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MuddyJeepZJ 05-19-2010 09:03 PM

Project Stay out of the Pines.
Going to be a build with tons of pics of the long arm build up on a TJ. All work is designed, cut, welded, fabricated, etc by Joe from EndlessMtnFab EndlessMtnFab

Originally Posted by EndlessMtnFab
Bolting on a long arm kit can generally be done in a weekend. Properly designing & building a suspension takes time. Although not an "easy" task, most folks with a bit of knowledge and skill can build a long arm and wheel it. But it takes a little extra effort to set one up for suitable street driving.

8.8 axle Pre-Removal

8.8 Removal

Ballistic Fab Brackets

8.8 truss Mock-up

MuddyJeepZJ 05-19-2010 09:04 PM

231 Transfer Case Upgrade/Rebuild

Originally Posted by EndlessMtnFab
Ryan is also up against some driveline angle issues. His tucked skid, combined with 4.5 inch springs leaves him with a drivesshaft angle of 22 and a pinion angle of 19. The average 1310 CV maxes out at roughly 25 and Ryan is currently using 18 so far. This doesn't leave sufficient amount for droop. In fact .... the CV binds before the coils can fully unseat. The solution we are considering is a clearanced 1350 Setup to allow for greater strength AND flex. A clearanced 1350 generally offers 32-35 of movement.

Rear Coil Relocation

MuddyJeepZJ 05-19-2010 09:05 PM
Frame Repair

Originally Posted by EndlessMtnFab
In regards to the repair .... both sides will be cut out equally. The passenger side damage is not as extensive as the driver side; however, I do see random spots of soft/pocked metal and will be pro-active in the repair. The patch will be .125 plate and will be "frenched" into the cuts. Once welded, I will grind everything flush and plate over with a larger piece to ensure sufficient overlap. The overlapping plate will be perimeter & plug welded.

MuddyJeepZJ 05-24-2010 09:28 PM

8.8 Bracket Removal and Truss Build

MuddyJeepZJ 05-24-2010 09:29 PM

MuddyJeepZJ 05-25-2010 08:49 PM

Finishing up the Rear truss.
Bent to attach to truss
Welded into place
ABS Sensor Removal and hole filled
Lower Control Arm Brackets

MuddyJeepZJ 05-31-2010 06:52 PM

8.8 Breather tube relocation

Truss Welded Up

LCA mounted on Axle

Hendrix 05-31-2010 06:58 PM

Thats some great work so far. Crawled

littledevilTJ 05-31-2010 07:24 PM

damn thats a lot of rust!!!

MuddyJeepZJ 05-31-2010 08:18 PM


Originally Posted by littledevilTJ (Post 9552191)
damn thats a lot of rust!!!

Yeah I was shocked myself. Hence the name of the thread. The amount of rusted off pieces of metal along with sand inside he frame was amazing.

MuddyJeepZJ 05-31-2010 08:20 PM

Cross Member Round #1 using 2x5 steel
After making the proper height allowances to clear the transfer case and allow access to remove the nuts and bolts it was determined that the 2x5 piece of metal had far too much movement for our liking and we decided to move on to another idea.

Threaded bungs being inserted into frame rail for cross member to attach to

Cross Member Round 2 using 1/4" flat steel
Save a Horse ride a band saw!
Cutting the UCA brackets out of 2x5

MuddyJeepZJ 05-31-2010 08:22 PM
Rear cross member mocked up with LCA and UCA brackets in place.
Additional bracing will be coming after final fitment as well.

MuddyJeepZJ 06-06-2010 08:10 PM

Cross Member Round #2

MuddyJeepZJ 06-24-2010 08:38 PM

Getting close to the back being complete.

MuddyJeepZJ 06-25-2010 09:38 PM

Ford Shock Mounts

The time now is 05:07 AM.

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