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Unread 03-12-2012, 10:25 AM   #361
1Badboy
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Read the whole build. Thanks for the Cliff notes at the end. Like what you did with the front coil buckets, for alittle extra stretch. Would of been easier going straight to a fuel cell to start. Got a similar build I'm doing, but with an ATX backhalf kit for the frame and fuel cell. Thanks for sharing your build. Sub'd....Johnie

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Unread 03-12-2012, 06:55 PM   #362
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Originally Posted by REDLYNER View Post
Looking stout man. When are you planning on having it wheelable?
Thank you, hoping to have it done and wheeling on the 23rd/24th of March.

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Originally Posted by Louie4 View Post
Just went through the build. It's going great. I can't wait to see how it does on the trail with the new suspension.
Thanks, I'm very excited too. Might have to bump up to a 2" lift and 37s just to get clearance I want...but I'm all for that!

Quote:
Originally Posted by 1Badboy View Post
Read the whole build. Thanks for the Cliff notes at the end. Like what you did with the front coil buckets, for alittle extra stretch. Would of been easier going straight to a fuel cell to start. Got a similar build I'm doing, but with an ATX backhalf kit for the frame and fuel cell. Thanks for sharing your build. Sub'd....Johnie
No problem. Probably would have been easier with a fuel cell but I wanted the cargo space and economically it was a good try even if it doesn't work out. I will give it another shot with a 2nd tank if I can't get it all to fit right. I might try to put in a fuel cell or take a shot at building one myself that uses a stock TJ sending unit. With the abilities and skills I've learned so far it wouldn't take much for me to design a unit and have it cut out with a plasma cnc. Then just TIG it up...but I don't know how to TIG yet.

You could very well see my rig under the knife again next winter with a back half, fuel cell, and a new front axle with 37s attached
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Unread 03-12-2012, 07:14 PM   #363
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Originally Posted by gtxracer View Post
Thanks, I'm very excited too. Might have to bump up to a 2" lift and 37s just to get clearance I want...but I'm all for that!
I know it will be tough but I'm sure you'll weather the storm.
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Unread 03-12-2012, 07:45 PM   #364
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Thank you, hoping to have it done and wheeling on the 23rd/24th of March.
Can't wait to see this! This saturday the 17th will be my last wheeling trip on my old axles. planning on starting the swap the following Saturday!
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Unread 03-12-2012, 08:32 PM   #365
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I know it will be tough but I'm sure you'll weather the storm.
My buddy Greg says the same thing...I hope you guys are right

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Originally Posted by nibstools View Post
Can't wait to see this! This saturday the 17th will be my last wheeling trip on my old axles. planning on starting the swap the following Saturday!
Thanks nib! It feels good to upgrade doesn't it? Just wait until you make the first cut on your tub or frame...after that first vomiting fit you get used to the feeling and it goes away eventually.
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Unread 03-12-2012, 08:36 PM   #366
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Thanks nib! It feels good to upgrade doesn't it? Just wait until you make the first cut on your tub or frame...after that first vomiting fit you get used to the feeling and it goes away eventually.
Oh I've already opened the rear wheel wells up, cut the front fenders off for tube fenders, rebuilt the frame front and rear and installed f250 shock towers in the rear for outboard shocks. Amongst other minor mods!
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Unread 03-14-2012, 12:56 AM   #367
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Oh I've already opened the rear wheel wells up, cut the front fenders off for tube fenders, rebuilt the frame front and rear and installed f250 shock towers in the rear for outboard shocks. Amongst other minor mods!



Snuck out to the garage tonight so I could finish up some things from the weekend. Got my HH187 back up and running and burned together the coil retainers and tacked them on the frame. Going to try to get the suspension together and done before the end of the week (Friday night). These aren't as nice as I would have liked to make them but I see a backhalf and coilovers in my future so I didn't want to spend too much time on them.



Then I got started on the bender. I've been researching and planning for the past few days and made a final plan the other night. Made a materials list and picked up all the goodies yesterday. I had some of it already so it came together well. I will be making a write up for it but here's some pics-
















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Unread 03-14-2012, 07:07 AM   #368
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what is the purpose of the big tube with the three smaller pieces welded on?
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Unread 03-14-2012, 11:23 AM   #369
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Clamps the ram in place and mounts it to the bender. I'll snap some better pics when I have time to get back in the shop and finish it.
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Unread 03-16-2012, 12:21 AM   #370
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Tonight I got the bender done








And I got the front suspension cycled for the last time and done. Can't use the stock pitman arm after all, but it's just barely hitting. If I limited my uptravel just a little more it would work.


