CrazyJim's Jeepspeed/Prerunner XJ build

[crazyjim]

WELP! Another day down. We didn't get nearly as much done as I would have liked, but we definitely made forward progress. Keep in mind, this is the first time I've EVER bent tube on a bender, it's definitely a mental work out with all the numbers and angles.

We started off by cutting the front half of the T&J cage off, to get ready to build the DOM a-pillars.

http://i251.photobucket.com/albums/gg319/digitalc0nvict/XJ%20Phase%202/IMG_1418.jpg


After that, we started mocking up and finally bent some tube. Now, we had to figure out where to START bending, what angle to bend, and where to START bending again. On top of that, I wanted to follow the inward angle of the a-pillar, which we figured to be around 10* in. So we started bending, this is what we came up with:

http://i251.photobucket.com/albums/gg319/digitalc0nvict/XJ%20Phase%202/IMG_1395.jpg

It ended up fitting beautifully, I couldn't be happier with the pillars

http://i251.photobucket.com/albums/gg319/digitalc0nvict/XJ%20Phase%202/IMG_1406.jpg

http://i251.photobucket.com/albums/gg319/digitalc0nvict/XJ%20Phase%202/IMG_1403.jpg

My down tubes are now at exactly 90* both directions.

http://i251.photobucket.com/albums/gg319/digitalc0nvict/XJ%20Phase%202/IMG_1410.jpg

http://i251.photobucket.com/albums/gg319/digitalc0nvict/XJ%20Phase%202/IMG_1401.jpg


More TIG welding :D

http://i251.photobucket.com/albums/gg319/digitalc0nvict/XJ%20Phase%202/IMG_1412.jpg


We then pulled it back out, and started 360 welding everything. We also started to triangulate the roof, but got hung up on a few tubes. Notching correctly is probably the HARDEST part about this build so far. It's such a bitch to get right. We were pretty wiped by 2 am when we called it quits.

http://i251.photobucket.com/albums/gg319/digitalc0nvict/XJ%20Phase%202/IMG_1419.jpg

http://i251.photobucket.com/albums/gg319/digitalc0nvict/XJ%20Phase%202/IMG_1421.jpg




Anywho, more updates in 2 weeks, next weekend I'm going to Mexico!

[tcm glx]

Nice jim!!!

[tone]

So when do you wanna make another one? :) it's lookin good man!

[BajaCurt]

next weekend I'm going to Mexico!

OMG did hell freeze over?!?!
Right on Jim!
Have a blast and eat plenty of tacos.

[crazyjim]

Nice jim!!!

Thanks man, still trying like mad to finish before my deadline!

So when do you wanna make another one? :) it's lookin good man!

Haha, man I'm not sure if I EVER want to make another one, this is such a PITA... I think starting from scratch would probably be easier though, rather than adding to an already existing / welded cage.

OMG did hell freeze over?!?!
Right on Jim!
Have a blast and eat plenty of tacos.

Yea yea yea, Tony told me he'd keep my big ass safe :D I'm trusting him. It'd be nice to see you down there!

[1xfloppy]

shit...looking good jim!!!

[tcm glx]

Taking Jim down for some good times in mexico next week Curt. Fly down and join us!!

[GrimmJeeper]

lookin good! how/where are you planning on going through the firewall?

[crazyjim]

I'm not going through the dash with this one. I will be on the MJ however. But I won't be engine caging the XJ.

[Cache96]

Cage is looking good!!!
Where in mexico are you going?

[tcm glx]

I'm not going through the dash with this one. I will be on the MJ however. But I won't be engine caging the XJ.

You mean not through the firewall right? I know you are going through the dash.

Cage is looking good!!!
Where in mexico are you going?

Santo Tomas to San Quintin on the B500 course backwards....

[crazyjim]

You mean not through the firewall right? I know you are going through the dash.



Santo Tomas to San Quintin on the B500 course backwards....
Yes sorry that's what I meant. Not going through the firewall.

[tone]

You mean not through the firewall right? I know you are going through the dash.



Santo Tomas to San Quintin on the B500 course backwards....


I'd take my vacation time to go do that sounds like a blast! Got room on the roof? :)

[tcm glx]

I'm not going through the dash with this one. I will be on the MJ however. But I won't be engine caging the XJ.

Cage is looking good!!!
Where in mexico are you going?

I'd take my vacation time to go do that sounds like a blast! Got room on the roof? :)


I have room inside.. hahaha, Damn Broncos have plenty of passenger room. Its a quick 2 day trip we are doing this time...

[tone]

What days I seriously might be game!

[FatCity Ryan]

Is this thing done yet?

[silverslk]

Does this mean the race with the ranger is back on???

[FordGuy]

Summer of 2012

[tcm glx]

Summer of 2012

ha ha ha ha

[crazyjim]

Haha bastards. Its not done yet, I only get to work on it on the weekends as my schedule permits. And ranger race is definitely back on.

[FlexdXJ]

Haha bastards. Its not done yet, I only get to work on it on the weekends as my schedule permits. And ranger race is definitely back on.

