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Unread 11-13-2006, 09:43 AM   #1
geauxturbo
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Long Arm Build

(Edits throughout so read everything if you are looking to copy any of this...and always measure yourself.. don't blindly trust a guy on the web with Louisiana skewling )

Well, been working on this project for a couple months. Get a little done here and there. Did all the work with a 4.5" Harbor Freight grinder, a tape measure, and a carpenters triangle. (borrowed a friends welder to tack it together since I have ZERO welding skills and then had my buddies dad do the final burn with his 220) Pretty much just copied the Clayton system using pics I found on the web

Used Currie JJs (2.5"x1.25"-12 for the lowers) with the threaded shanks and RE rubber joints for the opposite ends. Got some nuts to match from mcmaster.com, picked up some 2.5x2.5x.25" tube for the truss and 2x2x.25 for the lowers. Uppers are 1.5" square tube .125". Used the smaller shanked JJ for the uppers (2.5" x1"-14 I believe). The RE Joint and the JJ take a 9/16" bolt (4" length is perfect)... grade 8 can be had at Lowe's if you don't order them from McMaster. So, you'll need to dig out that 9/16" drill bit if you have one already. If not, you'll need one...

4"x2" box tube will be helpful making your brackets if you don't order them from somewhere. I also had some 1/4" plate I got from the scrapyard for misc. tabs and such. Then it was just just cut for a couple hours every so often when I had time.

I got the front installed last night. I'm very pleased so far.

Put the passenger side on first, bolted it all up, then went to the driver side and did that side. I waited to make the final cut on my radius arms when I had the lower on that side on as to get it the right length.... I don't have that much faith in my old geometry skillz Ran out of time to get the rear lowers on and the triangulated uppers go on with the F150/Explorer 8.8 (centered pinion and I got the F150 axle for free so I said why not make a centered pinion 8.8 with stock parts from my explorer axle and F150 axle).









Now onto gettin' the rear done

Total project cost including cutting wheels and paint is 649... Stress relief from flying sparks is PRICELESS!!

Bunch of Measurements - Page 2 post #19
Front end installed weak test flex shots - Page 4 post #59
Rear mock up shot - Page 5 post #62
Rear mock up with adj. Truss end brackets - Page 8 post #117
Finished Install Pics - Page 9 post #126
Poser Flex SHots - Page 9 post #131
Offroading Pics - Page 10 post #136
Video - Coming soon

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Last edited by geauxturbo; 01-22-2007 at 07:27 AM..
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Unread 11-13-2006, 09:56 AM   #2
hollandbriscoe
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Looks great. However,Let me preface what Im about to say by saying that i know nothing about suspensions, it looks to me that you are going to have a weak spot on your upper control arm bracket since you are only welded at the corner of the pipe and not wrapped around the corner a bit.
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Unread 11-13-2006, 10:04 AM   #3
geauxturbo
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Quote:
Originally Posted by hollandbriscoe
Looks great. However,Let me preface what Im about to say by saying that i know nothing about suspensions, it looks to me that you are going to have a weak spot on your upper control arm bracket since you are only welded at the corner of the pipe and not wrapped around the corner a bit.
Its welded on the inside and outside... its solid. If I had a break or even a vice I probably could've made a bend in the metal and made it contact around the corner.... but even so I'm really not worried about the strength. If I see any stress fractures appear I can pull it off and easily re-fab a radius arm bracket.
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Louisiana 4X4
'97 TJ Sport Black, 3.5" RE, PSC Trail Cage, Ford F150/Explorer Hybrid 8.8 Aussie locked, Lockright in the XJ HP 30, 4.88 gears, Borla Headers, No Muffler, 35x12.5 R15 Baja MTZs, Currie TrackBar. Homebuilt Longarm 4 link, AA HD SYE, TW CV DS, Warn tire carrier, Jeeperman front bumper, Warn X8000i with Amsteel Blue rope with a safety thimble, CO2
GeauxLook@myJeep
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Unread 11-13-2006, 10:18 AM   #4
Bill_Dunnigan
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so what here, did you buy prefabbed, i wanna do this!!!
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Unread 11-13-2006, 10:21 AM   #5
geauxturbo
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Quote:
Originally Posted by Sait
so what here, did you buy prefabbed, i wanna do this!!!
The joints. ... well, bolts and nuts too.
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Louisiana 4X4
'97 TJ Sport Black, 3.5" RE, PSC Trail Cage, Ford F150/Explorer Hybrid 8.8 Aussie locked, Lockright in the XJ HP 30, 4.88 gears, Borla Headers, No Muffler, 35x12.5 R15 Baja MTZs, Currie TrackBar. Homebuilt Longarm 4 link, AA HD SYE, TW CV DS, Warn tire carrier, Jeeperman front bumper, Warn X8000i with Amsteel Blue rope with a safety thimble, CO2
GeauxLook@myJeep
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Unread 11-13-2006, 10:23 AM   #6
JeepinYahoo
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That is super cool
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Unread 11-13-2006, 10:27 AM   #7
JSBlu974X4
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wanna build me a kit? haha :-)
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Unread 11-13-2006, 10:28 AM   #8
hollandbriscoe
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Ok thats cool just wanted to make sure
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Unread 11-13-2006, 10:32 AM   #9
geauxturbo
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Quote:
Originally Posted by JSBlu974X4
wanna build me a kit? haha :-)
If you wanna wait 6 months and its only tacked together HEck, can't even guarantee that since I have to give my friend his mig machine back

