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  #31  
Old August 1st, 2016, 09:10
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Re: Project Unicorn - a light duty trail rig

lol.

i already smogged it. 2 seconds under the hood, evap test and plug in.

(strokers pass a sniff test anyway)
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  #32  
Old August 1st, 2016, 10:32
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Re: Project Unicorn - a light duty trail rig

Atlas in a 2wd XJ...
There is a ton of bolt on bullshit out now for armor and stuff. Why not just collaborate with Dallas and think up something a little custom and different?

Do you already have these rubicon d44s around? I'm thinking of building a TJ rubicon 44.
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  #33  
Old August 1st, 2016, 18:49
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Re: Project Unicorn - a light duty trail rig

As you get older, there are things you decide just have to be certain ways, period.

In my case, there need to be always hot USB ports everywhere. There are about 10 in my house. 4 in my tow rig. 6 in my camper.

After a lot of trial and error, my favorite USB port is the Blue Sea 1039 dual 2.4 amp charger.

https://amzn.com/B01AHYC88A


There wasn't an awesome place for it, so I tracked down WizardPC over on ShapeWays and we put our heads together.

He built me a custom 3D printed switch bezel that has Blue Sea twistlock 12v outlet, 1 Blue Sea dual usb charger, and 5 jeep style switch ports.




It turned out super nice. He offers it for sale here:

http://www.shapeways.com/product/U7Y...ionId=59373292


I didn't take a lot of pictures through this process. I don't really like doing electrical so I just pushed through it so not to be annoyed.

4 gauge on a 100 amp fuse from the battery to the first fuse box, which breaks off to the accessory fuse box and later to the stereo amps (I'll get there..).




8 gauge over to the accessory fuses.



14 gauge into the cab, up under the dash, and feeding both the 12v port and the usb ports. The extra switches are just filling holes for the moment, I'm not even sure what they will end up being in the long run.

All installed and ready to go!




If any of you decide to buy one of these and install, you'll want the 90* bend spade connectors, it is a snug fit.

https://amzn.com/B01GKFR09W

Here's the 12v outlet I used as well:

https://amzn.com/B001U4ZZPK
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Last edited by cal; July 14th, 2017 at 17:17.
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  #34  
Old August 1st, 2016, 19:18
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Re: Project Unicorn - a light duty trail rig

That's awesome... Exactly what i was trying to build myself.

I'm ordering one
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  #35  
Old August 1st, 2016, 19:37
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Re: Project Unicorn - a light duty trail rig

Quote:
Originally Posted by Redxj5150 View Post
Atlas in a 2wd XJ...
There is a ton of bolt on bullshit out now for armor and stuff. Why not just collaborate with Dallas and think up something a little custom and different?

Do you already have these rubicon d44s around? I'm thinking of building a TJ rubicon 44.
If i stumbled over a TJ rubicon 44, I'd slap it in there and run.

I have a friend who may or may not have some G2 Core 44's sitting around, but its empty housings. Not quite prepared to jump into the expense of completing them yet. 184 days until King of the Hammers and only so much money..

I'm thinking I may look for a dana 30 (even low pinion) to throw in this thing for now.
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  #36  
Old August 1st, 2016, 20:48
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Re: Project Unicorn - a light duty trail rig

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  #37  
Old August 2nd, 2016, 15:33
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Re: Project Unicorn - a light duty trail rig

Quote:
Originally Posted by wizardPC View Post
Good job on those! I've added it to my wish list.
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  #38  
Old August 4th, 2016, 12:01
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Re: Project Unicorn - a light duty trail rig

Quote:
Originally Posted by cal View Post
Not 100% sure at this point, but somewhere in the ballpark;

4" lift (4" deaver leafs, shackle relocators, 4" pac coils)
JK Rubicon 44's front and rear
4.88 gears, 35 spline rear, 32 spline inner/outer front
33" AT's
Atlas 3.8

I'll let Russ whisper to the motor and see what happens there, but we can be sure something will go down.

As far as bumpers, sliders, etc - what's available has changed so much that I really have no idea what is out there anymore. As much as it sounds contradictory to say when you're talking about 300 horsepower and an atlas on JK axles, I mean this to be more of a commuting and camping rig - just built to where it won't break or wear things out quickly.