Uh huh, Sure it is............:D

[crazyjim]

UPDATE:

Went over late yesterday, as I've been working 16 hour days lately. In installing the cage, we figured out that we'd either have to lose the hood pop lever inside the cab, or relocate it. I opted for hood pins. We started on those yesterday, and got them all set up. Like everything they took 3 times longer than expected. The pins weren't long enough to just bolt down to my header panel, so we had to weld a washer down to the header panel, then weld a nut down to IT. Anyway, here's how they came out:

http://i251.photobucket.com/albums/gg319/digitalc0nvict/XJ%20Phase%202/hoodpin3.jpg

http://i251.photobucket.com/albums/gg319/digitalc0nvict/XJ%20Phase%202/hoodpin2.jpg

http://i251.photobucket.com/albums/gg319/digitalc0nvict/XJ%20Phase%202/hoodpin4.jpg

http://i251.photobucket.com/albums/gg319/digitalc0nvict/XJ%20Phase%202/hoodpin1.jpg

[crazyjim]

While Lee was working his magic trying to tig a galvanized washer and bolt to a galvanized body, I started cutting material and building my LCA's. These are 2" .250 wall 4130 with 1.25" chromo heims. I think they'll be strong enough for me :D


http://i251.photobucket.com/albums/gg319/digitalc0nvict/XJ%20Phase%202/LCA2.jpg

http://i251.photobucket.com/albums/gg319/digitalc0nvict/XJ%20Phase%202/LCAandDawn.jpg

http://i251.photobucket.com/albums/gg319/digitalc0nvict/XJ%20Phase%202/LCA3.jpg





Going back over there today, we're going to the welding shop to get some bigger tig rod and some other goodies. Stay tuned for today's progress (tomorrow) :D

[GrimmJeeper]

pepsi? where's the dr pepper can!? lol

looks beefy dude, but I can't tell cause dawn is tiny. those would look like long arms if you were holding them :D

[J Money]

Those LCA's look super beefy. Nice work.

[crazyjim]

pepsi? where's the dr pepper can!? lol

looks beefy dude, but I can't tell cause dawn is tiny. those would look like long arms if you were holding them :D

I stopped drinking Soda haha, that was the first can I grabbed out of Lee's garage fridge :)

Those LCA's look super beefy. Nice work.

Thanks, hopefully they'll hold up!

[crazyjim]

UPDATE:


We didn't get much done this weekend, but we got a pretty major item finished. We were both pretty beat, so we worked on small table stuff rather than getting down and dirty. Lee finished up welding the LCA's we assembled yesterday. While he was doing that I measured, cut, and prepped the material for the upper control arms.

For the uppers we used 1.5" .120 wall DOM sleeved with 1.75" .120 wall DOM. Fisheyed on one side and plug/rosette welded on the other. For the open end we used 1/4" stainless plate. Keep in mind the axle side isn't finished yet on the UCA's, I still need to drill the hole, and round out the ends. Also going to brainstorm on what kind of plating we're going to use to gusset and reinforce the ends. Hopefully the control arms will hold up :D

http://i251.photobucket.com/albums/gg319/digitalc0nvict/XJ%20Phase%202/IMG_1456.jpg

http://i251.photobucket.com/albums/gg319/digitalc0nvict/XJ%20Phase%202/IMG_1457.jpg

http://i251.photobucket.com/albums/gg319/digitalc0nvict/XJ%20Phase%202/IMG_1465.jpg

http://i251.photobucket.com/albums/gg319/digitalc0nvict/XJ%20Phase%202/IMG_1471.jpg

http://i251.photobucket.com/albums/gg319/digitalc0nvict/XJ%20Phase%202/IMG_1475.jpg

http://i251.photobucket.com/albums/gg319/digitalc0nvict/XJ%20Phase%202/IMG_1480.jpg

http://i251.photobucket.com/albums/gg319/digitalc0nvict/XJ%20Phase%202/IMG_1466.jpg

http://i251.photobucket.com/albums/gg319/digitalc0nvict/XJ%20Phase%202/IMG_1469.jpg

http://i251.photobucket.com/albums/gg319/digitalc0nvict/XJ%20Phase%202/IMG_1474.jpg

http://i251.photobucket.com/albums/gg319/digitalc0nvict/XJ%20Phase%202/IMG_1489.jpg

http://i251.photobucket.com/albums/gg319/digitalc0nvict/XJ%20Phase%202/IMG_1494.jpg

http://i251.photobucket.com/albums/gg319/digitalc0nvict/XJ%20Phase%202/IMG_1493.jpg

http://i251.photobucket.com/albums/gg319/digitalc0nvict/XJ%20Phase%202/IMG_1492.jpg

[crazyjim]

I also got the front end back together while Lee was welding. I installed my spiffy BajaHID.com Hi/Lo HID kit along with new fresh new US DOT cut off headlight housings. My old VVME kit stopped going high / low, and my housings had mud caked in the bottom of them. She looks good with a new set of eyeballs...

http://i251.photobucket.com/albums/gg319/digitalc0nvict/XJ%20Phase%202/IMG_1459.jpg

http://i251.photobucket.com/albums/gg319/digitalc0nvict/XJ%20Phase%202/IMG_1496.jpg

[tcm glx]

Lookinng really good Jim... I am digging those UCA and LCA!

[GrimmJeeper]

I am digging those UCA and LCA!

I agree, does Lee feel like mass producing em? :D

[Ryan93]

I agree, does Lee feel like mass producing em? :D

seriously haha

[crazyjim]

Thanks guys... and we talked the idea over yesterday about building these for the Jeep world. The problem is the lowers have about $250 in them in material alone, plus welding supplies, fab time, and welding time. They're expensive. The uppers don't have quite as much, but have more fab time in them, as well as welding time.

[grandrunner]

BEEFFYYYYYY! LOOKS STRONG AND THE WELDS LOOK REALLY GOOD TOO.

[Brown Dog]

X2 on the Beef! Looks corn fed!
(I don't think we paid for the product placement, so THANK YOU!)

[tone]

I thought fo sho you were gonna go with a long arm setup.. Are you trying to keep it low budge or are adj's with DBs the new long arm?

[Papercut]

Liking the lower and upper control arms. When its time to make my new long arms I think I'm going to do something like those.

