Just another Budget Build...

[99SJ_Ex]

So I've decided to put together a little time-lapse of how my college-paid BB is going...

This is about a month after I got it...
http://i303.photobucket.com/albums/nn151/exodus99wi/Jeep%20Project/TheCreepSummerof2007.jpg

After I installed my sliders...
http://i303.photobucket.com/albums/nn151/exodus99wi/Jeep%20Project/sliders.jpg

WF09 - The one time I got stuck... :S
http://i303.photobucket.com/albums/nn151/exodus99wi/100_0088.jpg

Installation of RC 3in w/AAL and 31in BFGs
http://i303.photobucket.com/albums/nn151/exodus99wi/Jeep%20Project/100_0308.jpg

Now in its most current state with JCR Rack, Hella 500/500FF, RR SYE, ZJ DS in back...
http://i303.photobucket.com/albums/nn151/exodus99wi/IMG_0380.jpg

My Wish/To-Do list:
Bumpers Frt & Rr
RC Full Leaf-packs
MTRs or KM2s
B&M SuperCooler
4.10s Frt & Rr with least Frt Locker

[99SJ_Ex]

I bet I could have given Aaron a run for his money on the Pic of the Month contest... :banghead:

[XJ&CHZ4ME]

looking good Flash....I like to se these builds come together...and at some point there are some rigs that cross the line and look like my hunk of crap :D

[CherBear]

I am a big fan of that light bar.

[vincepru]

looking good Flash....I like to se these builds come together...and at some point there are some rigs that cross the line and look like my hunk of crap :D

im following that line :eye: i had a pristine 98 limited. now its a pos 98 limited lol

[99SJ_Ex]

This one's by far from pristine, although by then end of the summer, it may have some new accessories... All depends on how fast I can CAD everything up... ;-)

[99SJ_Ex]

I am a big fan of that light bar.

I am too, however, the Hellas JCR recommends need a shim system to work properly.. Right now I have a bolt acting as a spacer between the mounting tab and the bracket for the light, The covers are basically wedged between the two, but I will be also taking a dremel to those so they are right-side up... I think the light tabs should have been welded further down on the cross pipe so aiming the lights is easier/better... Just my $0.02 on the matter...

I also gotta figure out how I'm going to mount my 48in Hi-lift (Farm Implement version from Fleet/Farm) cause I don't wanna bang the crap out of the rack/my roof/rain gutter...

[XJosh95]

Kinda jealous of what your college budget can do in a year compared to my 45+ hour/week budget did for me over the last year. Lookin good!

[REWSTER]

Kinda jealous of what your college budget can do in a year compared to my 45+ hour/week budget did for me over the last year. Lookin good!


X2

i really like the rack, it makes mine look like a cheep piece of crap, I think its the first i have seen on a 4dr

[99SJ_Ex]

X2

i really like the rack, it makes mine look like a cheep piece of crap, I think its the first i have seen on a 4dr


Yeh, when I first got it, I actually had doubts about how well it would look, but once I painted it and had it sitting up there, it looked really good...

I tried to aim the lights last night but I need to make a spacer in stead of the bolts so that the bracket for the light sits flush on the rack tab. I also found out that after I wrapped the wire conduit with electrical tape, one of the center spot lights doesn't work... Looks like I'll be outside again later today...

[99SJ_Ex]

So its been awhile since I updated this, and a lot has/is going on... Going to start with a list of whats going on (courtesy of another build tread for the layout, thanks VAhasnoWAVES!) and then some of the latest shots from the last trip to Apple Valley Farms in WI.


