Clayton Off Road 05 TJ 5.5" Long Arm install - JeepForum.com
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Unread 07-23-2013, 03:25 PM   #1
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Clayton Off Road 05 TJ 5.5" Long Arm install

We are starting on this build this week, it's a nice clean TJ with only 48k on it. It's getting our 5.5" Long Arm Suspension Lift Kit, Bilstein shocks, SYE kit and a Tom Woods drive shaft. We will be using the factory transfercase skid plate for now. Here are a few pictures as we progress through the install of our parts:







Tom Woods/ AA SYE kit:





We use these brackets to determine where we need to weld our new control arm brackets:



Getting the frame all cleared out:



Using the location plates:



Getting the new control arm brackets in place:





Alex
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Clayton Off Road

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Unread 07-23-2013, 03:28 PM   #2
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New control arm brackets tacked into place:



Fully welded:







Cutting off some of the old control arm brackets with the plasma:



Cut through the welds along the top edge with a cutoff wheel:



Use a hammer to take the pieces off:





Then clean it up a little and the rear control arm brackets are totally off:



Add some paint to prevent the East Coast death rust:



Alex
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Unread 07-26-2013, 12:18 PM   #3
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Starting to work on the rear axle bracketry:



Getting it ready for the truss:



Tacked in:



Fully welded in place:



Axle painted, and lower arms bolted in:



Nothing the factory skid plate:



Tight fit next to the LCA brackets:







Getting ready set the pinion angle, 2 degrees down:



Alex
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Unread 07-26-2013, 12:32 PM   #4
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To set the pinion angle, we use a bottle jack to make sure we get the pinion exactly where we want it:



Centering the rear axle over the body, we use ratchet straps and pull the body where we want it:



Once the pinion angle and track are set we put the upper arms in. Adjust the upper arms to the exact length so the bolts go in easily:



Rear arms in:



Starting on the front end:







Cleaning up the old trackbar mount and adding our bracket to make it a double shear bracket:



New double shear track bar mount up front:



Trackbar bracket ready for paint:



Alex
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Unread 07-26-2013, 12:40 PM   #5
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New front end parts (JKS disconnects, new pitman arm, trackbar and bracket, springs, and control arms) installed:



Clayton Off Road springs and Bilstein shocks installed:



Front radius arms, springs, and shocks installed:



Front and rear suspension complete:



Starting on the exhaust. Cut flange off the cat about a half inch in front of the necked down portion:



Grind off the weld off and knock old pipe out of the flange:



Clean up the ID of the flange:



Cut flange off the muffler right at the end of the muffler pipe:



Clean up the ID of the flange so it goes over the new muffler with a little play:



Alex
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Unread 07-26-2013, 02:04 PM   #6
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Weld bolt into the flange on the cat facing the muffler:





Cut about an inch off the inlet to the muffler:



Put the flange on to the cat. it's a tight fit so you may need to use a hammer. Try and angle it towards the center of the Jeep. Then install the muffler:



Make sure the muffler is centered between the upper control arm and the transfer case. I like to use a level to get it level with the frame rail:





Tack weld both flanges in place when the muffler is located where you want it:





Unbolt the muffler and weld around the inside of the cat flange:



Outside as well:



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Unread 07-26-2013, 02:07 PM   #7
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Once it is welded up you can bolt it back on:



AA SYE and Tom Woods shaft are installed along with the new muffler:



Cut the tip of tail pipe off the old exhaust where it is a full diameter after the bend. Clean up the end and it needs to be hammered a little to get it round:



Slide the tail pipe in to the muffle and angle it slightly to the outside of the Jeep. Put a couple tack welds on if you are going to have a custom tail pipe bent up to exit in the stock location:









Alex
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Unread 07-29-2013, 01:09 PM   #8
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We finished up our part of the build today and got the TJ ready for it's owner:



Next up is this TJ:



Alex
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Unread 07-29-2013, 01:26 PM   #9
M1Garand
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Looks really good. What does an install along with parts for something like this cost? I'm debating building up my TJ and selling my 2012 JK Rubicon.

-Kyle
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Unread 08-02-2013, 10:14 AM   #10
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Kyle,

Give us a call or email us via our contact page on our website: http://www.claytonoffroad.com/contact.htm

Adam will be able to give you a much better idea on what it'll cost. We have built Jeeps for customers in Texas and other states then shipped them once they were complete.

Alex
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Unread 08-04-2013, 10:41 PM   #11
M1Garand
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Yeah I wouldn't ship my Wrangler anywhere to have work done on it. I've done a few things to it myself in my garage at the house, and anything else I just had installed at a local shop. I figured the cost to get my Jeep to the other side of the country and back would better be served going into more modifications or install labor.

Thanks for the reply
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