[Papercut]

Hey Jim I just picked the T&G cage up too. Did you weld the plates in or blot em? If welded did you plate the underside of the body? I hear that's what most people do because its so easy the weld thru the sheet metal.

[crazyjim]

X2 on the Beef! Looks corn fed!
(I don't think we paid for the product placement, so THANK YOU!)

Haha no problem, thanks for an awesome product at a smokin' price!

I thought fo sho you were gonna go with a long arm setup.. Are you trying to keep it low budge or are adj's with DBs the new long arm?

At the amount of travel our Jeep's pull, I think short arms are a better bet. They give you way better geometry than a long arm setup, unless your long arms were on drop brackets as well. The advantage to long arms would be if you were going to pull 12-14" out of the front, they would have a larger arc, and move less front to rear throughout travel. With this 10-11" I'll be pulling, the short arms are a better option. They're stronger, less weight, and are at a 0 degree plane at ride height.

[crazyjim]

Hey Jim I just picked the T&G cage up too. Did you weld the plates in or blot em? If welded did you plate the underside of the body? I hear that's what most people do because its so easy the weld thru the sheet metal.
I haven't finished mine yet, but I'll be bolting the plates in, sandwiching the body between them and then stitch welding to the floor. Eventually I'll probably run support tubes from the bottom plate to the frame rail somewhere.

[Loose_Nuts_Enterprises]

All little trick for prepping washers, nuts, etc for tig welding is to dip them in muratic acid, and then rinse them with water. Works really well on the zinc plated "gold" looking stuff and only takes about a minute of your time to do. You can get the acid at the hardware store.

Looks awesome! Everything takes longer than expected, and if you don't give it the time, you'll never be happy with the end result.

Keep slavin' away....

[V84BAJA]

WOW!!

[GrimmJeeper]

Nice tip Dan! Home Depot also has the acid, in the pool and spa chemicals section. Anywhere that sells chemicals for pools should have it in stock as its used to balance the PH levels.

[crazyjim]

All little trick for prepping washers, nuts, etc for tig welding is to dip them in muratic acid, and then rinse them with water. Works really well on the zinc plated "gold" looking stuff and only takes about a minute of your time to do. You can get the acid at the hardware store.

Looks awesome! Everything takes longer than expected, and if you don't give it the time, you'll never be happy with the end result.

Keep slavin' away....

Damn, what a good idea, I've never heard of that. Works with galvanized etc? I'll definitely go pick some up this weekend, I'm sure we'll have some more similar welds.

Also thank you for the props, and thanks for the encouragement. I'm desperately trying to get this together by Dec. but it's got me worried with the amount of time I can actually dedicate towards this.

WOW!!

Thanks Tom! Means a lot coming from you.

[GrimmJeeper]

The acid works on anodizing too, eats it right off. Just don't leave the part in there too long the acid will eat the aluminum too :D

[crazyjim]

The acid works on anodizing too, eats it right off. Just don't leave the part in there too long the acid will eat the aluminum too :D
I use EZ-Off oven cleaner for anodizing, works great!

[GrimmJeeper]

yep

[Loose_Nuts_Enterprises]

I use EZ-Off oven cleaner for anodizing, works great!

EZ Off only works so well though. It will turn red to a nice shade of pink. We used to do that on out old BMX race bikes. Then again, the chemicals to anodize were probably a lot better back then.

[crazyjim]

Hmmmm weird. I used it to polish my black brake and clutch levers as well as my gold wheels on my 86 250r back in the day!

[crazyjim]

Well... I got tired of not being in the desert again, so I decided to get back to work on the XJ with the little time I do have. I made the decision finally on where to run the dash bar. It's going to run under the dash. I may regret it later on when I see how much dash I'm going to have to cut out, but I think in the end it will make for a nicer build.

http://i251.photobucket.com/albums/gg319/digitalc0nvict/Cage/7076c805.jpg

http://i251.photobucket.com/albums/gg319/digitalc0nvict/Cage/5721fb21.jpg



Don't mind the surface rust... I feel bad for neglecting her. She's back at my house for the next couple weeks. I'm going to work on getting the surface rust off, and also remove all the asphalt insulation shit on the floor.

[FlexdXJ]

You still aren't done? :D

[tone]

Sweet its about time! Bar behind the dash is a good call too it will look nice. :D

[h-townxj]

Well at least someone is making progress the d**n tj keeps robbing me of all my money in gas and parts. And I just bent the inner c's. Oh well adventually the xj will be running. I can't wait to see the xj all done man

[XJLI]

OMG IT STILL EXISTS

[tone]

Oh and if you still wanna get rid of that rear bumper I still want it! :)

[casual]

Hey Jim I know you've changed your setup a few times..got any suspension parts for sale...
Springs,leafs, shocks, arms, ect.?

[crash02]

glad to see you working on the jeep again.

[xjjeeper19]

I can't believe it's been over a year since I stuck the head on that thing... Hurry the fawk up would you?

Justin

[casual]

I can't wait to see this beast back in action! Its moved decently before. I can't wait to see it once its completled.

Videos are a must!

[crazyjim]

Thanks for the words of encouragement everyone, I'll take it along side the sh*t talking :D

As for parts, I really already sold everything I'm not going to use. Sorry.

[crazyjim]

New update:

Picked up a new D30 today, this will save a LOT of time on my build, which is always a good thing. Chris Amrein built this for his Jeepspeed, but ended up going a different route. So I lucked out!