(BOLD = have)
(GREEN = installed)


Front:
- 3.55 D30
- Dana 4.10 D30
- Ball Joints
- 3.5 RC Coils
- 4in RC Disconnects
- 1 3/4 Poly Spacers
- Dodge Durango Steering Gearbox
- Bilstein 5100 Series Shocks
- IRO HD Track Bar
- Short-arm Upgrade (Undecided)


Rear:
- 3.55 C8.25
- '00 Ford 8.8 w/4.10, Posi, Discs
- Rugged Ridge HD SYE
- ZJ Drive Shaft
- Bilstein 5160 Shocks
- Extended Shackles


Tires:
- 31x10.5R15 Cooper Discoverer STT
- Craiger Ds w/offset

Armor & Extras:
- 24in 'Muffler' Straightpipe
- JCR Low-Pro Roof Rack
- Hella 500s
- Hella 500FFs
- HiCountry 4x4 Frt Tow Pts w/D-rings
- AJ's Super Sliders
- Gas Tank Skid
- T-case Skid
- CA Mini-skids

https://lh3.googleusercontent.com/--Cm0A8Isfc8/Tj9f13uEq2I/AAAAAAAAABY/cULGht4-fa0/184159_2317561538539_1234518151_32846701_386978_n. jpg

https://lh4.googleusercontent.com/-O6qGE7fc25g/Tj9f3MY29pI/AAAAAAAAABk/atyqjpRsr1s/s720/216819_2317715062377_1234518151_32847094_1033879_n .jpg

https://lh4.googleusercontent.com/-BiRAqGvRiwU/Tj9f38xvlWI/AAAAAAAAABo/V_p02jUYbH0/s720/216904_2317711542289_1234518151_32847083_3865216_n .jpg

https://lh6.googleusercontent.com/-AJyzhQQTbjc/Tj9f4TYIZnI/AAAAAAAAABw/sVk_uAXvMf8/s640/223843_2317577858947_1234518151_32846735_4507007_n .jpg

https://lh5.googleusercontent.com/-7Lm9pK-yHaM/Tj9f4QDLJaI/AAAAAAAAABs/xBfG6kAk8PM/s640/253241_2317604939624_1234518151_32846814_4305973_n .jpg

https://lh4.googleusercontent.com/-64hrW5dvWB4/Tj9f5DqgW1I/AAAAAAAAAB0/84_I56j3pqI/s640/284974_2317688781720_1234518151_32847011_4280988_n .jpg

Finally, wanted to show that my Fiance was there, she did enjoy it, and she should be in attendance at WF2012!! In Order from Left to Right: Rebecca, Me, Phil(Max-Bilt)
https://lh6.googleusercontent.com/-dGDSqxKwxzo/Tj9f5USCuDI/AAAAAAAAAB4/KSZfx_Hp3cQ/s720/284979_2317488776720_1234518151_32846550_5033198_n .jpg

[XJ&CHZ4ME]

were you wheelin in flip-flops?

I like your style.

[99SJ_Ex]

were you wheelin in flip-flops?

I like your style.

Yes I was!

I destroyed 2 pairs of shoes that day and was down to flip flops, in the end those we w gone as well... The drive home was interesting and I believe someone reported 'BigFoot' tracks in the park later that day... :shhh:

[VAhasnoWAVES]

great pictures. looks like a blast!

on the shoes bit... i see people bring crappy shoes, bring boots... and in the end, they still end up dirty. i use flops as well. take them off and at the end of the day hose off from the knees down and put 'em back on. but ive practically got "indian feet" as someone once told me. i can walk on hot pavement, rocks, hot sand, sticks, even through pricker bushes. your results may vary.

what school do you go to?

[99SJ_Ex]

I just finished my B.S. in Technology Education at University of Wisconsin - Stout in Menomonie.

And I had boots, but Friday night I left them outside the tent and it rained all night... I emptyied about a gallon out of each the next morning so I rly didn't want to wear them...

[99SJ_Ex]

O. M. G.

If you haven't done a Durango Steering Upgrade on your Cherokee or TJ, you NEED to do it!!!!!!!!!!!!!

I followed this article http://www.cherokeeforum.com/f51/durango-steering-box-upgrade-3805/

I can turn my steering with 1 finger! I can't wait to get on the trails!!!

[VAhasnoWAVES]

night and day difference? i dont get it, i can cruise down the highway with one finger no problem. i suppose id have to drive one to see what all the hype is about.






but she prefers 2 fingers with a "come here" motion.

[Fore Wheeler]

I don't understand how it can be faster lock to lock, but turn's easier?

keep us posted once you use it off road.

