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post #436 of 498 Old 05-15-2020, 07:17 PM Thread Starter
tbunch
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Lots of pics for this one. Been busting my butt I n this thing to try and get it done.

First off was wrapping up the double shear. Got some new wire, built a gusset and burned it all together. Ended up with this.
b4635bb6-fc0e-4e45-9aea-63ec6456a2a2_1589590712741.jpgeeaad694-2700-4d09-b38f-182dbf060c1a_1589590691966.jpg

It could be prettier, but it will get the job done. I learned later in the day I will have to grind the outside of it down a hair as it touches the rotor as well.

Then I did the steering shaft. With the box relocation I had to redirect the shaft under the radiator and off the frame rail. Picked up a steering shaft bearing, used an existing 3/4” hole in the frame and welded a nut to the outside. Then used a second lock it to make sure it stays put.
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Steering joint and cut up some old steering shaft and we were in business. Need to snip the locknuts down as they hit the track bar at full lock, otherwise no clearance issues.

Then lots and lots of painting. I’m basicay hoping this will be the final install for some items like the front link mounts and the axle. But most of the links are probably in for good now.

Lots of hours of painting, wrenching, fitting with torquing beadlocks, wrestling giant tires and so on and I accomplished my goal of getting it onto its own weight (in front).
397dfa3a-4066-4dc2-a4a2-aff17c812f7a_1589590821412.jpg97422c7a-2b0b-4eec-ab58-ee9b8c5acfab_1589590775831.jpg23b745ca-a578-4575-b6e1-ea97220424cf_1589590792476.jpg9ae003b2-dd7b-4cc0-ae62-48a37c236a9a_1589590837955.jpg2e1be95f-c711-455a-b455-e564fffefd45_1589590854190.jpg

I’m pretty happy! Everything seems to clear exactly as it was planned so far. I had to mock the hydro ram up and pull the diff cover a couple times for clearance but eventually got it right.

My weight estimate for the front corners seemed to be almost exactly correct. I estimated 785lbs. The upper spring (rated at 150lbs) compressed to exactly 11 inches meaning I have a corner weight of 750, pretty dang close. This puts almost 7” of shaft out (if you count the rubber bumps at the bottom. I’m on the fence if I want to keep the springs as they are, or go to a 200lb upper. That would give me a little more leeway as weight will go up with passengers and fuel.

Either way I like the way it looks and it’s nice to reach the milestone of having one end down. Gonna focus energy on the cage and tub now so I can get the rear end together. I can’t really check for tire clearance since the back is on jack stands and doesn’t like getting flexed without falling off and killing me. More to come!

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611333C4-AF5C-4072-8407-C89AE9A91CBC_1589590808267.jpg  
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post #437 of 498 Old 05-17-2020, 06:54 PM
lovett86
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Havent been on the forum that much lately. I see your still crushing it on the jeep. It looks great, keep it up.

its a rusty one

https://www.jeepforum.com/forum/f22/90-yj-frame-swap-build-up-1434246/
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post #438 of 498 Old 05-17-2020, 08:17 PM Thread Starter
tbunch
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Thanks lovett86, not a lot of folks in the forums anymore anyways, but I like having a record of what I’ve done somewhere. Probably gonna need to print a copy or something so it doesn’t all disappear one day.
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post #439 of 498 Old 05-17-2020, 09:52 PM
lovett86
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Were putting in a 25x40 shop at the house hopefully this fall, fingers crossed. My jeep has been sitting outside the last couple of years so it hasn't seen alot of action. If all goes well il be back in business with it.

its a rusty one

https://www.jeepforum.com/forum/f22/90-yj-frame-swap-build-up-1434246/
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post #440 of 498 Old 05-20-2020, 05:01 PM Thread Starter
tbunch
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I’m jealous Lovett86!

Things keep moving on in my little messy garage thought!

The next phase is getting the cage completely finished so I can pull it for paint and spray the tub with bedliner. Looking it over I wanted a little more strength at the joints so I went gusset crazy and put the hole saw and the plasma to work.
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There are even a few more I didn’t get in the pic that will reinforce where the coilovers mount. I’m also redoing the mounting tabs on the tube for some much longer ones that will be stronger. I finally retired my original Milwaukee hole saw that has done every single notch on this thing so far, plus a few others before. I worked it hard and it just dulled out.

I also got most of the cage/slider tie-in work done. Because of the irregularities in the frame shape and the fact that the tub is a little beat up they aren’t perfectly matched front to back, but they are pretty close to symmetrical side to side so it look balanced.
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Lots of grinding and cutting and tacking to get things so sit tightly. Should be very strong though.

I had one casualty as my very first porter cable grinder seems to have finally bit the dust. I’ve beaten the piss out of it for almost 5 years on everything I’ve built. I have others, but I was starting to think it might live forever!

Took tomorrow off so I’m hoping I can do all the finish welding to pull the cage. Quite excited to be near that point!
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post #441 of 498 Old 05-20-2020, 07:42 PM
NashvilleTJ
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Damn, Tbunch - you are the tube king!