4130 trussed, sleeved on the long end.
Gusseted C's, gusseted upper mounts
Relocated 4" lower shock mounts
Re-inforced bump pads
Beefy LCA mounts
Limit strap mounts
High mount track bar setup for high steer (WJ / Terraflex)
Ruff Stuff? diff cover
4.88 gears installed by RWK Haus Supply

All in all, it's exactly what I was looking to build, and I got a sweet deal on it from Chris. Thanks again Chris! It was good meeting you, and I hope to see the Jeep done in the near future, it's badass!

http://i251.photobucket.com/albums/gg319/digitalc0nvict/XJ%20Phase%202/c0edd23f.jpg

http://i251.photobucket.com/albums/gg319/digitalc0nvict/XJ%20Phase%202/fdcca94f.jpg

http://i251.photobucket.com/albums/gg319/digitalc0nvict/XJ%20Phase%202/3bcc926d.jpg

http://i251.photobucket.com/albums/gg319/digitalc0nvict/XJ%20Phase%202/e3cb3230.jpg

[R1D3R]

Drool :-),
Making me have to start my build.

[crazyjim]

Thanks man! Im pumped! And anything that makes you jump on your build faster is a good thing!

[tcm glx]

Glad to see you back on the build Jim... miss hanging out in the desert with ya!

[casual]

New update:

Picked up a new D30 today, this will save a LOT of time on my build, which is always a good thing. Chris Amrein built this for his Jeepspeed, but ended up going a different route. So I lucked out!

4130 trussed, sleeved on the long end.
Gusseted C's, gusseted upper mounts
Relocated 4" lower shock mounts
Re-inforced bump pads
Beefy LCA mounts
Limit strap mounts
High mount track bar setup for high steer (WJ / Terraflex)
Ruff Stuff? diff cover
4.88 gears installed by RWK Haus Supply

All in all, it's exactly what I was looking to build, and I got a sweet deal on it from Chris. Thanks again Chris! It was good meeting you, and I hope to see the Jeep done in the near future, it's badass!

http://i251.photobucket.com/albums/gg319/digitalc0nvict/XJ%20Phase%202/c0edd23f.jpg

http://i251.photobucket.com/albums/gg319/digitalc0nvict/XJ%20Phase%202/fdcca94f.jpg

http://i251.photobucket.com/albums/gg319/digitalc0nvict/XJ%20Phase%202/3bcc926d.jpg

http://i251.photobucket.com/albums/gg319/digitalc0nvict/XJ%20Phase%202/e3cb3230.jpg

Hey you picked up his D30. That thing is beef. He built out beam and was saw this on numerous occasions. Chris deffinetly does good work and I am forever thankful for meeting him!

[crazyjim]

Hey you picked up his D30. That thing is beef. He built out beam and was saw this on numerous occasions. Chris deffinetly does good work and I am forever thankful for meeting him!
Nice! So you're the one who did the motor work for him then. He was saying he just finished building a beam for someone.

[SoCal Off-Road]

let me know if you need anything jim.

hey tone like your sig.....

[crazyjim]

let me know if you need anything jim.

hey tone like your sig.....
Thanks Tom, will do!

[crazyjim]

Well we made some progress on the XJ again this weekend, the cage is finally ready to go back into the Jeep for good, and get welded in. We were wrapping up everything that was going to be against the roof so we could get full 360 welds on everything.

We focused on gusseting the cage yesterday. I'm not running an X above my head, because of my height, and the fact that this will still be street driven without helmets. Instead I ran a straight tube forward down the center, and gusseted all the corners.

We decided on curved gussets for the windshield to help a bit with vision, but went straight with all the others. It took us SEVERAL hours to get the curved gussets where they needed to be. It'd be one thing if they were all 90* corners, but they're not, especially around the windshield. The tubes are on completely different planes.

http://i251.photobucket.com/albums/gg319/digitalc0nvict/Cage/370d9035.jpg

http://i251.photobucket.com/albums/gg319/digitalc0nvict/Cage/27b92d09.jpg


Once those got worked out, we banged out the straight ones in a matter of minutes.

http://i251.photobucket.com/albums/gg319/digitalc0nvict/Cage/00f0846c.jpg

http://i251.photobucket.com/albums/gg319/digitalc0nvict/Cage/85051f6b.jpg

http://i251.photobucket.com/albums/gg319/digitalc0nvict/Cage/e1e533c2.jpg

Lee got a bit carried away with his tacks.

http://i251.photobucket.com/albums/gg319/digitalc0nvict/Cage/5c84ef55.jpg

http://i251.photobucket.com/albums/gg319/digitalc0nvict/Cage/ad554b1d.jpg

http://i251.photobucket.com/albums/gg319/digitalc0nvict/Cage/d39f3ebf.jpg

http://i251.photobucket.com/albums/gg319/digitalc0nvict/Cage/99efd486.jpg





Stay tuned for further updates, the next sets will be with the cage being permanently welded into the Jeep. It'll be a few weeks, as I'm going to Mexico with Tony, Andy, and the guys this coming weekend.

[tcm glx]

Looks freaking outstanding Jim!

[xcm]

very nice, thanks for posting pics.

its allways nice to see pics of prerunners being built, instead of prerunners being SOLD.

[crazyjim]

Thanks guys, and it definitely feels better to be posting pictures of progress rather than pictures of an empty driveway!

[GrimmJeeper]

lookin good Jimbo, hopefully you finish yours before I finish mine. Or at least maybe we can both finish them at the same time and hitch up Tone and drag him sideways across the dunes :D

[scottmcneal]

lookin good Jimbo, hopefully you finish yours before I finish mine. Or at least maybe we can both finish them at the same time and hitch up Tone and drag him sideways across the dunes :D
LOL, thats the only way his is going to make it mike. Looks great jim, wish i had this setup in mine.

[casual]

That was us. I'm digging that diff cover..I want!

[tone]

lookin good Jimbo, hopefully you finish yours before I finish mine. Or at least maybe we can both finish them at the same time and hitch up Tone and drag him sideways across the dunes :D

Lol hopefully I'll be done by then too so I can give you guys a tour of the dunes :)

[xcm]

LOL THATS FUNNY, someone finishing a prerunner build...