Fore 'been watching' Wheeler

[99SJ_Ex]

I will try and hit some form of trail this weekend to let you know... And yes night/day difference (to me at least)... And As far as ease of turning, its effortless even sitting in park. I did notice that when looking where the lines go into the box, on the Durango box there is a spring loaded ball while the Cherokee box lacks spring loaded ball... I don't know if that effects the pressure in the box or not...

Taking a vice grip I clamped onto the input shaft of the Durango box and noted it takes exactly 3 turns to go lock-to-lock whereas the Cherokee box takes 3.25 to 3.5 turns (at least mine does...)

[99SJ_Ex]

Drove 3 hours, 157 miles this past weekend Down to Cedar Falls Iowa for Jeep Mania. Did a little bit of off-roading ('trail' was greener than Green at WF) and so far I am really impressed with this Durango Box! Drove straight and true down the road. In rocks I had very minimal overcompensation to deal with as the box took the brunt of the bumps and bounces.

I still have to beat on it on the trails really hard and see what it does, but overall everything is looking awesome so far!

[99SJ_Ex]

So I picked up the steel forms of my front and rear bumpers today... cameraphone pics to be posted tonight...

[99SJ_Ex]

So I have always been Ooogling over the bumpers I've seen on Jeeps and have known for quite some time that I needed these. I currently run the factory 2in receiver on the rear and HiCountry 4x4 Tow points up front. However, as some of you have seen, The H.C. 4x4 brackets left much want in a better towing point. So after doing some work at the school I'm student teaching at, I was offered the metal for both my bumpers as payment!

My schools technology metals/welding lab has a 4ft X 4ft Plasma cutting table, various welders, plasma cutters, etc...

I first started out by going to the Steel Supplier for our school to pick up two 60in x 12in sheets of 3/16in steel in which I was going to CnC out the bumpers...
http://www.naxja.org/forum/picture.php?albumid=324&pictureid=1993

After realizing I would save myself some time and $$, I decided to have the Tom and John make several bends in the sheets so my cutting and welding would be reduced...
http://www.naxja.org/forum/picture.php?albumid=324&pictureid=1994

For the Rear bumper, the face would be approx 5 1/4in (measured on the inside diameter) the top and bottom plates would be bent at 90 degree angles. The Front bumper's face would again be 5 1/4in I.D. and a 90 degree bend for the top. However, to make it look a little 'fancier' than a regular square tube bumper, I had the bottom plate only bend to a 45 degree angle.
http://www.naxja.org/forum/picture.php?albumid=324&pictureid=1995

My two 'bumper molds' loaded up and ready for the trip back to school...
http://www.naxja.org/forum/picture.php?albumid=324&pictureid=1996

I bought JCR's bumper tie in brackets for the front bumper as well as their D-ring weldable tabs... (pics later) And began setting up the front bumper. The plan is to have the ends tapered from the bottom up and also, if I can get the angles right, tapered from the front towards the back. Both these tapers will begin just outside of the d-ring tabs... (You can see the rough chalk lines in the picture)
http://www.naxja.org/forum/picture.php?albumid=324&pictureid=1997

I also picked up two 2in receiver tubes (6in long) from Fleet Farm for $8 a piece. One will go in each bumper. these will be used in the future to possibly hold a winch plate, and of course, pulling/pushing trailers...

Friday I hope to start cutting out the wedge pieces in the bumper so that I can bend the tapers and tack weld them... I'm hoping to have the front bumper done no later than the end of next week as I will only be working on it during my breaks in teaching...

[XJ&CHZ4ME]

sorry I did not get back with you sooner on the bumper dimensions you asked for. I honestly forgot. if you still need some let me know. I am excited to see how these turn out for ya. :thumbup:

[Sirus789]

looks good, reminds me of my old XJ, i did the same thing you did. That little XJ wasnt big or badass but it went everywhere. Keep up the good work! I had those coopers on my XJ also, tires make a difference.

[99SJ_Ex]

sorry I did not get back with you sooner on the bumper dimensions you asked for. I honestly forgot. if you still need some let me know. I am excited to see how these turn out for ya. :thumbup:

Actually if you could send me the dim for the width between the bumper mounts that would be great! I will be cutting slots through for the d ring tabs so that I can weld them to the mounts and then the mounts are bolted to the tie ins and everything is connected together all nice and tight. Was too busy today teaching the youngin's so I'll take a crack at them again Monday.