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Unread 03-20-2012, 12:05 AM   #371
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These might be out of order but I'm still dazed and out of whack from the last few days in the shop. Tomorrow will be a long day, hope to have just about everything done and only the little stuff left - tighten bolts, go over everything, double check welds, paint a little bit, mount fuel/brake lines, etc.

used the bread method to remove the ax15 pilot bushing


used some aluminum foil on new (Novak) pilot bushing, I think my crank is a few thousandths off


used the spare np435 input to align the new clutch Ford/CJ clutch and pressure plate (AX15)


all those bags gotta go in the pink case


CPS mount done and ready to go


pulled out the trans, slapped on the adapter


welded the rear spring retainers, they're meant to make contact on full bump. rear uptravel is right at 5" right now but the tub and tank skid may not like the last 2"...haha!
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Unread 03-20-2012, 12:11 AM   #372
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Kinda flip flopping around here on pics but it all comes together anyhow...


Found the neutral spot in the np435 and put on the top cover, then tested the shifting - all good


installed the AX15 clutch release bearing (throwout bearing) and it will NOT work, too thick


Here's why, contacts the pressure plate-


D300 twin stick setup went well...except when I decided I was too smart to remember that the cables have to shift OUT and had to weld on the 2.25" I cut short




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Unread 03-20-2012, 12:22 AM   #373
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Takes us to today, I'm almost finished with the rear shock hoops...

bent some plate, made some traces, cut off some side tube, and some corner mounts-


cut out the shock mounts


bent the tube...didn't snap any pics but the HF ram has been a pain in my ***. I made two 150 degree bends manually pumping the jack...took me about 10 minutes per bend instead of 2 and I was dead tired! haha.

Burnt in the shock tabs, I'll snap pics of the rest of it tomorrow.


frame cutout
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Unread 03-21-2012, 12:55 AM   #374
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Don't have time to give a full update but here's a quick rundown-

trans is in place, bolted up finally but there is still a 1/2" gap
need to attach pivot arm, couldn't mate everything with it in place
swapped the ax15 throwout bearing for a 80 cj7 4.2 unit
CJ clutch master and slave cylinders have been fitted and adapted with brackets
Bent the 1/4" (I believe) line for the clutch system, just need to fill and bleed it (tips welcome)
suspension is done and fully welded, ready to go
need to install the rear shocks - BBCS 11" from Poly
pitman arm still isn't machined...going to yell at them again tomorrow, gave it to them friday
d300 is assembled and put in some fluid to make sure it's sealed
need to finish fabbing the cable shifter mounts for the tub


Almost done...have to work tomorrow but will do some work tomorrow night. Thursday is THE day to get things done. Friday is going to be "final check" day and driving the Jeep a bit to dial in everything for the 90 minute drive to the trail.
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Unread 03-23-2012, 01:50 PM   #375
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Guess I should give a few updates now that I have a little time.

Here's how I adapted the CJ7 master clutch cylinder to the TJ factory master housing, just welded some studs on the housing (bracket) and gave it a little massage so it would fit.





CJ7 4.2 clutch release (throwout) bearing, the short one, versus the taller stock ax15 4.0 unit


quick bracket I made for the clutch slave cylinder, thanks to Alxj64 for the inspiration and the idea


This is the bar pin that I modified to extend the CJ master cylinder push rod to the clutch pedal. Might replace it later on but this was quick and easy. One hole is 1/2" the other is 7/16" for reference


Here you can see the relation of the new CJ master and the CJ slave cylinder, you'll need about 45" of line but 50-52" is what can work. I used a off the shelf line from O'Reillys that was already flared and ready to go, part number PA-451.

Stock master system has the sensor on it for the clutch (red wire insulation). If you don't want to have to push in the clutch to start the 4.0, just cut off the end that goes over the push rod and splice the wires together. Let's the engine think the clutch is pushed in. Previous owner did this for his wife when she had the jeep and it's convenient and also it's difficult to adapt the sensor to the CJ master.
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