[GreenJip]

Originally Posted by mjstranz

Hurry up and get it down Im ready to go wheelin again.

I know, I am itching to get the Jip out too. I have a personal goal to be ready by mid March. Funds will get tight towards the end of the build. I still have to order Adjustable Rear Track Bar, JB SS SYE and have my CV shaft shortened. Not to mention what little welding is left .

[ImSuck]

nice build, are you gonna paint it?

[GreenJip]

Now for the brake work. The TJ uses a combination T-Fitting / Breather tube. I started to go this route, but found out quickly that I would have a difficult time setting up the hard lines like this. So, I used the original breather fitting on the 8.8 and drilled a 25/64" hole between the track bar mount and pumpkin. Then I threaded the hole with a 7/16" - 20 tap.



For the T-Fitting, I used one that mjstranz had around. Its a stainless braided line. I don't know where he got it, maybe you can ask him. On top of the pumpkin there is a brake line retaining clip. I removed that bolt and again drilled the hole out with a 25/64" bit then threaded it with a 7/16" - 20 tap. I then secured the T-Fitting with a 7/16" - 20 X 1" bolt. In this pic, you can also see where I ground down the speed sensor so the sway bar would not hit.



Before I ran the hard lines, I put everything on the axle (carrier, axles, diff cover, rotors, pads, calipers and the two passenger side hoses mentioned in the parts list) I used zip ties to hold the hoses in place so I could figure out how I wanted to run the hard lines.

Diff Cover (Cheap on E-Bay)


Driver Side


Passenger Side


I will probably splice some tubing to protect the brake line where it rubs the caliper. I also need to figure out the best way to weld some mounts for the brake line ends. If anyone has some ideas for this, I would greatly appreciate it. My first thought is to just weld some nuts to the tubing.

[GreenJip]

Routing the hard lines proved to be a PITA for me. Maybe someone else will have better luck. At first, I wanted to cut and flare the lines to perfect length, but everytime I flared an end, it looked really bad. So I gave up and just used 30" lines with the 3/16" fittings. The Drivers side looks pretty good. The passenger side has an extra loop in it to make up fior the extra length. I will probably redo it later, because I hate the way it looks.

Hard Lines I Used


Drivers Side


Passenger Side

[GreenJip]

Originally Posted by ImSuck

nice build, are you gonna paint it?

Yes, I did this yesterday. Since I don't know when I can get the tubes welded, I wanted some paint on the axle before rust sets in. I will clean the area to be welded when I get that done.

The first thing I did was tear the axle back down, put the old diff cover on and capped the ends to keep water out. I also plugged that breather tube with that 7/16"-20 bolt. I used some Purple Magic to clean any grease and metal shavings off and let it dry in the sun.



After it dried, I hit it with some primer to help hold the paint.



Last, I finished it up with a coat of black. I thought that the cap indicated flat black, but it dried glossy. Oh well, I can always go back over it before the final install.



This process took awhile, because I had to wait 30 minutes between coats. I have two coats of each. Then I let it dry for an hour before I moved it in the garage.

Thats it for now. I am just waiting to get a welder lined up and have to save some hard earned cash for the other stuff I mentioned. I will post pics as progress continues, but for now the money train stops here!

[Thetrav5.9]

Looks like some good work, and like you are doing everything right THE FIRST TIME. Any plan for a locker in the rear? I went with 4.88s when I went with the 8.8 (4cyl) and welded the rear....but, if you are gonna use it as a DD i wouldnt suggest that. Again, nice work.

[TimBrown]

The axle is looking good. I'm glad you finally got to work on it. I will have to come by after work this week and check it out. My front axle should be ready tomorrow. Hopefully we can get it in soon and get out on the trails.

[GreenJip]

Originally Posted by Thetrav5.9

Looks like some good work, and like you are doing everything right THE FIRST TIME. Any plan for a locker in the rear? I went with 4.88s when I went with the 8.8 (4cyl) and welded the rear....but, if you are gonna use it as a DD i wouldnt suggest that. Again, nice work.

Thanks. Right now I am going to play around with this LSD. Maybe later on in the year I will get a Detroit Locker for the rear. It is kind of my daily driver, so welding or spools is not in my plans.

Originally Posted by TimBrown

The axle is looking good. I'm glad you finally got to work on it. I will have to come by after work this week and check it out. My front axle should be ready tomorrow. Hopefully we can get it in soon and get out on the trails.

Come on down. Theres not much to look at now. Its just a bare painted axle with brackets on stands. It won't be long. I missed Stranz's first ride with his new set up, but maybe we will all be able to ride together on the next ride.

[mjstranz]

Spool it!!! I did. The brake lines are from polyperformance.com and are poly performance made, and DOT legal.

[Chris_]

What is your CV drive shaft length?

[GreenJip]

Originally Posted by Chris_

What is your CV drive shaft length?

Sorry, I don't know yet. I will measure it when I get the JB SS SYE and do the final install on the 8.8 Currently I have the front CV shaft out of the doner axle. It is plenty long to cut down to the proper length at a driveshaft shop. When I get to that phase of this project I will post the measurement I get.

[mjstranz]

Got any more work done dude?

[1CleanTJ]

you and your friend should pick up a few more 8.8's at the junkyard, weld up the brackets and sell them on here the work looks great

[GreenJip]

Originally Posted by mjstranz

Got any more work done dude?

No, I got tied up with Tim's front axle, and I forgot to call the guy who is going to weld my tubes. After that, its a matter of budget. I have to get the SYE and send my CV shaft off for lengthening. I decided to get an HP from an XJ and regear that. Do you think that you will be able to help me set up the gears for the front? The axle bearings have proven to be a PITA. I am trying to figure out how I am going to change them.

Originally Posted by 1claentj

you and your friend should pick up a few more 8.8's at the junkyard, weld up the brackets and sell them on here the work looks great

LOL. We thought about doing that and building a jig to weld up the brackets. Thanks for the kind words.

[PBR]

Originally Posted by GreenJip

I do plan on welding the tubes at some point before I install it. I don't have much experience welding. So, I don't feel comfortable welding the tubes myself since the housing is cast.

Since this has been brought up again. Is the housing cast iron or cast steel? How can I tell the difference?

welding cast is not hard, just get the nickel electrode and weld up. cast iron now adays is so advance to where it easier to weld without cracking.

to tell the difference between cast steel and cast iron is if its cast steel there will be metal shaving if you drill a little hole some where if its cast iron drilling a hole it will be dust