P.S. on the bumpers you make tyler, when mounting them to the jeep, does it go chassis jcr tie in, bumper mount? Or, chassis, bumper mount, jcr tie in? I got their redesigned tie ins to I also have that plate on the inner side of the chassis...

[XJ&CHZ4ME]

my mounts are the tie in plates. They are one long piece that has all the holes on it so I dont have to do the sandwiching like added tie in plates do. I will shoot you a PM or a text this weekend with the measurements. They are in the shop and I am on the road today. :thumbup:

[99SJ_Ex]

Progress Made!

So being a student teacher does have responsbilities... Like teaching class every now and then... However, my Cooperating teacher did give me Tuesday and Wednesday to get a good chunk done...

First off I took the stock bumper off, relocated the horns and tried to relocate the vacuum reserve but the line broke so I just tossed it in back and put a screw in the line till I can fix it later...
http://www.naxja.org/forum/picture.php?albumid=324&pictureid=2000

I then removed the old HiCountry 4x4 Brackets and upon doing so, realized I had stripped the bolt right behind the driver side sway bar mount bolts. I figure will all the other tie in bolts on the JCR brackets, I can afford to not install one...
http://www.naxja.org/forum/picture.php?albumid=324&pictureid=2001

One issue I did have was a loud clunk when I turned hard right or left... After close inspection (not so close) I realized that when I installed the Durango Steering gearbox, I over-tightened the box bolts and bent/cracked the steering box brace... So I made a new one!
http://www.naxja.org/forum/picture.php?albumid=324&pictureid=2002

I powder-coated the JCR tie in brackets before I installed them, was it necessary? Probably not, but they sure do look good!
http://www.naxja.org/forum/picture.php?albumid=324&pictureid=2003

After deciding on the taper I wanted for the ends of the bumper, I plasma cut off the 'folded' section...
http://www.naxja.org/forum/picture.php?albumid=324&pictureid=2004
http://www.naxja.org/forum/picture.php?albumid=324&pictureid=2005

I was just going to weld the piece back on at a 45 degree angle, but realized making it a 90 degree angle made the bumper look a lot more aggressive...
http://www.naxja.org/forum/picture.php?albumid=324&pictureid=2006

Tack-weding in the filler plate to connect the two angle sections.
http://www.naxja.org/forum/picture.php?albumid=324&pictureid=2007

Capping the ends in, I was thinking about 'wrapping' the sides, but decided that if I ever went hog-wild with fender cutting it wouldn't look good...
http://www.naxja.org/forum/picture.php?albumid=324&pictureid=2008

80% of the joints welded, 30% ground down, 2in receiver placed in hole cut with plasma torch.
http://www.naxja.org/forum/picture.php?albumid=324&pictureid=2009

Bracing for the receiver installed, bumper mounts tacked for proper placement.
http://www.naxja.org/forum/picture.php?albumid=324&pictureid=2010

Whats Left
Plot and drill bumper mount holes
Finnish welding bumper mounts on
Cut holes and weld in Shackle Tabs
Weld in a couple more gussets for reinforcement
Finnish grinding welds
Prime and Paint


SO SORRY for this post being sooooooo long!!!!

[Fore Wheeler]

Liking this a lot, nice work.

Can't wait to see it in march.

[99SJ_Ex]

Liking this a lot, nice work.

Can't wait to see it in march.

Thanks! Hopefully I will also have a matching Rear bumper by then as well... I've been so focused on the front that I haven't had much thoughts on the back other than incorporating a receiver in that one as well...

I am also debating if I should try and make a 'pre-runner' style hoop for it or leave it as is... I think adding the hoop might give it a 'too much going on' look, but at the same time, in this neck of the woods, would be beneficial against deer...

[962door]

It looks really good!

[Fore Wheeler]

I like the looks of hoops, and they have function of keeping deer off your paint as well as giving strength to the bumper. Just don't make a stinger, those are silly.

[99SJ_Ex]

Well no hoop for the time being... but easily added at a later date...

