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post #346 of 386 Old 02-06-2020, 01:03 AM Thread Starter
tbunch
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Thanks man!

Now a quick vent on stupid mistakes!

I was prepping the T-case for install tonight and decided I needed to replace the gasket on my trans/t-case adapter since I’d separated it on removal.. quick job, 4 bolts, but ooooh no, can’t be that easy. On removing it, it stuck to the output shaft. Since the adapter is also the rear bearing retainer it pulled the 2 piece mainshaft slightly apart, not much, but enough that it wouldn’t go back in, fiddled with it for a while, finally got it in, but something was off because it wouldn’t shift and was stuck in 1st. Crap..

After playing with it for a while more and trying to remove the top cover from the cab I finally accepted I had to pull the trans.

So now I’ve spent most of the night pulling the trans, opening it up, fixing it and putting it all together.and back in. There’s been some language in the garage to say the least. But it’s fixed. (Forward shift fork had popped off when the shaft split, stupid easy fix)

Moral of the story, pay attention and don’t make stupid mistakes!

29bbb2f1-9c9a-45ee-a7aa-2887cb74a7fa_1580976167827.jpg

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post #347 of 386 Old 02-06-2020, 06:29 PM
lovett86
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Good thing it's a light weight tranny. Lol. I helped a guy at work pull one of those 10 years ago.

its a rusty one

https://www.jeepforum.com/forum/f22/90-yj-frame-swap-build-up-1434246/
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post #348 of 386 Old 02-06-2020, 10:37 PM Thread Starter
tbunch
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Quote:
Originally Posted by lovett86 View Post
Good thing it's a light weight tranny. Lol. I helped a guy at work pull one of those 10 years ago.
That’s for sure. I cheated and just seperated it from the bellhousing, means you can drop it in like 5 min flat since Its only 4 bolts and the shifter. Lining it all back up is much more tedious than just taking it from the bell housing though so.. 6’s?

T-case is even easier, got that re-installed in about 10min!
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I had to cut the floor a little more to fit the shifters in, but in all it was pretty simple.

Then I shuffled the jackstands around so I can mock the rear links soon. Planning to build the crossmember link brackets.. again.. tomorrow. I bought some and was going to modify them, but in the end I felt my modifications would make them much weaker than if I built them fresh, so that’s the plan. See how it goes.
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post #349 of 386 Old 02-07-2020, 08:11 AM
lovett86
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I did a hand full of mustang's that way at my old house. When your dealing with long tube headers it makes a big difference.

its a rusty one

https://www.jeepforum.com/forum/f22/90-yj-frame-swap-build-up-1434246/
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post #350 of 386 Old 02-07-2020, 06:46 PM Thread Starter
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Well progress today. Had to drive all over town picking up stuff, but it was worth it.

First off I addressed the crossmember. When I built it originally it was only meant to handle d44’s and 35-37’s, not tons and 40’s. Since the bottom is now clear of brackets I decided to plate it. I picked up some .188 flat stock and whipped up this bad boy.
6904c08c-1296-4e82-9f41-ab810307c4e2_1581125005904.jpg
Then slowly welded it on.
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Unfortunately I was waiting on consumables for the plasma cap this was laboriously hole-sawed. (They showed up like 20 min after I finished this)

I also used got some .25 flat stock to re-make my lower link brackets (also put the cutoffs to works since no plasma bits) I was pretty happy with the results.
5dbccd17-b90d-431e-86d9-3fb53fd0d669_1581125072495.jpg
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I’ll plate the tops later when I finish weld it, but I learned last time to tack until it’s basically ready to run.

I got it Mack installed and I’m happy with the clearance!
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Lots of room for activities.

I also tackled the seat mounts. Originally I had planned to run flat stock with the seats mounted to them, but as I looked at my mounting width I realized I might get away with something else and picked up some trick tabs at the local 4x4 shop. Miraculously my tube mounting width was exactly what it needed to be, I couldn’t have done any better if it was the original plan, so I talked them in and burned them on. Still need to do the other side.
950c41c1-9169-4c4d-8b63-ce36cc4b6fc9_1581125156411.jpg
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That’s where the pictures stop, but there was a little more I did. Mostly mocking up the rear axle. I had to pull it out and knock the lower brackets off as well as the truss as it was leaned too far with the pinion set correctly. Got it all mocked back in at ride height and cut the upper link tubes. I’m hoping to get tube for the lowers tomorrow.

Overall I’m stoked, I feel this version is looking much more clean and professional (ish) then the last one, experience pays off.
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post #351 of 386 Old 02-07-2020, 07:01 PM Thread Starter
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I should mention, the change with the crossmember does change my link geometry. I’ve run some link numbers though and I’m still where I want to be, under 100% AS, but that figure did go up. I just have to run it in the top hole for the upper link. If I find it really is problematic then I’ll just change it later, but those upper link towers would be a pain to change so I’m just gonna run it for now, I have just over 5” of separation at the frame, originally I had 7”.
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post #352 of 386 Old 02-10-2020, 06:13 AM
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Looking good.

