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December Specials at Jeephut.comROCK BOTTOM prices on LIFT KITS at Rockridge4wd!! WANT TO Alloy usa heavy duty ball joint kits

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Unread 06-10-2013, 09:23 AM   #31
BDS-Tech
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There was plenty of commotion around the BDS R&D Shop when I stopped by Friday late afternoon. Seems the approaching deadline to have the KJ prepped in time for the 2013 Ultimate Adventure has brought the team together as they work to complete suspension, drivetrain, cage, body mods, fuel cell and more. I mentioned in the last post parts have been arriving on the daily are are prepped for install. There’s still a number of areas that require fabrication and finish welding. Suspension linkage is nearly completed and uses a 4-link front and triangulated 4-link rear. 14” stroke Fox 2.5 remote coilovers arrived and are awaiting a set of Pac Racing springs to be installed (will have more on the coil specs when they arrive). Fox 2.0 bump stops will be installed soon to help keep our soon to arrive 40” Nitto Trail Grapplers off of the fenders. Up front our PSC JK steering box has been mounted to a reinforced front “framerail” and accepts the OE steering shaft linkage. The “framerail” is being notched to allow the track bar clearance at full compression.

Parts awaiting to be installed are heavy duty ball joints and axle seals from Alloy USA, our Nitro 5.13 Gears, Nitro 30-spline front shafts and Air-Ox Locker front, ARB Air Locker rear and Nitro 35-spline shafts, JK NP-241 Rocktrac T-Case with 4.0:1 low range, and an ARB air compressor. A shiny new Warn 9.0 Rc winch is sitting on deck ready to get recess mounted into a front bumper that we will be built in the coming week(s) to protect the front end and the new radiator, intercooler, and electric fan we have to go in. Driveline’s Plus is building a custom set of driveshafts for us as we move towards having this Jeep Liberty CRD mobile again. The fuel cell is being built in CA and just for fun we opened up the sunroof hole to accept the larger 36×40” Sliding Ragtop. Plenty more to come on this project, stay tuned for updates and more.












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Unread 06-10-2013, 07:38 PM   #32
02libbyfirstcar
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This is my favorite build of all time. Keep up the good work!
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Unread 06-13-2013, 09:21 AM   #33
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Here's some update photos from last night... more info to come.


Paper templates before we cap off the body cut




Electric fan, radiator and intercool arrived. Now to figure out fitting them all in behind the grill along with our Warn 9.0 Rc winch and Rigid LED Lighting.


JK 241 Rocktrac bolted right up, no body mod necessary, no indexing needed.

Pac Racing C/O springs arrive 12x3x250 and 14x3x350 for front. 12x3x200 and 14x3x300 for the rear
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Unread 06-13-2013, 10:28 AM   #34
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It’s been a couple days since we updated you on Project KJ, our ’05 Liberty CRD for the 2013 Ultimate Adventure (UA) hosted by 4Wheel & Off-Road Magazine. This week the guys running full steam to getting this Jeep prepped, with tons of fab work still needing to take place and off the shelf parts arriving daily. This week the suspension and steering work continued, t-case was installed, radiator and intercooler arrived and mocked into location, and body work began to cap off the rear window chop. Only 12 days remain until this Jeep needs to hit the road for the secret start point of UA and the guys are starting to feel the pressure.

To get a lower 4Lo range, we went with a NP-241 Rocktrac case out of a JK Rubicon. This will give us 4.0:1 low range and help improve its crawling capabilities. The case bolted right up to our 545RFE tranny, no indexing or body mods needed. Driveshafts are being sourced from Drivelines Lines Plus and should be hear the first part of next week. Pac Racing dropped off the springs to fit our Fox 2.5 coilovers. We went with 12x3x250 and 14x3x350 up front for the weight of the diesel, winch and tubework and stuck with a 12x3x200 and 14x3x300 coil for the rear. Shocks are being assembled to reinstall on soon.

The new radiator, cooler, and electric fan are being mocked up and plumbed. Our Warn 9.0 Rc will mount below (recessed into the front bumper) along with a pair of Rigid dually lights. Air intake, winch controller, C/O reservoir mounts, and PSC steering pump/resevoir still need to be installed. Nothing like trying to cram 10lbs of $#!T into a 5lb bag. Time is not on our side at this point, stay tuned for more updates are this Jeep comes together.
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Unread 06-13-2013, 11:30 PM   #35
kyle_craig
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I'm looking forward to seeing how the axles hold up to 40s...neat build!
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Unread 06-14-2013, 07:38 AM   #36
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Project KJ Update: Lots of progress yesterday, the rear window chop is getting capped off as well as the tailgate. Pac Racing coils are installed on the Fox 2.5 remote coilovers and will be going back into the Liberty soon. Our fabbed motor mounts are being modified to allow the 4-link to fully compress. The roof has been cut to accept the sliding rag top. While up there, the remaining "ribbed" roof panels were cut off and a patch panel was installed. Body/Fender modifications continue as we mock up the fenders to accept our 40'' Maxxis tires on 17'' B.A.D. beadlocks at full stuff. Stay tuned fore more as we prep for the 2013 Ultimate Adventure that begins 6/29/13.