I promise there's more pics, of the bumper process as well as the huge build I did on the heep oh Monday, but they are all on my phone and I haven't had time to upload them yet...

[99SJ_Ex]

Finally I've had time to update the finished product, as well as throw in some photos of the 18hr project I completed during/after the bumper install! So here it goes!

**Note: All photos were taken with a cell camera and therefore lack super good details, but y'all can't see anyways so it shouldn't matter much... :gee:

Using the plasma torch, I cut out slots for the D-tabs right next to the bumper mounts that I had tacked in.
http://i303.photobucket.com/albums/nn151/exodus99wi/Jeep%20Project/photobucket-2058-1325169674095.jpg

From the back you'll see that once I inserted the tabs, I will be able to weld the tabs to both the bumper and the mounts, this creates a super strong tow point by having everything tied together.
http://i303.photobucket.com/albums/nn151/exodus99wi/Jeep%20Project/photobucket-2206-1325169700490.jpg

Mocking up the tabs so they are in the proper position before welding.
http://i303.photobucket.com/albums/nn151/exodus99wi/Jeep%20Project/photobucket-3082-1325169726609.jpg

Here you can see the welds on the back side and how everything is tied together. Note the tabs are also welded 360 degrees on the front of the bumper as well, no chances taken here!
http://i303.photobucket.com/albums/nn151/exodus99wi/Jeep%20Project/photobucket-560-1325169751181.jpg

The final finished product before grinding, sanding, priming, and painting...
http://i303.photobucket.com/albums/nn151/exodus99wi/Jeep%20Project/photobucket-2971-1325169777632.jpg

I used RustOleum Self-Etching Primer in 3 light coats, followed by Velspar Zinc Primer to make sure I had the best protection I could get for under $15... You can also see some goodies that I got :)
http://i303.photobucket.com/albums/nn151/exodus99wi/Jeep%20Project/photobucket-2018-1325169804684.jpg

I used RustOleum Industrial strength Flat Black paint on the entire bumper because I figured it would be the easiest to touch up as well as it will fit the paint scheme my jeep will hopefully undergo later this year...
http://i303.photobucket.com/albums/nn151/exodus99wi/Jeep%20Project/photobucket-2137-1325170005828.jpg

Lining everything up in the shop...
http://i303.photobucket.com/albums/nn151/exodus99wi/Jeep%20Project/photobucket-3224-1325170047474.jpg
http://i303.photobucket.com/albums/nn151/exodus99wi/Jeep%20Project/photobucket-1878-1325170073250.jpg

The final Product mounted up and ready to go!
http://i303.photobucket.com/albums/nn151/exodus99wi/Jeep%20Project/photobucket-1934-1325170099437.jpg
http://i303.photobucket.com/albums/nn151/exodus99wi/Jeep%20Project/photobucket-491-1325170123685.jpg

And the front bumper is now complete! There will be several modifications in the future including: drill&tap hole for flag mount; drilling holes and/or welding on hoop for driving lights. But for now it is done and work will soon begin on the rear bumper!

[99SJ_Ex]

As seen in a picture above, I recently found that my upper control arms were badly bent causing my front axle to be not aligned and so on and so forth.
http://i303.photobucket.com/albums/nn151/exodus99wi/Jeep%20Project/photobucket-3112-1325172606046.jpg
http://i303.photobucket.com/albums/nn151/exodus99wi/Jeep%20Project/photobucket-945-1325172635825.jpg

I decided to pick up new adjustable uppers from T&T Customs, as well as an adjustable track bar and track bar mount since I knew I would be raising my jeep a couple more inches in the future and still had the OE track bar that was also causing my some tracking issues. For that I purchased a R.E. adj track bar. All this I purchased through Phil at Max-Bilt along with some other misc stuff seeing as I planned on doing the whole project at his place.
http://i303.photobucket.com/albums/nn151/exodus99wi/Jeep%20Project/photobucket-2018-1325169804684.jpg

Since I was doing so much on the front end, I figured I might as well work on the rear/gears that I had been planning and ocasionally buying parts for, so for the rear I picked up a Ford 8.8 out of a 2000 Ford Explorer that had disc brakes, a LSD diff and 4.10 gears. Picked it up at a local salvage yard for $125
http://i303.photobucket.com/albums/nn151/exodus99wi/Jeep%20Project/Ford88.jpg

I bought some d30 gears off a guy on ebay, but when they got to me low and behold they were standard cut and not reverse, but thats a story for another time... For now I am still on a lookout for reverse cut 4.10s for the d30...

