just another 1 ton tj - JeepForum.com

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post #1 of 169 Old 10-11-2012, 09:07 PM Thread Starter
babyhulk
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2005 TJ Wrangler 
 
Join Date: Jul 2009
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just another 1 ton tj

Started this build with the intention of keeping it very simple. You will see as it goes along it's alot more in-depth than I planned on it being. I started the swap with a 05 tj that was already modified pretty good being that it had rk longarm,AA sye,37 pitbull rockers and a bunch of other mods that will go along with the swap.

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post #2 of 169 Old 10-11-2012, 09:12 PM Thread Starter
babyhulk
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Join Date: Jul 2009
Location: concord
Posts: 263
The swap will consist of a dana 60 kinpin 5:38,detriot,tnt truss with all new brackets,great lake diff cover. 14 bolt 5:38,arb,rk truss+all new brackets,disk brakes,great lake diff cover and pinion guard. gen right alien tank, ballistic high steering with 7/8 heim sterring kit.

I Got a smokin deal on a dana 60 kp and a 14 bolt for $1300. The 60 already has a tnt truss with high sterring arms and comes with a rebuild kit for a 14 bolt. The 14 bolt also has a brand new disk brake conversion,new rotor and calipers.
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post #3 of 169 Old 10-11-2012, 09:21 PM Thread Starter
babyhulk
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Ordered all my parts from east coast gear, arb, 5:38 rp for the rear, detriot, 5:38 for the front and warn hubs. I also ordered my diff covers and pinion guard from Great lakes Offroad.
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post #4 of 169 Old 10-11-2012, 09:27 PM Thread Starter
babyhulk
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Location: concord
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My genright tank came in and is very impressive. When i get ready to stretch the rear 5", it is going to fit perfect with the 14 bolt. Install was super easy i had to drill 2 holes threw the frame and that was the hardest part. The only down side to the tank is the loss of the five gallon that it sacrifices for the extra room for the stretch.
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post #5 of 169 Old 10-11-2012, 09:32 PM Thread Starter
babyhulk
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I ordered my wheels and relized that the Dana 60 had 1/2 wheel studs and the 14 bolt had 9/16 studs. So i went over to my friend's machine shop (thank's joey) and pressed out the dana 60 studs, redrilled and installed the new 9/16 studs.
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post #6 of 169 Old 10-11-2012, 09:43 PM Thread Starter
babyhulk
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Join Date: Jul 2009
Location: concord
Posts: 263
Update the interior a little with a set of corbeau a4 wide seats,spod over head switch panel and laser V rocker switches(otratw). Personally I like this style of switch better than what comes with the spod. It shows when the switch is activated and the symbol makes it easy to identify the switch. In place of the spod panel i built my own, using alot of the 12 volt guys fuse panel and relay setup. While I was wiring the spod in I went ahead and mounted the Arb compressor and got that out of the way.
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post #7 of 169 Old 10-11-2012, 09:48 PM
sjones26573
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Nice shirt.

The Offroad Club @ NC State; Founder
The Yellowtail Build
Jeep-Owner.com
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post #8 of 169 Old 10-11-2012, 09:55 PM Thread Starter
babyhulk
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Shirt?
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post #9 of 169 Old 10-11-2012, 10:10 PM
sjones26573
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Quote:
Originally Posted by babyhulk View Post
Shirt?
Post #5, second pic, machine shop.

The Offroad Club @ NC State; Founder
The Yellowtail Build
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post #10 of 169 Old 10-14-2012, 08:00 PM Thread Starter
babyhulk
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Join Date: Jul 2009
Location: concord
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I needed to find a smaller and mutch quieter Muffler, due to the long arm and the almost flat skid plate. Before the swap i had a 40 series flowmaster and it was just to loud.At highway speed it droned and it rubbed the floor pan causing it to get way to hot. I tried a few different applications and finally landed on a thrush muffler, it was small and very quite for its size.
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post #11 of 169 Old 10-14-2012, 08:08 PM Thread Starter
babyhulk
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Steering and trac bar showed up from Barness today... Started cutting as much as possible of the 14 bolt lip, it still hangs down more than I like but it is smooth. Maybe one day I'll get around to shaving it.
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post #12 of 169 Old 10-14-2012, 08:17 PM Thread Starter
babyhulk
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Wheels showed up today so I got started install the new pitbulls. Removed the 30 and the 60 rolled in its place to start checking fitment, it's going to be tight.....
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post #13 of 169 Old 10-14-2012, 08:31 PM Thread Starter
babyhulk
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So wow what a day. This is not going to be a simple one ton swap.The front axel was suppost to be a bolt in application with the tnt truss. The guy that had it before me told me the upper mount was for a rock krawler joint and it wasn't. So i had to order a new one from tnt $250. Also the guy welded the coil retainers way to far forward and if i run the rk trac bar and tnt trac mount my tb is going to be about a 2 foot shorter than the drag link. From everything i have read the trac bar being short than the drag link is not good and u should get them as close in length and as parallel as possible. I havent had a chance to cycle the suspention but from the looks of it with the way the lower control arm mounts are the control arms will come in contact with the frame. My personal opinion if your doing this swap and planning to run the tnt truss dont get the trac bar bracket, other than that its a great truss.
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post #14 of 169 Old 10-14-2012, 08:41 PM Thread Starter
babyhulk
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Posts: 263
Moved my coil retainers back as far as they would go,im going to have about 3.5 of stretch in the front with the lower control mount being longer and the 60 being wider.I built the axle side trac bar bracket,it was by far the hardest part of the build with the tools I have.It did end up being perfect, the trac bar and the drag link are parallel. Also got the 14 bolt done other than replacing the brakes,the rk truss fits perfectly and will allow me to tie back into my suspension.
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post #15 of 169 Old 10-16-2012, 08:59 PM Thread Starter
babyhulk
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Join Date: Jul 2009
Location: concord
Posts: 263
The jeep is finally on all fours. Man it's a wide *****...
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