I do really want a Genrite gas tank for it, but I can't see myself paying the price.
I started laughing because I was thinking this was going to be a budget rig...
Actually if the atlas is free and the Russ P stroker is cheap to free, find some factory JK rubicon axles for cheap and it wont be that bad...
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  #39  
Old August 4th, 2016, 12:02
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Re: Project Unicorn - a light duty trail rig

Dallas has a set of empty Rubicon 44 housings in his shop that I wrote my name on, and he didn't cry about it.

The question is can I find some cheap lockers..
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  #40  
Old August 4th, 2016, 13:19
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Re: Project Unicorn - a light duty trail rig

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Originally Posted by cal View Post
The question is can I find some cheap lockers..
I have a welder.
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  #41  
Old August 4th, 2016, 15:20
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Re: Project Unicorn - a light duty trail rig

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I have a welder.
That will work great!

I'll install a button with a light by my axles. When its on, weld them up. When it goes out, suck that weld back out so I can go around corners.

Of course, you'll have to fabricate some carriers to weld up, but this way its easy to go 35 spline..
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  #42  
Old August 4th, 2016, 20:40
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Re: Project Unicorn - a light duty trail rig



.
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  #43  
Old August 4th, 2016, 21:16
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Re: Project Unicorn - a light duty trail rig

Quote:
Originally Posted by cal View Post
As you get older, there are things you decide just have to be certain ways, period.

In my case, there need to be always hot USB ports everywhere. There are about 10 in my house. 4 in my tow rig. 6 in my camper.

After a lot of trial and error, my favorite USB port is the Blue Sea 1039 dual 2.4 amp charger.

https://amzn.com/B01AHYC88A


There wasn't an awesome place for it, so I tracked down WizardPC over on ShapeWays and we put our heads together.

He built me a custom 3D printed switch bezel that has Blue Sea twistlock 12v outlet, 1 Blue Sea dual usb charger, and 5 jeep style switch ports.


I think these are so neat. I'm ordering the one with jeep switches and contra switches tomorrow.

Last edited by cal; July 14th, 2017 at 17:17.
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  #44  
Old August 7th, 2016, 06:48
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Re: Project Unicorn:

Quote:
Originally Posted by cal View Post
So driving the rig for a couple of months, I had a slowly increasing vibration in the rear end. I had been operating under the assumption the rear end (8.25) was going out, but I started noticing puddles of ATF when I parked. Not cool.

It turned out the bushing the rear yoke rides in was totaly shot. I could move the yoke .120-.180 side to side in the housing. Did some reading here, found the part numbers, ordered a bushing and seal and tore into it.





After draining the fluid, the tailcone is 6 bolts and slides off pretty easy.



Drive the old bushing and seal out of the tail housing.








Reverse the process









If you do this, watch for this oil line, which apparently likes to fall out and not be noticed, causing you to pull the housing back off and install it again.






If anyone needs to do this, the parts came from transmission parts USA:

760-000076635 76635 A340 AW4 A40 Transmission extension housing bushing. (38 MM) 1 $2.94 $2.94
940-000094401 94401 Jeep AW4 Transmission extension housing seal 1987-on. 1 $3.70 $3.70
Hi Cal, how did you removed the old bushing? I took the extension housing out of the tranny but having a hard time taking the bushing out.

Thanks

Last edited by cal; July 14th, 2017 at 17:19.
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  #45  
Old August 7th, 2016, 08:56
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Re: Project Unicorn:

Quote:
Originally Posted by StratoXJ View Post
Hi Cal, how did you removed the old bushing? I took the extension housing out of the tranny but having a hard time taking the bushing out.

Thanks

If you see these two grooves that run along side of the bushing:



I used a long rod where the tip just squeeze into those grooves, and a big hammer



You can see the dimples where i beat the hell out of the bushing removing it




I let the bushing drive the old seal out. Its been in there for a long time, so you're going to have to hit it pretty good. IIRC I did two swings on each side, back and forth.

Pounding the new one in, I used a socket barely bigger than the new bushing as a driver, with some spray lube around the outside of the new bushing to make it go easier. Make sure you clock the lubrication hole correctly when you put the new one in.
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Last edited by cal; July 14th, 2017 at 17:19.
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