Pulling my Heep in onto Phil's new hoist...
http://i303.photobucket.com/albums/nn151/exodus99wi/Jeep%20Project/photobucket-2035-1325169829470.jpg

Instead of working on it in 3 different sections over 3 different days, it turned into 1, 18hr long project... Should have been shorter, but we had to run to the parts hut a few times to grab things we forgot about...
http://i303.photobucket.com/albums/nn151/exodus99wi/Jeep%20Project/photobucket-2928-1325169860199.jpg

Now, for some reason I lost a bunch of pictures of the majority of the project, but the remainder are those of the rear axle...

Getting it lined up so we know where to weld the mounts on...
http://i303.photobucket.com/albums/nn151/exodus99wi/Jeep%20Project/photobucket-1802-1325169885267.jpg

Driverside caliper we ened up using the passenger side stock brake hose, we simply welded the metal tab on it to the spring perch...
http://i303.photobucket.com/albums/nn151/exodus99wi/Jeep%20Project/photobucket-1837-1325169907201.jpg

Passenger side brake hose we had to run to the parts hut for... We simply asked them for a rubber hose that had the ford banjo block on one side and 3/16in brake fitting on the other side. Again we mounted it to the spring perch.
http://i303.photobucket.com/albums/nn151/exodus99wi/Jeep%20Project/photobucket-3145-1325169933749.jpg

We decided it would be a good idea to mount the shock mounts up flush with the axle instead of hanging down under the axle like the OE ones were... After the project we realized we didn't think that through as we were still using the shocks for a 3in lift and were bottoming out over every bump... Yesterday I purchased some stock rear shocks figuring that we removed about 3in of height by moving the shock mount...
http://i303.photobucket.com/albums/nn151/exodus99wi/Jeep%20Project/photobucket-2299-1325169958200.jpg
http://i303.photobucket.com/albums/nn151/exodus99wi/Jeep%20Project/photobucket-3229-1325173995007.jpg

That pretty much wrapped up the project as we couldn't do the front gears so I just left the front drive shaft off. Driving back to River Falls however, I began noticing a lot of noise when I was using the brakes, so the next day I checked the rears at school and realized they were metal on metal! The calipers were fine the rotors and pads were junk from sitting so long, so I replaced them...
http://i303.photobucket.com/albums/nn151/exodus99wi/Jeep%20Project/photobucket-3032-1325169982378.jpg

That's all she wrote for the moment! More pics will arise as I find/take them of the little projects comping up. Planned so far are using an old rubber door mat to make some wheel well guards to protect the front door hinges, rear bumper, front gear install, and replacing the exhaust manifold.

[XJosh95]

What proportioning valve did you use? Stellar performance?

[99SJ_Ex]

Hah! Who needs proportioning valves?? Didn't touch a thing and they work better than stock.

[Fore Wheeler]

We decided it would be a good idea to mount the shock mounts up flush with the axle instead of hanging down under the axle like the OE ones were... After the project we realized we didn't think that through as we were still using the shocks for a 3in lift and were bottoming out over every bump... Yesterday I purchased some stock rear shocks figuring that we removed about 3in of height by moving the shock mount...
http://i303.photobucket.com/albums/nn151/exodus99wi/Jeep%20Project/photobucket-2299-1325169958200.jpg


it looks like the shock mount is hanging below the axle tube. it looks like it would be a good spot to get hung up. :dunno:


I like the bumper, nice work.

[99SJ_Ex]

Its simply the way the picture was taken Dan, it is flush with the bottom...

And I have been looking into producing these bumpers as well as the rear once I have that one completed...

[Fore Wheeler]

i though that was the case, it looks like a hook in the pic.

can't wait to see it in person in March.

