJ,35mtr/k IRO 7" LA F/R Detroit F/HP-4.56 R/Aussie 44A. ARB Snorkel/JRC Sliders/ Protofab w/9500S./Bushwhackers. Novak242 TCcable.
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post #21 of 1162 Old 04-17-2009, 03:31 AM
BLACKzj52
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Quote:
Originally Posted by AgitatedPancake View Post
I was 17 when I got it, I'm 21 now. I actually got it as a hand-me-down from my dad, beaten and abused with about 160k on it.

The front axle...yeah...although now the mounts and steering can hold up to quite a beating (and have).

I actually ended up going slightly different than that pic for the TRE's. The very top TRE is an ES2027L. It has the same taper as the others, but slightly larger diameter which I found out my arms had been drilled for. I returned the other 3, and got another 2027 and to ES2026R's to match it. The 2027 and 2026 are high angle TRE's, and actually have more metal attatching the stud part to the knuckle, so I figured stronger. I think they are supposed to be like 40 apeice, but I know people and got em for around 20 apeice.

Thanks about the welds, took a class at my local community college a few years ago, and just been getting more experience as I build =D.

The gears in the 44 was my first attempt at gearing ever, if you take your time and don't skimp they arent hard, it can just be VERY tedious....I'm not sure I'd do it again in anything besides like a ford 9" or yota 8" lol.

Thanks for all the comments guys, i appreciate it!
how long would you say it took you to get the hang of welding?

i wanna learn to weld and set up gears.. that would be sweet

keep up the good work

- John - 23 and learning <-- ORIGINAL
- 1996 Black ZJ Limited: 5.9 swap, LA's, axles, absolutely built to hell
- 1998 Platinum 5.9 Limited: DD with some lighter modifications
My Build Thead
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Senior at The Ohio State University
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post #22 of 1162 Old 04-17-2009, 03:56 PM Thread Starter
AgitatedPancake
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Thanks again for the comments guys!

Redstar - feel free to take any ideas as I probably took them from someone else =D I havent had it on the road with the new shock mounts yet, I dove right into the bumper after I completed those. I'm going to be putting limiting straps from the lower shock mounts up to the outer bolt on the crossmember (in the middle of the gusset), and the shocks can't compress fully with my bumpstops so it should hold up just fine.

sadass - live and learn eh? Haha I've really found out that its MUCH better and less frustrating to build something right the first time compared to skimping to just get it on the road.

John, mig is REALLY easy to pick up. a little practice and you'll be able to watch your puddle and form the weld how you want, it's fun to learn too!

To contact me, email Greg@Frobotfab.com
Frobot Fabrication Facebook
01 WJ 5 Speed Claytons LA's, 36" Iroks, 35 spline 9" rear, Custom Ruffstuff 60-9" front axle.
Build Thread: http://www.mallcrawlin.com/forum//showthread.php?t=7387
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post #23 of 1162 Old 04-17-2009, 04:46 PM
GraKee99
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Quote:
Originally Posted by AgitatedPancake View Post
John, mig is REALLY easy to pick up. a little practice and you'll be able to watch your puddle and form the weld how you want, it's fun to learn too!
Glad you saw such good results with a welding class. I am taking one in the fall and plan on building a front and rear bumper. The rear one will probably be modeled after yours cause I am sick of dragging it.

I come out to Roseville every year just about, I will have to give you a shout the next time since Sacramento is so close.

Brian

WJ, WK, CJ5


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post #24 of 1162 Old 04-17-2009, 05:03 PM Thread Starter
AgitatedPancake
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Yeah man, it helps that i had an entertaining teacher haha. Ill be going back sometime for tig welding, but in the one class i took i learned to fluxcore, mig all positions, stick weld in all positions, oxyacetalyne weld, oxyacetalyne cutting, plasma cutting...yeah .

Just let me know when your headin out and we'll do something!

