Long Arm Build for a TJ - Page 4

**Tommy R** · 03-18-2008, 10:58 PM

Made some progress tonight. So I decided to make new front lowers because the originals weren't providing enough thread engagement with the elongated front wheelbase. Here's the new arms installed at the same length the original ones were set at. I estimate the wheelbase now to be approximately 1.5" longer than it was.

I'll use the original front lowers for the rear lowers. That'll be in a couple weeks.

I also welded the brackets to the frame rails. Not entirely, because I want a second person around to hold the exhaust out of the way while I weld inside the rails, but it's coming along nicely. I started with tight welds and made 2-3 passes so far:

The second issue I've come across is this... The sway bar and bracket contact the drag link ball joint when turning to full lock. I tried using a sleeve of tubing to raise the pin out of the way and it worked, but it just revealed the ball joint/bracket issues.

I'll hack the OEM bracket and make something that'll provide more clearance.

Believe it or not, the bolt head doesn't contact the ball joint, but it's way too close. But, the axle is lacking some caster at the moment so when leaned back it may be a non-issue:

Tommy

geauxturbo · 03-19-2008, 07:42 AM

You can grind that bolt head down a little.. I did. We don't live in the rust belt and if you can't get it off, you can always grind it the rest of the way off.

Dude, your junk is lookin' HAWT. Good work man.

**Tommy R** · 03-19-2008, 07:53 AM

Not sure how I feel about a guy telling me my junk is hot, but I'm flattered just the same.

Yeah, I'll grind that bolt head, if necessary. The big(ger) concern is the ball joint clearance, but it shouldn't be a big deal.

Thanks for compliments, Lance! And thanks for letting me check out your rig when I was in town. Let me know when you get up to Austin!

Tommy

WingnuTJ · 03-19-2008, 10:54 AM

Great write up!
Just a concern that was mentioned before.... Where you arm attaches to the frame I see a Zerk fitting just begg'n to get ripped off. Just my opinion! That would bother me and just incase
"I'm We Todd did"

Either way love the write up, like I mentinoed before! keep up the pic's and posts!

1 ton yj · 03-19-2008, 12:33 PM

JJ's are greaseable through the bolt as well.

**Tommy R** · 03-19-2008, 03:36 PM

Oh, thanks for the comment, but before I do final installation I'll rotate the joints 1/2 a revolution to get the zerks up top.

Tommy

**JeepRocks86** · 03-19-2008, 07:00 PM

you can also get flush grease fittings.

go to www.mcmaster.com and type in " Flush-Style Grease Fittings"

I'm going to go with those eventually. I think i've broken around 4 or 5 grease fittings off so far with my clayton system.
for example

**Tommy R** · 03-19-2008, 10:25 PM

Dangit. I would've had all the welding done tonight, but I ran through the spool of wire before I finished. Ugh! Anyway, so tonight I made the upper arms, finished welding the brackets to the frame, and got everything tacked together. Here's some pics....

And removed ready for final welding:

Tomorrow I finish welding and start painting and clearance the ball joint/sway bar bracket. Friday I reassemble. Saturday I take it to get aligned. I can't wait!

Tommy

Airborne4X4 · 03-19-2008, 10:47 PM

Nice work. Keep it up. Too many threads started around here and then forgotten, so keep us informed about this build. You're making me itchy for a long arm build of my own.

**Tommy R** · 03-19-2008, 10:51 PM

Thanks! It's been fun, but tiring and a lot of work since I only have maybe 3/4 of the tools I'd like and my garage is way too small.....but whose isn't, right?

Tommy

tweba99 · 03-20-2008, 09:48 AM

Are you planning on butt welded those nuts to the tube for your uppers?

**Tommy R** · 03-20-2008, 10:03 AM

Yup, just butt welded. A sleeve like I used for the lowers would've been nice, but wasn't available. At least the uppers aren't subjected to the same stresses and loads as the bottoms so I'm confident it'll hold up fine.

Tommy

tweba99 · 03-20-2008, 11:54 AM

Quote:

Originally Posted by Tommy R

Yup, just butt welded. A sleeve like I used for the lowers would've been nice, but wasn't available. At least the uppers aren't subjected to the same stresses and loads as the bottoms so I'm confident it'll hold up fine.

Tommy

I am sure it will hold up fine since Geauxturbo's is but I would say that the uppers are under just as much stress, if not more than the lowers, just not impact loads.

They do make round inserts in the size you would need for the uppers. I used round inserts on all of my arms since square inserts were not available. I am running a different suspension setup than you front and rear and I am running 2"x.25" tubing for my uppers and lowers so I could use the same inserts on everything.

**Tommy R** · 03-20-2008, 10:54 PM

Well, the uppers will be under compression and tension, but not subjected to the bending forces the lowers will see when I'm resting on rocks and such. I would've liked inserts, nonetheless, but I couldn't find any in the size I was using. I made a ton of progress tonight, but smugmug appears to be down right now so I can't access the pics I just uploaded and post them here yet. Yeesh!

Tommy

**Tommy R** · 03-20-2008, 11:38 PM

Got the arms all welded up tonight and primed and applied a quick coat of satin black. It could use a better paint job, but I don't really care about that right now.

Tomorrow after work I hope to get things wrapped up.

Tommy

03-19-2008, 10:54 AM	#49
WingnuTJ Registered User Join Date: Nov 2005 Location: Grand Rapids, Michigan Posts: 105 Profile Gallery Classifieds My Jeeps	Great write up! Just a concern that was mentioned before.... Where you arm attaches to the frame I see a Zerk fitting just begg'n to get ripped off. Just my opinion! That would bother me and just incase "I'm We Todd did" Either way love the write up, like I mentinoed before! keep up the pic's and posts! __________________ Lifes a Jeep! Wheel IT!