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Louisiana 4X4
'97 TJ Sport Black, 3.5" RE, PSC Trail Cage, Ford F150/Explorer Hybrid 8.8 Aussie locked, Lockright in the XJ HP 30, 4.88 gears, Borla Headers, No Muffler, 35x12.5 R15 Baja MTZs, Currie TrackBar. Homebuilt Longarm 4 link, AA HD SYE, TW CV DS, Warn tire carrier, Jeeperman front bumper, Warn X8000i with Amsteel Blue rope with a safety thimble, CO2
GeauxLook@myJeep
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Unread 11-13-2006, 10:40 AM   #10
geauxturbo
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Rear Frame brackets. I will have to cut the skid like the Clayton kit and remove the last bolt... if you built your own you can choose whether or not you are willing to do that.

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Louisiana 4X4
'97 TJ Sport Black, 3.5" RE, PSC Trail Cage, Ford F150/Explorer Hybrid 8.8 Aussie locked, Lockright in the XJ HP 30, 4.88 gears, Borla Headers, No Muffler, 35x12.5 R15 Baja MTZs, Currie TrackBar. Homebuilt Longarm 4 link, AA HD SYE, TW CV DS, Warn tire carrier, Jeeperman front bumper, Warn X8000i with Amsteel Blue rope with a safety thimble, CO2
GeauxLook@myJeep
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Unread 11-13-2006, 12:15 PM   #11
TXST8tj
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i'm impressed. do you have plans to do a new tranny skid?
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Unread 11-13-2006, 12:30 PM   #12
geauxturbo
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Quote:
Originally Posted by TXST8tj
i'm impressed. do you have plans to do a new tranny skid?
Yeah, I just gotta find a good one to copy Some sort of flatter skid.. probably go with a crossmember style that you can drop the skid without having to support the tranny.

Gotta address the front steering as well.. tired of bending tie rods and drag links...

And then there is gearing

and tube fenders

and .... uh... well, you know
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Louisiana 4X4
'97 TJ Sport Black, 3.5" RE, PSC Trail Cage, Ford F150/Explorer Hybrid 8.8 Aussie locked, Lockright in the XJ HP 30, 4.88 gears, Borla Headers, No Muffler, 35x12.5 R15 Baja MTZs, Currie TrackBar. Homebuilt Longarm 4 link, AA HD SYE, TW CV DS, Warn tire carrier, Jeeperman front bumper, Warn X8000i with Amsteel Blue rope with a safety thimble, CO2
GeauxLook@myJeep
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Unread 11-13-2006, 02:06 PM   #13
tweba99
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Man, this is GREAT to see something like this on the board. I am PM'ing you with some questions...

Good work.
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Unread 11-13-2006, 03:41 PM   #14
JeepNazi101
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Props to you man!! Nice Work!! Keep up the good work.


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Unread 11-13-2006, 04:25 PM   #15
sbninja
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Nice job, i've been thinking of fabbing up my own long arms.
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