To contact me, email Greg@Frobotfab.com
Frobot Fabrication Facebook
01 WJ 5 Speed Claytons LA's, 36" Iroks, 35 spline 9" rear, Custom Ruffstuff 60-9" front axle.
Build Thread: http://www.mallcrawlin.com/forum//showthread.php?t=7387
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post #25 of 1162 Old 04-17-2009, 05:06 PM
Greeeeenberg
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Location: Suring, WI/ Houghton, MI (School-MTU)
Posts: 1,157
Dude tig is pretty hard. you need lots of patience and a study hand. Ive done all of them and tig was my favorite just cause of the challenge. Remember dab push dab push. Oh and when you start out the sharper the tip on the tungsten the better so you can get that nice ball at the end.

I had the most fun though with the plasma cutter. I wish I would have bought my jeep sooner so i could have used the computer operated on that i ran for my high school to make me some bumpers.

97 ZJ Orvis 5.2 108K.

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post #26 of 1162 Old 04-17-2009, 05:46 PM
GraKee99
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Quote:
Originally Posted by AgitatedPancake View Post
Yeah man, it helps that i had an entertaining teacher haha. Ill be going back sometime for tig welding, but in the one class i took i learned to fluxcore, mig all positions, stick weld in all positions, oxyacetalyne weld, oxyacetalyne cutting, plasma cutting...yeah .

Just let me know when your headin out and we'll do something!
Ya, I have been trying to take it for 4 years now and my final semester I get too. I'm excited. Hopefully I will learn that much.

Brian

WJ, WK, CJ5


Colorado Jeep Club Member #188
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post #27 of 1162 Old 04-18-2009, 02:22 AM
theksmith
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awesome build! got any more picture of how you trimmed and fixed the rear tire-well / fender... did you re-weld the 2 pieces together, or just fold the outside in?
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post #28 of 1162 Old 04-18-2009, 06:54 PM Thread Starter
AgitatedPancake
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Alright finally got some time to get some more work in on the bumper =D Today I just got a little time, but I spent it making the peices for hte other side to match.

It came out really close even on the test fit




The only problem...the drivers side is sticking out further then the passenger side. I havent touched the peices since I cut them, so with a little grinding and shaping I should be able to suck it up to match the other side


VS.












And, as a side note...if I forget to update this build thread I have the detailed bumper build going on here =D
http://www.jeepforum.com/forum/f13/wj-rear-bumper-mock-up-build-742283-post6954083/

To contact me, email Greg@Frobotfab.com
Frobot Fabrication Facebook
01 WJ 5 Speed Claytons LA's, 36" Iroks, 35 spline 9" rear, Custom Ruffstuff 60-9" front axle.
Build Thread: http://www.mallcrawlin.com/forum//showthread.php?t=7387
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post #29 of 1162 Old 04-20-2009, 03:42 PM Thread Starter
AgitatedPancake
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Alright the drivers side finally matches the passenger side! As we speak I'm letting it cool down, I've been doing alot of finish welding with the voltage CRANKED...things have been getting damn hot. Anyways on with the pics!



It's pretty much a boatsided bumper lol.


THIS ***** IS HEAVY!


Underside


Yup, finally getting there =D. All I have to do now is finish up at the front to blend with the fender, and skin the top in 1/8"

To contact me, email Greg@Frobotfab.com
Frobot Fabrication Facebook
01 WJ 5 Speed Claytons LA's, 36" Iroks, 35 spline 9" rear, Custom Ruffstuff 60-9" front axle.
Build Thread: http://www.mallcrawlin.com/forum//showthread.php?t=7387
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post #30 of 1162 Old 04-20-2009, 06:35 PM Thread Starter
AgitatedPancake
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Well I was moving it around a little for the work I did after that last post, I can lift and move it around without too much of a problem myself, I'd guess as of now probably 100-110lbs...just a guess though. Maybe I'll weigh it sometime.

Anyways for the rest of the day I ground down a little visible weld, and welded/ground some of the intersections for asthetics. The metal I'm working with is a little bit rough so I'm thinking spray on bedliner instead of normal paint to mask the imperfections, besides I think it'll look cool =D


To contact me, email Greg@Frobotfab.com
Frobot Fabrication Facebook
01 WJ 5 Speed Claytons LA's, 36" Iroks, 35 spline 9" rear, Custom Ruffstuff 60-9" front axle.
Build Thread: http://www.mallcrawlin.com/forum//showthread.php?t=7387
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