[GrimmJeeper]

LOL THATS FUNNY, someone finishing a prerunner build...

truth.

[Papercut]

Looking good Jim, Let me know if you need a hand some weekend.

[CHINA XJ]

I am a fan from China, Cherokee XJ, would like to see progress pictures back!

[Jump This]

How long does it take to build a friggin' Cherokee?
Slow ass builder......


;)

[GrimmJeeper]

look who's talking, how long has yours been in the shop Rick? Longer than Jim's has I bet haha.

[crazyjim]

Haha I was just thinking the same thing. I'm pretty sure that's why the ;) face. I've been recovering from surgery for the past 3 weeks, so I've fallen behind again, but don't you worry your pretty little head off, I'll get back on it soon enough. :D

[GrimmJeeper]

If you need a hand some time let me know Jim, my schedule is pretty open right now.

[cal]

Haha I was just thinking the same thing. I'm pretty sure that's why the ;) face. I've been recovering from surgery for the past 3 weeks, so I've fallen behind again, but don't you worry your pretty little head off, I'll get back on it soon enough. :D


I heard the operation was a failure and you're still a man?

[GSequoia]

I heard the operation was a failure and you're still a man?

But he's got one hell've a rack now!

[crazyjim]

I heard the operation was a failure and you're still a man?


It's true, it was too big to get rid of. It's a more manageable size now though.


But he's got one hell've a rack now!


Now? Pfft.

[tbburg]

It's true, it was too big to get rid of. It's a more manageable size now though.For some reason a movie title (http://www.imdb.com/title/tt0248845/) just popped into my head,..

[johnnyc]

Hey Jim, what's with the late night text messages? I figured you must have my number confused with somebody else's. :D

[crazyjim]

Hey Jim, what's with the late night text messages? I figured you must have my number confused with somebody else's. :D
Hahahaha woops! Wrong Johnny! My bad dude :D

[GrimmJeeper]

Hahahaha woops! Wrong Johnny! My bad dude :D

or maybe the operation WAS a success :eyes:

[johnnyc]

That's what I was afraid of. That he was in the mood for a little Asian, and he thought of me. :wierd:

[crazyjim]

Got the cage in the Jeep for good now. Once all the top tubes were 360 welded we were able to get her down and welded in permanently, then finished the b-pillar X today. Overall I'm super pumped with the results!

http://i251.photobucket.com/albums/gg319/digitalc0nvict/Cage/261db9f9.jpg
http://i251.photobucket.com/albums/gg319/digitalc0nvict/Cage/4d7541a2.jpg
http://i251.photobucket.com/albums/gg319/digitalc0nvict/Cage/f58669c6.jpg
http://i251.photobucket.com/albums/gg319/digitalc0nvict/Cage/aaa99b5b.jpg

[tcm glx]

That b pillar is nuts Jim!! Nice job!

[Ryan93]

looks killer Jim!

[xcm]

looks awesome, envious of your tig.
...
whats next?

[crazyjim]

Thanks guys, I appreciate the compliments. A lot of time went into the layout, and it's slow progress. I'm not even the one welding and I'll never tig another cage. The time involved getting the notches right etc is insane. Measure, cut, notch, test fit, grind, test fit, grind, test fit, grind, weld. Hahaha.

Next we're going to be getting the C-Pillar in and mocking up / mounting my rear shocks. Should be fun!

[V84BAJA]

The time involved getting the notches right etc is insane. Measure, cut, notch, test fit, grind, test fit, grind, test fit, grind, weld. Hahaha.

Next we're going to be getting the C-Pillar in and mocking up / mounting my rear shocks. Should be fun![/QUOTE]

I might know someone looking for a good fabricator!Looks great Jim.

[GrimmJeeper]

hey Jim is red again! Welcome back man! :D

[Mike L]

When is the dash going back in? I am interested to see how it all fits together. Is the engine cage next?

[FlexdXJ]

That cage looks awesome Jim. After WF my Jeep is hopefully going down to HD Offroad for a cage, guess i'm gonna keep it all internal. I think 32's and 3" of lift would look sorta goofy with a halo on top!

[scottmcneal]

Hey JIM, you still in banning area? They have a thing going on out there, i have it in my sig if you could come by and say hi sir.

Sorry on the H J

[crazyjim]

Got the shocks mocked up and mounted, C & D pillar bars down and in, need to finish welding the rest of the cage and add bracing for the shocks.


http://i251.photobucket.com/albums/gg319/digitalc0nvict/XJ%20Phase%202/1f905f6b.jpg


Here you can see the sleeve we used for the D-Pillar bar. A piece of 2" .120 wall. Since we tucked the cage so high, the d-pillar bars on the T&J cage were a bit short.


http://i251.photobucket.com/albums/gg319/digitalc0nvict/XJ%20Phase%202/ff7ff11e.jpg


Here are the spring plate / shock mounts I decided to use, made by RuffStuff! These things are beef as hell, 1/4" thick on the plates, and 3/16" on the shock tabs. The Bilstein's with spacers are 1.25" wide so we made a spacer a BIT larger, to deal with warping due to welding, worked out beautifully.


http://i251.photobucket.com/albums/gg319/digitalc0nvict/XJ%20Phase%202/e9c16ccd.jpg


We disassembled the leaf packs and started cycling for travel numbers and mocking up the shocks.

http://i251.photobucket.com/albums/gg319/digitalc0nvict/XJ%20Phase%202/22d3f19c.jpg

http://i251.photobucket.com/albums/gg319/digitalc0nvict/XJ%20Phase%202/daf751da.jpg