[99SJ_Ex]

Here's a little preview of what I've gotten done on the rear bumper so far... This is not solid mounts, just test fitted...

http://a1.sphotos.ak.fbcdn.net/hphotos-ak-snc7/p480x480/398466_10150477386824811_502354810_8869349_1350520 463_n.jpg

[99SJ_Ex]

So I finally have the time/gumption to post up the build of the Rear Bumper... Now this one was rushed and completed in only 2 days compared to about 2 weeks on the front bumper...

So I started with a folded piece of 1/4in just like last time only it was 3in; 90 degree bend; ~5.5in; 90 degree bend; 3in...
http://www.naxja.org/forum/picture.php?albumid=324&pictureid=1996

I used the same system of cutting and folding to achieve the taper I wanted in the bumper for ground clearance...
http://www.naxja.org/forum/picture.php?albumid=324&pictureid=2101

http://www.naxja.org/forum/picture.php?albumid=324&pictureid=2104

I removed the 2in reciever, mostly by breaking all the bolts off, as well as the rear bumper (real pita) and opened up the holes that lead to the inside of the 'frame channel', the orange squares show where these holes are, I made the final opening about 3in X 2in...
http://www.naxja.org/forum/picture.php?albumid=324&pictureid=2099

http://www.naxja.org/forum/picture.php?albumid=324&pictureid=2098

Using the reciever as a guide, I marked where the holes needed to be on the 3inX1.5in Channel steel I will be using as bumper mounts. These will mount to the frame using the same holes used to mount the receiver. I will also be welding on some plates out of 3/16in that will have mounting holes to bolt up to the stock bumper mount placements.
http://www.naxja.org/forum/picture.php?albumid=324&pictureid=2102

Drilling the holes...
http://www.naxja.org/forum/picture.php?albumid=324&pictureid=2100

Mock up of the mounts to the bumper... Shortly after this I realized I needed to shorten them up by about 5in... Better to shorten than to try and lengthen them..
http://www.naxja.org/forum/picture.php?albumid=324&pictureid=2105

The final products/mounts... These use 8 bolts each, all grade 8.8 so They should never come off... Unless I try towing a freight train... They will slide into the channels through the holes I made and bolt up and the bumper will be welded to the ends.
http://www.naxja.org/forum/picture.php?albumid=324&pictureid=2097

Receiver and bracing welded into place. Using some angel iron and channel iron, I reinforced the receiver so that when using a clevis or a receiver hitch, it should bend or pull out of the bumper... Hopefully...
http://www.naxja.org/forum/picture.php?albumid=324&pictureid=2107

Once I welded everything together I realized that it would be very difficult to install the stock mounting bolts, or to insert/remove the pin from the receiver, so I made some nice cut-aways on the bottom so that I had access to both.
http://www.naxja.org/forum/picture.php?albumid=324&pictureid=2115

Added safety chain loops made from 1/2in round stock... Overkill, but we like overkill :patriot:... Primed and ready for rustoleum non-rubberized bed liner...
http://www.naxja.org/forum/picture.php?albumid=324&pictureid=2109

All mounted up, I know the ends are short and don't follow the body, but I ran out of time (all done at high school shop I was student teaching in) and I also wasn't sure what path I was taking with rear quarters so figured I could always modify it in the future...
http://www.naxja.org/forum/picture.php?albumid=324&pictureid=2113

[99SJ_Ex]

I also took some steel scrap we had and welded in the lower control arms... I figured since I replaced my trashed uppers with aftermarkets, it would put more stress on my stock lowers... Hopefully this works till I can save up some $$$ for adjustable lowers...
http://www.naxja.org/forum/picture.php?albumid=324&pictureid=2114

DEJA VU!!!!
Yet again I found my Heep in the shop completely torn apart!!! Went down to Max-Bilt to put my re-ordered gears for the d30 in since they were there and on my way, the rear diff went BOOM :smsoap:
http://www.naxja.org/forum/picture.php?albumid=324&pictureid=2111

So a lot of money later, I now have new gears and bearings in both axles :rattle: I really shouldn't cry, but it was money I didn't have...

This was the only bearing in the 8.8 that survived... Sort of... :wierd:
http://www.naxja.org/forum/picture.php?albumid=324&pictureid=2112