87 YJ, 5.7/TH350/NP241, Custom 4 link/ Radius Arms, ADS Nitrogen Shocks, 35" Cooper STT

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post #353 of 386 Old 02-10-2020, 09:47 AM Thread Starter
tbunch
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Spent some time on Sunday getting the axle mocked in! Getting exciting now. I tacked all the link ends in and put it all together. Cycled the suspension and took some pics! (And goofed around with absurd flex that can’t actually happen...
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Then I did some detailed measurements and put them in the almighty 4link calculator. Here’s the results:
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In all I’m pleased. If I could start again I’d increase the frame seperation, but since I had to change the crossmember for clearance unexpectedly I didn’t have the foresight to just tack things in place. I can cut it up later if it’s bad, but the numbers give me enough confidence to run it like this.
Now I can seal the deal and burn it all in for good!
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post #354 of 386 Old 02-10-2020, 03:11 PM
lovett86
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Looks good.

its a rusty one

https://www.jeepforum.com/forum/f22/90-yj-frame-swap-build-up-1434246/
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post #355 of 386 Old 02-14-2020, 11:42 AM Thread Starter
tbunch
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Couple little things. Since it was part of my last build version I re-designed my crossmember support. It was fairly simple because the spacing just happened to work out in my favor. Used my old bracket to make a new template, did some brainstorming with chalk on the floor and ended up with this.
9845ac7a-16b6-4aa1-8b36-cc66feb93077_1581704852086.jpg
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Basically mounts via a poly bushing to the crossmember. I have a cage tie in kit that I was originally gonna use but changed plans on. I added some gussets and got it all welded together.
8fe36215-eb01-4c01-9aad-b85f787fe9bd_1581704908638.jpg

With that wrapped up the crossmember is basically done. I acetone it for paint and put it inside so it will warm up enough for the paint to stick.
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I’m really happy with the way it came out, however, I’m questioning if it will be strong enough. It mounts using 4, grade 8, 3/8 bolts all the way through the frame, with the holes in the frame sleeved, but the footprint on the mountings feels small relative to the weight and size of the running gear. I have the advantage that I’m not running big power, but I’m picturing coming down hard, backwards off an obstacle and all the vehicle weight and stored energy being shockloaded into that bar, and all of a sudden it doesn’t feel so beefy... I’m debating adding gussetting from the crossmember to the frame at an angle as one option, or possibly running a tube with bushing ends from the crossmember to the transmission crossmember to help with the twisting and lateral force. I may also just be overthinking it... I don’t know anymore.. but by that same token I’ve also toyed with the idea of totally rebuilding it with .25 mega huge square tube or something absurd! But I’d cry a little if I did that since I’m quite proud of the workmanship on this piece. But looks won’t save me if it’s weak.
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post #356 of 386 Old 02-14-2020, 12:10 PM
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I think that looks plenty beefy. If you hit hard enough to break that thing loose, youíve probably got bigger problems.

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post #357 of 386 Old 02-14-2020, 12:29 PM Thread Starter
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Originally Posted by NashvilleTJ View Post
I think that looks plenty beefy. If you hit hard enough to break that thing loose, youíve probably got bigger problems.
That gives me some reassurance. I've seen both trains of thought; the guy that built his out of 1/2" thick unobtanium, plated with kyber crystal and gusseted in 37 places with dark magic and ancient Indian enchantments that folded like tissue paper, and then the guy that built his out of toilet paper rolls and Elmers glue, but has been holding strong for years with 54" stickies, dumptruck axles and a space-shuttle engine.

I can appreciate your input with the attention to detail on your build!
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post #358 of 386 Old 02-15-2020, 10:24 PM Thread Starter
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Little more progress today. Added some gussets to the crossmember to brace up the links, seems I didn’t take pics though. Then reinstalled it with all the bolts and actually tightened it all down for the first time for real. It may come out again before I’m done, but it’s almost ready.

Then I took on some small sidetrack projects. Worked on the 14b mini shave. I cut the bottom lip mostly off, the. Ground smooth. I may still cut more, but I’ll be into the bottom bolt hole if I do., I may also just leave it like this, and if I end up hanging up on things I can do a real shave kit or shave cover later.
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I also cleaned up and painted 2 of the beadlock wheels, then mounted one of the tires up. I think I’m ditching the yellow this round since I pulled all the yellow stuff off. I love yellow, but it felt a little hot-wheels I’m my application. I toyed with the idea of going yellow cage, links, wheels and bits and calling it the McKrawler, (last year my buddy said the red and yellow made him think of McDonald’s) but decided against it. Either way, I don’t think this looks bad.
81e2f5be-c743-4423-8c97-0eb4d5e2d935_1581830061382.jpg

Lots of other small less fun stuff like replacing bearings and parts, but if all goes well the rear coilovers should be mounted this week!
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post #359 of 386 Old 02-16-2020, 07:58 AM
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I think Iím ditching the yellow this round since I pulled all the yellow stuff off.

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post #360 of 386 Old 02-18-2020, 08:27 AM Thread Starter
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Hey hey hey now! I didn't say I don't like the yellow.. (hard backpedaling).. actually yellow is my favorite color, but with the red it was a bit much, and the red was there first. Maybe once I get all other aspects really dialed in on this thing it'll get a proper paint job and I really might go full yellow.
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