When you do this, remember to make a spacer that's the same size as the leafs you took out:

http://i251.photobucket.com/albums/gg319/digitalc0nvict/XJ%20Phase%202/2a9f1db2.jpg
http://i251.photobucket.com/albums/gg319/digitalc0nvict/XJ%20Phase%202/86cf61d8.jpg


Also from Dan over at RuffStuff, these 360* wrap shock tabs. These allow you to do a full 360 weld all the way around the tab.


http://i251.photobucket.com/albums/gg319/digitalc0nvict/XJ%20Phase%202/ff572f72.jpg

http://i251.photobucket.com/albums/gg319/digitalc0nvict/XJ%20Phase%202/ac1d6f31.jpg
http://i251.photobucket.com/albums/gg319/digitalc0nvict/XJ%20Phase%202/1e6aca29.jpg
http://i251.photobucket.com/albums/gg319/digitalc0nvict/XJ%20Phase%202/2844111d.jpg
http://i251.photobucket.com/albums/gg319/digitalc0nvict/XJ%20Phase%202/516b4399.jpg


Back on her feet at ride height.


http://i251.photobucket.com/albums/gg319/digitalc0nvict/XJ%20Phase%202/a646d905.jpg

[crazyjim]

I might know someone looking for a good fabricator!Looks great Jim.

Haha, too much of a pain in the ass, and I'm waaaayyyy too slow ;)

When is the dash going back in? I am interested to see how it all fits together. Is the engine cage next?

Dash should be going back in in a few months, it's staying out until we wrap everything else up. I'm interested to see how it fits together as well, nervous.

That cage looks awesome Jim. After WF my Jeep is hopefully going down to HD Offroad for a cage, guess i'm gonna keep it all internal. I think 32's and 3" of lift would look sorta goofy with a halo on top!

Nah, man a cage in a STOCK vehicle wouldn't look goofy, it's smart!

[tcm glx]

Looks badass! Glad you are so back into it!

What were the travel numbers?

[crazyjim]

I'll be pulling right at 12" in the rear without going into negative arch on the springs. I'm going to see what Joel can do with the 12" and go from there, if I feel I need more, I'll move the mounts higher to go negative. However, I think I'll be fine, and he recommends against it obviously and says it causes a nasty buck.

[chris_amrein]

That looks really good Jim! Got any pics of the frontend under it yet?

[crazyjim]

That looks really good Jim! Got any pics of the frontend under it yet?
Not quite yet, I still need to buy WJ brakes/knuckles for it before I can put it under the front of the Jeep. Then we'll start on steering etc.

[GrimmJeeper]

he recommends against it obviously and says it causes a nasty buck.

i'll throw my 2¢ on that too, with my last setup i was bumped at negative arc, and it bucked like crazy on a full compression hit. The valving was so stiff that I rarely got to full compression but when I did it was pretty noticeable.

[silverslk]

NICE!!! Those shocks are SEXY!!!!

[sjstar]

hey i was thinking of running the same bump pads you are running in the back. Any reason you didnt run them on the frame side and have your striker on the axle. Also what was the squish rating for those bumps at max compression? thanks

[AeroSync]

Looks awesome man. What rims are those? They aren't the same ones at the beginning I think.

[crazyjim]

hey i was thinking of running the same bump pads you are running in the back. Any reason you didnt run them on the frame side and have your striker on the axle. Also what was the squish rating for those bumps at max compression? thanks

I ran them that way because they are single post mounting, where the stock spot is two post. They smash down about half the thickness of the rubber if you subtract all the void spaces, to be safe. I've got a set of brand new black poly's from polyperformance that I'm not going to end up running if you'd like them.

Looks awesome man. What rims are those? They aren't the same ones at the beginning I think.

Thanks man, the wheels on the Jeep in the beginning were Centerline Telstars. I loved them, wish I hadn't gotten rid of them. The ones on it now are powdercoated American Racing AR-23's. Also light and VERY strong.

[sjstar]

http://i33.photobucket.com/albums/d76/ihatethepavement/82ffce17.jpg
So this is what i was thinking of running. First i would plate the frame then i would have the two 1 3/4 dom tubes come down to a base plate for the bump to bolt to then i would plate between the two tubes and sleeve between the two plates in the middle.
Then on the axle i would just make a nice wide flat striker pad for it to contact on. Just whats thought up in my head.
How much you thinking for those bumps?

[CTeunuch]

Looking great. Where are the pictures in the first post taken? Specifically the first 2 or 3, it looks like a place outside of LA I saw when I visited a few years ago.

[crazyjim]

How much you thinking for those bumps?

Not sure, let me check how much they were from Poly.

Looking great. Where are the pictures in the first post taken? Specifically the first 2 or 3, it looks like a place outside of LA I saw when I visited a few years ago.

Thanks! Those first shots were from Azusa canyon.

[Dirt Yota]

Truck looks good my fellow DR friend! I've taken a turn for the worst in this "Jeep thing" and I'm hooked!

[tcm glx]

Updates...............

[mxracer624]

Updates are.......... its tits.. saw it the other day!

[tone]

Update: jeep is in drive way winning trophys ;)

[Goatman]

I'll be pulling right at 12" in the rear without going into negative arch on the springs. I'm going to see what Joel can do with the 12" and go from there, if I feel I need more, I'll move the mounts higher to go negative. However, I think I'll be fine, and he recommends against it obviously and says it causes a nasty buck.


Jim, what springs are you using, I assume Deavers? Sorry, didn't read back to see. I'm still trying to figure out rear travel and shock placement on our KOH car build. I don't know how much more spring droop to expect in the real world, on the rack with 35's and beadlocks bolted up the droop is 9" below where the spring would be flat. How did you determine you'll get 12"?

