Project Stay out of the Pines.

**MuddyJeepZJ** · 05-19-2010, 10:03 PM

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

Quote:

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, 10:04 PM

231 Transfer Case Upgrade/Rebuild

Quote:

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, 10:05 PM

Frame Repair

Quote:

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, 10:28 PM

8.8 Bracket Removal and Truss Build

**MuddyJeepZJ** · 05-24-2010, 10:29 PM

**MuddyJeepZJ** · 05-25-2010, 09:49 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, 07:52 PM

8.8 Breather tube relocation

Truss Welded Up

LCA mounted on Axle

**Hendrix** · 05-31-2010, 07:58 PM

Thats some great work so far. Crawled

littledevilTJ · 05-31-2010, 08:24 PM

damn thats a lot of rust!!!

**MuddyJeepZJ** · 05-31-2010, 09:18 PM

Quote:

Originally Posted by littledevilTJ

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, 09:20 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, 09:22 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, 09:10 PM

Cross Member Round #2

**MuddyJeepZJ** · 06-24-2010, 09:38 PM

Getting close to the back being complete.

**MuddyJeepZJ** · 06-25-2010, 10:38 PM

Ford Shock Mounts