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post #442 of 498 Old 05-20-2020, 10:54 PM
GraySkies
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Quote:
Originally Posted by tbunch View Post

I had one casualty as my very first porter cable grinder seems to have finally bit the dust. Ive beaten the piss out of it for almost 5 years on everything Ive built. I have others, but I was starting to think it might live forever!
You didn't list symptoms, but could it just be the brushes wore out? If it's a Porter-Cable, they are likely readily available, and are probably less than 10 bucks...

Michael
Western Washington
'66 CJ5 under construction
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post #443 of 498 Old 05-21-2020, 06:05 PM Thread Starter
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Thanks, not the tube king, but I’m learning lots!

As far as the grinder, I’m guessing it’s the brushes, I’ll play with it later Since the priority is finishing this thing.

As for today, I got where I wanted to be. I spent a good deal of time cleaning the gussets up and getting things to fit, then a lot of time finish welding everything. Under the Jeep was a pain and I really would love a lift. Once I was satisfied I called a couple buddies and we wrestled it out. It was not easy coming out, very very tight, but it came out eventually.
47beb6f7-4da0-4f2b-b322-fceb9001d1b8_1590105754521.jpg
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Not a lot of change you can see, but it was a ton of work. I’m quite happy with the cage, just debating if there is anything I want to reinforce before I call it good. As of now there are a few finish welds left and I could paint it.

Going out of town for a couple days, but then I’ll be right back at it.
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post #444 of 498 Old 05-22-2020, 02:35 PM
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Looks awesome!
I see you still using the Harbor Freight jack stands in spite of the recall
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post #445 of 498 Old 05-22-2020, 04:26 PM
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Dont be jealous until its built. The bank and the county might tell me no. Which would be a huge disappointment since the wife is saying YES. I've been working out of a 16x25 garage that's absolute crap. Your progress is looking awesome as usual.

its a rusty one

https://www.jeepforum.com/forum/f22/90-yj-frame-swap-build-up-1434246/
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post #446 of 498 Old 05-22-2020, 07:10 PM Thread Starter
tbunch
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Quote:
Originally Posted by gyaniv View Post
Looks awesome!
I see you still using the Harbor Freight jack stands in spite of the recall [IMG class=inlineimg]/forum/images/JeepForum_2016/smilies/tango_face_grin.png[/IMG]
I know, I live on the edge. These are the ones I’ve had for like 6 years, I think the recall ones are different. Either way they don’t reach anything I own so I can’t do much with them beyond prop up the cage or axles.

Lovett, I’ll cross my fingers for you. I’m fortunate with my garage. It’s no shop, but it’s pretty dang big for a home garage setup. Next place we get we’ve said either needs a shop, or space to build one eventually!
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post #447 of 498 Old 05-29-2020, 07:39 PM Thread Starter
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Well, I’m pretty loopy from fumes, even with a respirator. I’ve been prepping all week then painting and spraying all day.

I had to finish the welding up, not tons, but all the areas I could t reach in vehicle. Then I welded on the passenger seat mount and all the harness tabs. Then lots of little cleanup, sanding and degreasing, then a bunch of coats of self etch primer and then what felt like 50 coats of rustoleum hammered. They call it gray, but it’s silver, I knew this going in so I like it.

b60f9c34-bcde-4686-9617-ffe07457599a_1590802250650.jpg
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I also changed out the rear coilover mounts to these wider ones that I feel better about.
1e1b898e-0202-4fef-b28d-382b2a9ebd1d_1590802331038.jpg

The. Lots of sanding and prepping the tub for bedliner. I had to do a little more patch welding and cleanup, but not tons. Then I added seam sealer over the weld seams and edges to make just finish it up, then sprayed it with raptor liner, same as the front of the tub.
dd593458-8466-49f9-81ba-ca6ee93ac0ff_1590802356977.jpg
Looks good, once this cures I’ll round up some buddies and we’ll plop it back in. Hopefully before the end of the weekend. Excited to see it finished!
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post #448 of 498 Old 05-30-2020, 07:05 AM
NashvilleTJ
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Thats going to look sweet.

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post #449 of 498 Old 05-30-2020, 07:31 AM
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Looks great dude!

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post #450 of 498 Old 05-30-2020, 11:43 PM Thread Starter
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Thanks all! The liner seemed pretty solid and the instructions say light duty after 24hrs so I rounded up the neighbors and we plopped it in. Mich easier going in than out since I cleaned up and rounded all the base plates. I had originally left them as squares with sharp edges that were catching on everything. I’m happy with it!
483639dc-1369-4349-a5ce-0da319efd9c6_1590903530626.jpg625f22ab-1cf7-4af7-a0e3-6e75778beb3c_1590903511305.jpgfa6be77f-a1d5-426d-8bd1-d1923d340f9d_1590903491757.jpg

Doesn’t seem to have warped from the last bits of welding as the holes basically line up. Haven’t bothered to bolt it up. I truthfully had a massive headache all day I can only attribute to a spray paint hangover.. that and it was almost 100 degrees here already... worth it though!
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