I've slowly been collecting parts for my rear axle swap over the last year or so. Now I'm taking a continuing ed welding class at the local CC and ready to start preparing the axle to go under the back of the heep. So far I've ordered 4.56's, Detroit locker, LCA, spring buckets, & shock mount tabs (ballistic) and I had Moser re-drill the axle shafts to 5x5 bp.
I've got custom LA's on the WJ made by a local friend. It uses radius arms up front, with a 3-link in the rear (2 long lowers + the factory upper A-Arm). I'd like to keep the rear suspension as is so I can keep the exhaust system in tact. I also would like to re-use the WJ's brakes on the 9 due to needing a E-brake to pass inspection and cheapness since I already have a complete set of rear WJ brakes from a WJ that was parted out.
My plan is to tack weld the LCA, spring buckets, and shock mount tabs on at home using my Clarke 130EN welder, then burning them in using a 220v welder during class. I thought I'd be best to get the shock tabs and LCA brackets as high up as possible on the axle for more clearance, i.e. around the axle center line. Is that correct? or is there a reason the factory design has the shock and LCA's below the axle? For the pinion angle, I'm going to measure the angle my current axle is at and add a few degrees (~10*), then weld on the spring buckets at 0*.
For the disk brakes, I did a quick mock up with the WJ caliper bracket and rotor to see that the hat of the WJ rotor was too deep. I will need to custom make a weld on caliper bracket using the plasma cutter at school. Any tips or pointers?
Also looking for recommendations for the upper mount. I have purchased a new a-arm upper ball joint and was thinking about making a weld on truss which the ball joint would bolt down to similar to the OEM setup.
Obviously this is my first time doing this, so any help or advise is appreciated.