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Unread 06-17-2013, 06:43 AM   #37
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It was a busy week last week in the BDS R&D Shop as the guys prep Project KJ for the 2013 Ultimate Adventure. The project white board is looming over the guys with a daunting task list and only 10 work days to complete. From body work to engine prep the team is working on all areas of the build. The plasma table was been getting a workout with plenty of parts getting cut out over the last coulpe weeks. A custom aluminum fuel cell was designed in Solidworks and cut out to snuggly fit the contours of our recessed cargo area. We went this route over the conventional cell to allow us to maximize the space available and still allow us room for the dual Optima batteries, air compressors and full size 40'' spare while allowing us to reuse the factory tank's internals to ease plumbing the system. The body work is still on schedule and is being prepped for a fresh coat of paint next week. To help us focus on the KJ body, electrical, and plumbing projects, we decided to pull the axles and drop them off at All Pro Off-Road to help us out with the gear/locker install. You may recall from an earlier update the JK Rubicon Dana 44s we were sleeved, trussed, and gusseted to accept the BDS 4-link suspension linkage, Fox 2.5 remote coilovers, and Fox 2.0 bumps. Internal upgrades for the axles include 5.13 Nitro Gear ring & pinions, air-Ox Locker front with 30-spline Nitro Gear chromoly shafts, and an ARB air locker rear with 35-spline Nitro Gear chromoly shafts. We'll have the axles back next week for final install along with custom driveshafts from our friends at Drivelines Plus to turn this KJ back into a rolling chassis.

In the meantime the work continues on the body and engine. Panels are being prepped for paint and the new radiator and intercooler are getting plumbed into the little I4 Diesel. Parts continues to arrive on the daily and we have big expectations for next week's build progress. A special thanks goes out to our buddies at Offroad Power Products, AFe Power, and Edge Products for go fast goodies to make sure our little 2.8L CRD is up to snuff with turning our 40'' Maxxis Trepadors. We'll have more on those upgrades as parts get installed. Stay tuned for plenty more in the coming days as Project Liberty takes shape.









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Unread 06-24-2013, 12:13 PM   #38
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With less than a week till the start of this year’s Ultimate Adventure the shop a bit chaotic right now, not to mention the fact that the vehicle still sits in 1000 pieces strewn across the R&D shop floor. A make-shift paint booth has been set up in the back corner as the the new BDS body/paint guy preps lays down the Anvil Gray paint on the doors and hood right now, followed by the fenders and body tonight/tomorrow. Wiring is getting buttoned up and drivetrain is being prepped to be reinstalled. The axles are pulled aside and the new Nitro shafts are assembled and installed, the PSC ram is being mounted, and heavy duty steering linkage is being fabbed up, and the axles trusses are being finish welded. Radiator/intercoolers have been plumbed into the CRD and a custom intake was fabbed up to run from the factory turbo up into the front cowl. Check out the photos for more on the build and stay tuned as we hit the home stretch to have this KJ prepped to hit the road Friday for the 2013 Ultimate Adventure.






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Unread 06-24-2013, 12:37 PM   #39
AlTheKillerr
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is there even a point in calling that thing a KJ any more???

cool build! I look forward to seeing some wheelin shots and videos.
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Unread 06-25-2013, 05:48 AM   #40
tex62
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crap I need to get my peterson's subscription back up so i can see this thing in action
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Unread 06-25-2013, 01:21 PM   #41
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Busy busy in the shop today, the rigs being worked on from all angles. I'll have photos to post later tonight/tomorrow once it gets out from paint. Here's the rendering for the final look. The color is called Anvil, it a slate gray used on the (2013) 10th Anniversary Rubicons along with black/red graphics. Being that we're running Rubi axles and a Rubi t-case, we thought it was fitting for this project.

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Unread 06-26-2013, 05:57 AM   #42
tex62
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that thing should be a blast. wouldn't mind driving it for a week!
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Unread 06-26-2013, 01:10 PM   #43
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Quote:
Originally Posted by BDS-Tech View Post
Busy busy in the shop today, the rigs being worked on from all angles. I'll have photos to post later tonight/tomorrow once it gets out from paint. Here's the rendering for the final look. The color is called Anvil, it a slate gray used on the (2013) 10th Anniversary Rubicons along with black/red graphics. Being that we're running Rubi axles and a Rubi t-case, we thought it was fitting for this project.

Rubi t case and axles with 40s. Cant wait.
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Unread 06-26-2013, 01:40 PM   #44
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Wicked !
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Unread 06-28-2013, 08:46 AM   #45
Strings72
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love love love this, I've always had a soft spot for Diesel liberty's.
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