Shackle relocation

[DutchVDub]

So today I finally got started on my shackle relocation. I used a write-up I found on Pirate as inspiration. http://www.bsfab.net/?p=71 <---- That's the write-up.

I'll let the pics do the talking.

Frame on jack stands and axle at full drop, the tires are just barely above the ground
http://i190.photobucket.com/albums/z97/DutchVDub/1992%20XJ%20Laredo/shackle%20relocater%2013Jun09/001.jpg

I Austin Powers'd it in
http://i190.photobucket.com/albums/z97/DutchVDub/1992%20XJ%20Laredo/shackle%20relocater%2013Jun09/002.jpg

Shackle angle at full drop
http://i190.photobucket.com/albums/z97/DutchVDub/1992%20XJ%20Laredo/shackle%20relocater%2013Jun09/003.jpg

Leafpac at full drop
http://i190.photobucket.com/albums/z97/DutchVDub/1992%20XJ%20Laredo/shackle%20relocater%2013Jun09/004.jpg

My dented shock
http://i190.photobucket.com/albums/z97/DutchVDub/1992%20XJ%20Laredo/shackle%20relocater%2013Jun09/005.jpg

the shaft is bent on it too
http://i190.photobucket.com/albums/z97/DutchVDub/1992%20XJ%20Laredo/shackle%20relocater%2013Jun09/006.jpg

How the spring sits with all the weight back on
http://i190.photobucket.com/albums/z97/DutchVDub/1992%20XJ%20Laredo/shackle%20relocater%2013Jun09/007.jpg

http://i190.photobucket.com/albums/z97/DutchVDub/1992%20XJ%20Laredo/shackle%20relocater%2013Jun09/008.jpg

http://i190.photobucket.com/albums/z97/DutchVDub/1992%20XJ%20Laredo/shackle%20relocater%2013Jun09/009.jpg

http://i190.photobucket.com/albums/z97/DutchVDub/1992%20XJ%20Laredo/shackle%20relocater%2013Jun09/010.jpg

[DutchVDub]

static hang, no axle pulling it down

http://i190.photobucket.com/albums/z97/DutchVDub/1992%20XJ%20Laredo/shackle%20relocater%2013Jun09/011.jpg

http://i190.photobucket.com/albums/z97/DutchVDub/1992%20XJ%20Laredo/shackle%20relocater%2013Jun09/012.jpg

Laying on the ground
http://i190.photobucket.com/albums/z97/DutchVDub/1992%20XJ%20Laredo/shackle%20relocater%2013Jun09/013.jpg

Where those big military wraps hit the floor inside the front spring mount
http://i190.photobucket.com/albums/z97/DutchVDub/1992%20XJ%20Laredo/shackle%20relocater%2013Jun09/014.jpg

http://i190.photobucket.com/albums/z97/DutchVDub/1992%20XJ%20Laredo/shackle%20relocater%2013Jun09/015.jpg

http://i190.photobucket.com/albums/z97/DutchVDub/1992%20XJ%20Laredo/shackle%20relocater%2013Jun09/018.jpg

measured on groung at 48.25"
http://i190.photobucket.com/albums/z97/DutchVDub/1992%20XJ%20Laredo/shackle%20relocater%2013Jun09/016.jpg

http://i190.photobucket.com/albums/z97/DutchVDub/1992%20XJ%20Laredo/shackle%20relocater%2013Jun09/017.jpg

Where I would ideally want the shackle to sit (measures 52" from eye to eye between shackle and front spring mount)
http://i190.photobucket.com/albums/z97/DutchVDub/1992%20XJ%20Laredo/shackle%20relocater%2013Jun09/020.jpg

[DutchVDub]

Started removing the flared out portion of box
http://i190.photobucket.com/albums/z97/DutchVDub/1992%20XJ%20Laredo/shackle%20relocater%2013Jun09/021.jpg

http://i190.photobucket.com/albums/z97/DutchVDub/1992%20XJ%20Laredo/shackle%20relocater%2013Jun09/022.jpg

test fitting
http://i190.photobucket.com/albums/z97/DutchVDub/1992%20XJ%20Laredo/shackle%20relocater%2013Jun09/024.jpg

I had my helper with me today
http://i190.photobucket.com/albums/z97/DutchVDub/1992%20XJ%20Laredo/shackle%20relocater%2013Jun09/026.jpg

mocked up and tacked together
http://i190.photobucket.com/albums/z97/DutchVDub/1992%20XJ%20Laredo/shackle%20relocater%2013Jun09/027.jpg

welding it together
http://i190.photobucket.com/albums/z97/DutchVDub/1992%20XJ%20Laredo/shackle%20relocater%2013Jun09/028.jpg