[crazyjim]

Jim, what springs are you using, I assume Deavers? Sorry, didn't read back to see. I'm still trying to figure out rear travel and shock placement on our KOH car build. I don't know how much more spring droop to expect in the real world, on the rack with 35's and beadlocks bolted up the droop is 9" below where the spring would be flat. How did you determine you'll get 12"?
Yes I'm running Deavers. Mine are a 9 pack I believe. I'm bumped at flat, with no shock shaft left. I did this to get the most out of my bypass tube, rather than letting some of it go unused. We'll see if this worked out in my favor or not. On full droop, without the driveshaft hooked up, I'm showing 11.40" of shaft, because my shocks are mounted straight up and down, this shows my actual travel. Not sure why you'd only be showing 9" of real wheel travel though.

[crazyjim]

Well, got the Jeep back on all 4 wheels this weekend. Going to definitely be ready for KOH this coming Feb. It won't be completely done, but it'll definitely be offroad worthy for KOH.

Big thanks to Chris Amrien for the front trussed D30, it worked out bitchen. That paired with Ballistic's 1.5" .250 wall steering with 7/8 heims makes a nasty strong front end I'm hoping. It's set up with a high steer knuckle from Teraflex, which posed a few more clearance issues with wheel backspacing and the steering.

Also a huge shout out to Tom Nissley from www.socaloffroad.net/ (http://www.socaloffroad.net/) for a SMOKIN' deal on a set of front Deaver Jeepspeed springs, got them cheap and fast. Thanks Tom!!!

Anthony (Tone) came out late last week to help wrench a bit, which was nice having an extra set of hands around. We got all the mounts for UCA's, LCA's, and track bar drilled out to 5/8" and 3/4" holes respectively. I had a buddy machine my pitman arm and drivers side knuckle for 3/4" bolts. Here's the front end going under the Jeep!

http://i251.photobucket.com/albums/gg319/digitalc0nvict/XJ%20Phase%202/IMG_1524.jpg

http://i251.photobucket.com/albums/gg319/digitalc0nvict/XJ%20Phase%202/IMG_1521.jpg

We got the Deavers installed along with wheels/tires to see how she was going to sit:

http://i251.photobucket.com/albums/gg319/digitalc0nvict/XJ%20Phase%202/IMG_1528.jpg

http://i251.photobucket.com/albums/gg319/digitalc0nvict/XJ%20Phase%202/IMG_1530.jpg

http://i251.photobucket.com/albums/gg319/digitalc0nvict/XJ%20Phase%202/IMG_1534.jpg


Bringing us to this weekend, I was busy with family stuff all weekend, being Christmas and all, but was able to get away a bit to start the steering and get most of it done. I had to order some more spacers from ballistic for the heims which is what stopped the progress for tonight. We started with the track bar to get everything squared up before doing steering. This track bar and mount is badass, thanks again to Chris for building a sweet axle. It should give me some nice geometry once it's all said and done.

http://i251.photobucket.com/albums/gg319/digitalc0nvict/XJ%20Phase%202/IMG_1547.jpg

One small problem I ran into was the axle side track bar mount. it was designed (I'm assuming) for a 3/4" heim, not a 7/8". This created a problem for me running the 7/8". The Jam nut for the heim hits the mount when suspension is compressed, I considered running a jam nut on only the frame side, but after speaking with some people in the know, Dan Turner, I decided I'll be better off clearancing the mount for the nut instead.

http://i251.photobucket.com/albums/gg319/digitalc0nvict/XJ%20Phase%202/IMG_1549.jpg

Once we got the heims hung I realized I was going to have to run under the knuckle for the tie rod, which isn't a major concern for me as I won't be doing much crawling. The truss hangs down further anyway. However, not only will I have to run UTK, but I need a larger spacer to space the heim down. Chris warned me of this when I bought the axle, recommending 1" or so tie rod to help clearance. With a single high mis spacer moving the heims down though, it clears the 1.5" just fine. I see not real reason to change it for 1/4" of clearance.

http://i251.photobucket.com/albums/gg319/digitalc0nvict/XJ%20Phase%202/IMG_1550.jpg

http://i251.photobucket.com/albums/gg319/digitalc0nvict/XJ%20Phase%202/IMG_1553.jpg

http://i251.photobucket.com/albums/gg319/digitalc0nvict/XJ%20Phase%202/IMG_1552.jpg

As you can see here, there's not a TON of clearance under the beefy ass track bar mount:

http://i251.photobucket.com/albums/gg319/digitalc0nvict/XJ%20Phase%202/IMG_1555.jpg


Speaking of clearance, we ran into another concern. The Teraflex knuckle moves the ear for the drag link forward, and in, to ride near the wheel lip. With my wheels being 3.75" backspace, it puts them quite close to the heim. We're talking less than an 1/8" when the "BFGoodrich" rolls by. This will be temporarily solved with some small 1/4" wheels spacers until I can grab some new wheels with a slightly different offset.

http://i251.photobucket.com/albums/gg319/digitalc0nvict/XJ%20Phase%202/IMG_1548.jpg



All in all I'm happy with the progress that's been being made, and it feels REAL now. I actually feel like I'm making forward progress, and that the XJ may actually be done some day. :D

[tcm glx]

bout time you get some work done!! lol

[scottmcneal]

Hey jim, i think you screwed up dude.The truss is on the bottom and it is going to get hooked on parking bumps at the mall.:)

Looks good jim, can't wait to see it out in the desert.

[tone]

Nice. Let's bang the rest out!

[sallys xj]

looks great

[crazyjim]

Thanks guys, I'm happy with the progress. Just hope she performs well.

