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FS: Wrangler RGB Multicolor Fog Light LEDs: Awesome EffectSavvy Aluminum Gas Tank SkidFS: 2007-2013 Jeep Wrangler "HALO" Angel Eye Kit

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Unread 05-19-2010, 09:03 PM   #1
MuddyJeepZJ
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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
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









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Last edited by MuddyJeepZJ; 05-19-2010 at 09:23 PM..
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Unread 05-19-2010, 09:04 PM   #2
MuddyJeepZJ
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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













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Unread 05-19-2010, 09:05 PM   #3
MuddyJeepZJ
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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.
















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Unread 05-24-2010, 09:28 PM   #4
MuddyJeepZJ
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8.8 Bracket Removal and Truss Build













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Unread 05-24-2010, 09:29 PM   #5
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Unread 05-25-2010, 08:49 PM   #6
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Finishing up the Rear truss.


Bent to attach to truss

Welded into place


ABS Sensor Removal and hole filled





Lower Control Arm Brackets




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Unread 05-31-2010, 06:52 PM   #7
MuddyJeepZJ
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8.8 Breather tube relocation




Truss Welded Up




LCA mounted on Axle

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Unread 05-31-2010, 06:58 PM   #8
Hendrix
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Thats some great work so far. Crawled
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Unread 05-31-2010, 07:24 PM   #9
littledevilTJ
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damn thats a lot of rust!!!
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My OLD build thread:http://www.jeepforum.com/forum/f22/0...roject-935798/

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Unread 05-31-2010, 08:18 PM   #10
MuddyJeepZJ
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Quote:
Originally Posted by littledevilTJ View Post
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.
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Unread 05-31-2010, 08:20 PM   #11
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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
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Unread 05-31-2010, 08:22 PM   #12
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Rear cross member mocked up with LCA and UCA brackets in place.
Additional bracing will be coming after final fitment as well.
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Unread 06-06-2010, 08:10 PM   #13
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Cross Member Round #2











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Unread 06-24-2010, 08:38 PM   #14
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Getting close to the back being complete.















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Unread 06-25-2010, 09:38 PM   #15
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Ford Shock Mounts





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