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TJ 5.25" Speaker Adapters - NalinMFGZONE 4.25" combo lift for TJ available at Rockridge4wARTEC JK UNDER ARMOR - 4 door Bellypan Kits

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Unread 12-08-2013, 08:26 PM   #61
Sahara Surfer
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1999 TJ Wrangler 
 
Join Date: Jan 2006
Location: Pearland, TX
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Latest updates...

I got my Tom Woods extended drive shaft in. Mine ended up being 32 1/4 inches long.



Installed. Trully a thing of beauty.



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Unread 12-08-2013, 08:27 PM   #62
Sahara Surfer
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I finally got around to outboarding the rear shocks. I fancy myself to be somewhat of a fabricator. Ha! In the image below, you can see the lower shock mounts being made from square tube. The design is very similar to what can be found in some of the kits out there. I sized mine for the 1/2" pins on the Rancho RS999005 Shocks. Here is view of the lower mount installed, as well as a chunck of the frame gone (After chopping the frame for the extensions, this didn't faze me in the least) to make room for some Ford shock towers. There are a ton of threads out in the forums that served as go-by's and I am thankful to every one of them. Speaking of the Ford shock towers... I also have Blaine's handy notch in them. Although in my case, it is more for ease of assembly than weld penetration. With the tub out of the way, I have the luxury of being able to weld all around without obstruction.
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Unread 12-08-2013, 08:27 PM   #63
Sahara Surfer
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Once the shock mounts are tacked in and the springs are out, I can cycle the shocks from full bump to full extension to check for clearances...



Looks like we clear the installed tire too:



Once I am happy with all tolerances, I finish all of my welds.

I notched a piece of 3/16" angle iron and welded it to the back of the shock towers for strength. In practicality, this is not necessary for most people out there. In my case, there is the possibility that I may have to take my Jeep to a frame straightening machine to fix my 1/2" frame deflection. After taking a chunk out of my frame for the shock outboarding, I didn't want to leave less section modulus at these locations so that they end up being the only spots that do any of the "fix" bending.

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Unread 01-06-2014, 09:11 PM   #64
Sahara Surfer
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Nothing too exciting to report. I finished all of the electrical splices, fuel line and brake line extensions. BTW, the 5/16" stock fuel line is a pain to flare. I have a bunch of leftover 5/16" and 3/16" steel flare line fittings if anyone is in need of some.



Also, redid the exhaust piping and installed a new muffler.

And here is the completed suspension and drivetrain.



Now all I need is a buddy to help me pick up the rear tub section and place it back on the frame mounts for some sheet metal work.

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Unread 01-15-2014, 04:55 PM   #65
G Beasley
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2005 LJ Wrangler 
 
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Location: Eden, NC
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I have a upper rail section bent and ready to weld in if your interested ? It is 15" long and saves a good bit of fabrication .
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Unread 01-15-2014, 05:06 PM   #66
Sahara Surfer
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Quote:
Originally Posted by G Beasley View Post
I have a upper rail section bent and ready to weld in if your interested ? It is 15" long and saves a good bit of fabrication .
Oh Beasley! Where were you three months ago when I was looking at every junkyard in the South for that piece?!! Haha!

Thanks, buddy. But I already paid for an aftermarket panel that includes the entire bent rail. I really should have thought of coming to you first. After all, you did help another Jeeper out on this with his TJ-6 build.
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Unread 01-15-2014, 05:17 PM   #67
G Beasley
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No worries , wish I would have offered it sooner .
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Unread 01-19-2014, 08:14 PM   #68
Sahara Surfer
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I pulled my exhaust to complete the welds. I will media blast the joints and paint them for rust protection. Here is a view of the assembled exhaust system after the cat connection:



I also finally got around to putting the tub back on the frame.



The wheel well spaces look huge with the highline and the 33" tires on the OME 2.5 inch lift. I eventually want to go to 35's.

The build is getting pretty exciting now!
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Unread 02-17-2014, 06:10 PM   #69
Sahara Surfer
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More progress:

To attach the rollbar extensions, I used 6 inch long 2" diameter inserts with the same wall thickness as the factory rollbar. I also drilled some plug weld holes for additional hold.



Clamped things down, measured and remeasured to confirm the extension sections are straight and true...



Other side...



Once my extensions are welded in, it becomes pretty obvious that my earlier goof with the frame is messing with the tub alignment.



The cheap option is to shim the body mounts and get on with my life. Unfortunately, this will bug me and knaw away inside of me for many years. If only I hade been a perfectionist back when it really counted; when the frame was being put together.

So I decided to go with the more expensive option and take the Jeep to the frame shop. Luckily the frame shop is only five minutes away from my house and is run by a trusted shop owner. It is the perfect opportunity to test drive the Jeep after one and a half years of sitting idle.
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Unread 02-17-2014, 06:43 PM   #70
Sahara Surfer
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To make it easy on the folks at the frame shop to remove the rear portion of the tub while still having functional brake lights, I used a six pin Deutch connector to tie in the extended electrical rail.



After charging the battery overnight, I placed it back on the Heep and what do you know? It drives! Drove it right out of the garage! There were no exhaust leaks but one of the fuel line connections had a slight leak. I tightened it up some more and it ran like a champ. Huge milestone.



The drive was mostly uneventful, except for the big gap on the floor and the temporary cardboard sides threatened to blow away. Brakes are functional, no wobbles from the track bar, I do need a serious steering alignment after putting in the OME lift... Drove slow the whole way, I am surprised I didn't get pulled over by the fuzz... Yes, I did put the driver's seat and seat belt back in.
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Unread 02-17-2014, 06:48 PM   #71
clintrivera
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Are you planning on running a LJ soft top? If you are, I'm not sure you will be able to fold the soft top down due to the angle of the TJ roll bar that you extended. I had the same issue with my TJ-6. I just ended up never folding it down, I either ran it in sunrider mode or took the entire thing off.
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Unread 02-17-2014, 06:49 PM   #72
kyle_craig
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Awesome project! I'm looking forward to seeing more progress!
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Unread 02-17-2014, 06:56 PM   #73
Sahara Surfer
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While the frame is getting fixed, I took the opportunity to cut some sheet metal for the sides of the tub.



I can't wait to ge my Jeep back. There is still quite a lot to do, but it does feel like I am getting closer to completing this. To add to my excitemnet, the Olive Drab Monstaliner arrived today!! Woohoo!!
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Unread 02-17-2014, 07:01 PM   #74
Sahara Surfer
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Quote:
Originally Posted by clintrivera View Post
Are you planning on running a LJ soft top? If you are, I'm not sure you will be able to fold the soft top down due to the angle of the TJ roll bar that you extended. I had the same issue with my TJ-6. I just ended up never folding it down, I either ran it in sunrider mode or took the entire thing off.
Oh man, I need to post a picture for you. I placed my Bestop LJ frame on the Jeep and what do you know? The frame folds back and barely clears the rollbars! I was afraid of this too when I saw it on your build. Maybe the Besttop frame has more play than the factory softop frame?
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Unread 02-17-2014, 08:08 PM   #75
Sahara Surfer
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Quote:
Originally Posted by kyle_craig
Awesome project! I'm looking forward to seeing more progress!
Thanks! Me too.
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