I didn't like the look of the first bead so I ran another next to it to make sure
http://i190.photobucket.com/albums/z97/DutchVDub/1992%20XJ%20Laredo/shackle%20relocater%2013Jun09/029.jpg

http://i190.photobucket.com/albums/z97/DutchVDub/1992%20XJ%20Laredo/shackle%20relocater%2013Jun09/030.jpg

[DutchVDub]

http://i190.photobucket.com/albums/z97/DutchVDub/1992%20XJ%20Laredo/shackle%20relocater%2013Jun09/031.jpg

decided to practice vertical welding
http://i190.photobucket.com/albums/z97/DutchVDub/1992%20XJ%20Laredo/shackle%20relocater%2013Jun09/032.jpg

welded my tabs on (thankyou SpiderTrax)
http://i190.photobucket.com/albums/z97/DutchVDub/1992%20XJ%20Laredo/shackle%20relocater%2013Jun09/033.jpg

Made a hole
http://i190.photobucket.com/albums/z97/DutchVDub/1992%20XJ%20Laredo/shackle%20relocater%2013Jun09/034.jpg

mocked in place
http://i190.photobucket.com/albums/z97/DutchVDub/1992%20XJ%20Laredo/shackle%20relocater%2013Jun09/035.jpg

removed the lower to springs from the pack
http://i190.photobucket.com/albums/z97/DutchVDub/1992%20XJ%20Laredo/shackle%20relocater%2013Jun09/036.jpg

with the vehicles weight back on it
http://i190.photobucket.com/albums/z97/DutchVDub/1992%20XJ%20Laredo/shackle%20relocater%2013Jun09/037.jpg

http://i190.photobucket.com/albums/z97/DutchVDub/1992%20XJ%20Laredo/shackle%20relocater%2013Jun09/038.jpg

http://i190.photobucket.com/albums/z97/DutchVDub/1992%20XJ%20Laredo/shackle%20relocater%2013Jun09/039.jpg

http://i190.photobucket.com/albums/z97/DutchVDub/1992%20XJ%20Laredo/shackle%20relocater%2013Jun09/040.jpg

Now I just have to do the other side, but that'll have to wait for tomorrow.

[Stang5lgt]

Looks good man. But that steel is way too thin...:D LOL

[yossarian19]

Any plan to add gusseting to the sheet metal, or going to fill in the plug welds and call it a day?

[Stang5lgt]

Any plan to add gusseting to the sheet metal, or going to fill in the plug welds and call it a day?
He is tieing it to his cage that is what the hole in floor is for. It should be plenty strong.

[Hypoid]

http://i190.photobucket.com/albums/z97/DutchVDub/1992%20XJ%20Laredo/shackle%20relocater%2013Jun09/020.jpg

If you want it, I'm about to throw away a perfectly good gas tank. LOL

[DutchVDub]

Any plan to add gusseting to the sheet metal, or going to fill in the plug welds and call it a day?

the factory shackle bolt, 5 plug welds, all the edges welded, and a piece of 1.5" .120wall tube comin up through the floor. the tube is welded to the floor and once i snag some plate i'll also weld it to a platew that will the be welded to the floor.

[DutchVDub]

http://i190.photobucket.com/albums/z97/DutchVDub/1992%20XJ%20Laredo/shackle%20relocater%2013Jun09/020.jpg

If you want it, I'm about to throw away a perfectly good gas tank. LOL

nothing wrong with mine, its the high clearence version. :D

[Hypoid]

True, true!

I never thought about it that way, but you probably have some weight savings as well: What is it...5lb/gallon???

[Stang5lgt]

True, true!

I never thought about it that way, but you probably have some weight savings as well: What is it...5lb/gallon???I think is it 8lbs :D

[YELLAHEEP]

True, true!

I never thought about it that way, but you probably have some weight savings as well: What is it...5lb/gallon???

I think is it 8lbs :D



Well shit Dutch...... there's the whole reason it wasn't flexing the way you wanted it to........ :rolleyes:

:D

[DutchVDub]

finished it up mostly.

here is the tube coming up through the floor and welded. i'll be taking a piece of plate and drilling a hole in middle of it to weld the tube to and then weld the plate to the floor as well.
http://i190.photobucket.com/albums/z97/DutchVDub/1992%20XJ%20Laredo/shackle%20relocater%2013Jun09/041.jpg

Here is how it sits
http://i190.photobucket.com/albums/z97/DutchVDub/1992%20XJ%20Laredo/shackle%20relocater%2013Jun09/042.jpg

http://i190.photobucket.com/albums/z97/DutchVDub/1992%20XJ%20Laredo/shackle%20relocater%2013Jun09/043.jpg

And the shackle box
http://i190.photobucket.com/albums/z97/DutchVDub/1992%20XJ%20Laredo/shackle%20relocater%2013Jun09/044.jpg

[Stang5lgt]

Good job brutha! Looks like it moved your rear axle back some.