Tone, I'll let you know when were working on it again on a Friday!

[silverslk]

Too bad I cant view pb at work.....write up sounds good though Jim!!! hahaha

Yours will be running and mine wont (for KOH). What a turn of events!!

[crazyjim]

Too bad I cant view pb at work.....write up sounds good though Jim!!! hahaha

Yours will be running and mine wont (for KOH). What a turn of events!!
What?! The BTF beams goin on? Are you still planning on going for KOH?

[silverslk]

Still want to go to KOH. Not sure if it will be in my Bronco or not...... +3.5 beams = extended axles and a bit more than just a bolt in so it will kick my ass for a bit. Need spacers for the uniball beam pivot plus need to buy heims for the arms + associated spacers.

[chris_amrein]

Nice progress Jim. I like the short arms too.

Just FYI, when I built the frontend around the Teraflex knuckle I set it up to run the drag link under not over the knuckle. I don't think I had as much clearance as you do (I had less back spacing on my wheels I think) and also there are so many variables with the amount of pitman arm drop and track bar upper mount.

Also, I welded the counter sink washer to the lower track bar mount to run a 1/2 inch counter sink bolt the opposite direction you show. It was the one compromise I was never really happy with and I'd say your on the right track running it the way you show it there. I would recommend cutting that washer off though to get a better tightening surface.

It looks like your on the right track and I'm looking forward to seeing it done.

Chris

[crazyjim]

Nice progress Jim. I like the short arms too.

Just FYI, when I built the frontend around the Teraflex knuckle I set it up to run the drag link under not over the knuckle. I don't think I had as much clearance as you do (I had less back spacing on my wheels I think) and also there are so many variables with the amount of pitman arm drop and track bar upper mount.

Also, I welded the counter sink washer to the lower track bar mount to run a 1/2 inch counter sink bolt the opposite direction you show. It was the one compromise I was never really happy with and I'd say your on the right track running it the way you show it there. I would recommend cutting that washer off though to get a better tightening surface.

It looks like your on the right track and I'm looking forward to seeing it done.

Chris
So you were going to run the drag link UNDER the knuckle? Wouldn't you run into more bind issues this way? I haven't bolted up my pitman arm yet to see what the angle is going to end up being, need to wait for spacers. I suppose I can give that a shot though if things are way off and if it'll give me more room between the heim and the wheel/tire.

As for the track bar mount, I noticed the spacer, but figured it'd probably be fine for now. I may whack it of when I notch the plate for the jam nut.

Hopefully the next time you're out racing you can honk at me while you fly by it ;)

[chris_amrein]

I ran 1/2" bolts with misalignments that allowed plenty of misalignment so bind was never an issue. I'm pretty sure I would have run it on top but like I said the wheel backspacing/clearance was the deciding factor in putting it below. The only other thing to watch for is drag link-to-frame clearance at full bump.

Looking at the pics, it looks like your drag link and track bar will be close in length and angle. My only other recommendation is to hold off on welding the track bar until after you get your drag link mocked up. You might find you want to move the frame side of the track bar after you get your drag link in there. Like I side, it looks like they'll be pretty close, and I only say that because I cut/weld/cut/welded my track bar and drag link several times to get them right.

Chris

[Skullver]

yeah Jim, I have some 1/4" spacers from the jeep Mr Amrein sold me that I never used, they are yours if you want them, was going to use them for tire swings/spare mounts, but I am running 5x5.5" now.

[crazyjim]

yeah Jim, I have some 1/4" spacers from the jeep Mr Amrein sold me that I never used, they are yours if you want them, was going to use them for tire swings/spare mounts, but I am running 5x5.5" now.
That would be awesome, I'm assuming they're billet not cast?

[crazyjim]

I ran 1/2" bolts with misalignments that allowed plenty of misalignment so bind was never an issue. I'm pretty sure I would have run it on top but like I said the wheel backspacing/clearance was the deciding factor in putting it below. The only other thing to watch for is drag link-to-frame clearance at full bump.

Looking at the pics, it looks like your drag link and track bar will be close in length and angle. My only other recommendation is to hold off on welding the track bar until after you get your drag link mocked up. You might find you want to move the frame side of the track bar after you get your drag link in there. Like I side, it looks like they'll be pretty close, and I only say that because I cut/weld/cut/welded my track bar and drag link several times to get them right.

Chris
It looks like I'm going to have to put a bend in my drag link towards the end to clear. In order to run the heim under the knuckle it needs to be bent. Over the knuckle will be a terrible angle unless I run on top of the pitman arm as well, which won't work as I'll hit the oil pan.

[Skullver]

That would be awesome, I'm assuming they're billet not cast?

They are just cut from 1/4" hr steel, no studs or anything, just a clr'nc hole for the hub nub, and clr'nc holes for the studs, don't even think you could get real wheel spacers that thin as the studs wouldn't be able to be countersunk so it sits flush on the ub surface. He was using them to space out the knuckle, I forgot exactly why, too many projects between then and now:).

[crazyjim]

I'll take 'em! How much and you want paypal or what?

[Skullver]

I'll take 'em! How much and you want paypal or what?

Cheeap mang:). I will check on shipping tomorrow, see what they weigh and wether they can go in an envelope or needs to be flat rate box, $5 plus shipping? I'll throw in some steekers:). I can ship them tomorrow too if you need them asap. Just pm me your address and I'll send them off, and you can pay me whenever. Paypal is fine.

[crazyjim]

$5 + shipping works for me. And the more Steekers the better, my fridge isn't quite full. :D

Sooner the better, but don't rush out of your way to get them out to me.

[Papercut]

looking good Jim!

I'm free monday if you need a hand.

[FlexdXJ]

About friggin time! That thing looks BA Jim!