[YELLAHEEP]

Good job brutha! Looks like it moved your rear axle back some.

Shouldn't have - technically impossible unless he moved the centering pin or the hole it sits in in the spring perch. The distance from the front spring eye to the centering bolt didn't change nor did the distance from the centering pin to the rear spring eye.

I think it's the way his flare is mounted that gives that illusion.

[tysonxj]

How much did your pinion angle change?

Cheers,
Chris

[Stang5lgt]

Shouldn't have - technically impossible unless he moved the centering pin or the hole it sits in in the spring perch. The distance from the front spring eye to the centering bolt didn't change nor did the distance from the centering pin to the rear spring eye.

I think it's the way his flare is mounted that gives that illusion. When the spring flattens out axle has to move backwards since the front perch is non moving. It is a good thing gives a little more wheel base. But those are rustys flares...:D Dang I said the R word again...:shhh:

[DutchVDub]

actually the axle is back more because the TNT u-bolt eliminaters have 3 center pin holes for different axle positions and I remounted the axle on the holes that push it farthers back.

[YELLAHEEP]

actually the axle is back more because the TNT u-bolt eliminaters have 3 center pin holes for different axle positions and I remounted the axle on the holes that push it farthers back.

Heh, heh........ so 'Stang and I were both right....... :thumbup:

[JohnJohn]

Looks to me the military wrap was banging the front because it became the movement point when rolling over bumps. With the shackles so far forward you would hit a bump and the axle was forced to move forward and up.

48+" eye to eye seems way to short for a BOR pack?

[DutchVDub]

alcan said they are 49" so mine was a bit short for some reason, not a problem anymore though.

[Lurch1980]

Has the ride been effected at all, good or bad?

[JohnJohn]

alcan said they are 49" so mine was a bit short for some reason, not a problem anymore though.

The shackle droop forward might had caused them to measure shorter after running them a while. Flexing them backwards like that can shorten up the eye to eye measurement.

They look great now.

[DutchVDub]

Has the ride been effected at all, good or bad?


way softer ride. i could barely flex the leaves i'd removed by standing on them and i weigh 215lbs. between the removal of the lower two leaves and the new shackle angle this thing is a lot smoother on more flexy. once i get my new shocks i might be looking to install a sway bar again. i haven't run a front or rear sway bar in over two yrs now.

[DutchVDub]

The shackle droop forward might had caused them to measure shorter after running them a while. Flexing them backwards like that can shorten up the eye to eye measurement.

They look great now.

Troy was helping fuigure out what my issue were and getting with Alcan on it, but Alcan seems of no help and stubborn in their mindset. basically i'm just an idiot and their springs are perfect.

Thankyou again Troy for working with me so much.

[YELLAHEEP]

It's not a totally done issue Rich. I just need to see if there's been any changes over the last year or so that Alcan isn't considering. They say 49" is the length they've always used and that a stock set of XJ leaf packs are 1.75" shorter........ I may do some e-mailing of previous customers from the customer list I have and see if I can get some 4" FlexE measurements from those folks.

I need to find a full set still bolted together to get an accurate measurement, but the top leaf with the spring eyes that I have here measures right at 50"

Alcan will build them to my specs if I give them a compelling enough arguement....... but one customer's preference isn't enough in this case and I have to agree to an extent. Problem still exists though - we're not on the same page as far as stock length.

[Stang5lgt]

once i get my new shocks i might be looking to install a sway bar again. i haven't run a front or rear sway bar in over two yrs now.
http://www.youtube.com/watch?v=WIUWwKtkDgA
This is the day you removed your sway bar June 30th last year. Come on Ficticous you are not that old not to remember. I am sure the local scrapers were happy that day when they pulled in to Mickey Ds that day and found your sway bar in the parking lot. It was a Sunday too they probably thought it was a answer to there prayers. ;)

[DutchVDub]

you forget that i had a 99 xj lifted 4.5" before the 92. I never even put the swaybar back on that one when i lifted it. i also disconnected the swaybar on the 92 just before that first trip to slaughterhouse where we had to trim the 92's fenders and never reconnected them. i removed the swaybar completely the day we went down dakan rd because i got tired of the zipties breaking.

[jimgrms]

also the day his shackles were first relocated :>{)))