Team NAXJA/Petty Cash Racing stock class KOH XJ build

[cal]

Dallas and I have been doing some work on 4696 getting ready to race it.

Frame stiffeners had some large irregular holes (plasma cutter) around the steering box, and the box bolt washers were caving in letting the box get loose. We cut some new ones from .250 plate to fix it.

After a lot of big hard jumps, their dana 44 front was coming apart. The long side tube had broken the plug welds, the tube welds, and the truss. Spent several hours grinding out the plug welds, cutting out the welds around tube, etc.

 

[cal]

Then Dallas got in and welded the living hell out of it, and added a little material.

Their ram had been mounted to the diff cover, which was causing non stop leaks, and the tie rod was very not strait.

A new Aluminium tie rod, new ram mounts, all new joints.

 

[cal]

I'm not sure what diff cover this is, but the welds were too close to the bolt holes for washers, so into the mill to make some room.

I'm sure there will be some more after this weekend, then off to beat it like a rental car...

 

[Lowrange2]

Of course, just as I'm pricing 7075 Aluminum for my lower links... you post about aluminum (steering) links.

Aluminum is just so pretty.

 

[POLAR_JEEP_04]

Of course, just as I'm pricing 7075 Aluminum for my lower links... you post about aluminum (steering) links.

Aluminum is just so pretty.

WOD? that's who I was going to use but I'm going to hold off until next year

 

[Lowrange2]

WOD? that's who I was going to use but I'm going to hold off until next year

Stinky Fab Racing, probably... Or build my own.

Gunna have Cal tap them for me.

 

[POLAR_JEEP_04]

Stinky Fab Racing, probably...

ill have to look into them too when I do mine

 

[rockclimber]

I'm not sure what diff cover this is, but the welds were too close to the bolt holes for washers, so into the mill to make some room.

that looks exactly like the way my Ruffstuff cover was. I had to do pretty much the same thing.

 

[jbain08]

Great work guys I love all the pics and even though it's time consuming it's cool you take the time to post up pics so we can all keep up. I run a 44 up front with those same perches but for a bumpstop I run those red poly inserts. They've worked well for a year but now are no longer holding up. In one of your pics on the previous page I can see the lower part of your bump, any chance we can get a pic of your bumpstop setup? Also how much up travel are you guys running?

 

[cal]

More 4696. Sorry my pictures kind of suck a bit, we were in the last day hurry, I didn't stop and wash up to snap photos as often.

On to the rear end.

In a race pace reinstallation some shims were placed in the wrong order, and the rotor is rubbing the backing plate.

Apart it all comes for rearranging. Not even sure why this shim was in there, but I pulled it out.

Fixing some damage from an old broken axle.

Bearing race doesn't sit true anymore, so a little facing is due.

Quick refill

Chase the front diff cover bolt holes, seal and reinstall.

Power steering cooler. Not much room left on this car, so it goes under the radiator.

Time to make some airflow in that front skid.

And dimple die them!

Rebuild a rear shock mount.

Replace the fire extinguisher mounts with more better ones.

Slap a little paint on.

Ready to race!

Thursday morning we leave for Stampede. I hear its going to rain the entire weekend, this is going to be a dirty bitch when we give it back.

 

[cal]

Great work guys I love all the pics and even though it's time consuming it's cool you take the time to post up pics so we can all keep up. I run a 44 up front with those same perches but for a bumpstop I run those red poly inserts. They've worked well for a year but now are no longer holding up. In one of your pics on the previous page I can see the lower part of your bump, any chance we can get a pic of your bumpstop setup? Also how much up travel are you guys running?

On 4643 we run the Prothanes, 5" uptravel. The upper half of the bump is just a flat plate bolted to the bumpstop tower to hit the prothane.

On 4696 they run the factory bumps (ow! my kidneys!) and I have no idea on uptravel.

 

[RedHeep]

Badlands?

 

[cal]

Badlands?

Can't be away from work that long right now.

 

[md21722]

On a previous post I saw that it took 80-100 hours to make it race ready. I do not know much about race prep, can you give some highlights as to where the hours go? Do you replace certain parts before every race, etc?

 

[cal]

On a previous post I saw that it took 80-100 hours to make it race ready. I do not know much about race prep, can you give some highlights as to where the hours go? Do you replace certain parts before every race, etc?

I pull every suspension, steering, drivetrain, etc bolt. Inspect, wire brush clean, reinstall with fresh loctite and a torque wrench. Replace every lock nut (and they are all lock nuts). Wire brush and check welds. Pull and inspect, lube driveshafts, axles. Drain all fluids, inspect diffs, reseal and refill. Pull the serpentine and inspect the pulley's and bearings. Inspect belt. Inspect coolant hoses. Inspect fuel, brake and steering hoses/lines end to end for damage and chafing. Inspect rear wheel bearings. Repack and reset preload on front wheel bearings. Inspect all beadlock bolts, retorque or replace as necessary. Check brake calipers and pads. Bumpstops. Limit straps. Shocks (I should change shock fluid, but I don't, as I am not tooled to recharge them). Check radiator mounts and core support. Trans crossmember. Motor mounts. Trans mounts. Flush coolant. Change oil. Change fluid in atlas. Drain trans pan and replace fluid. replace power steering fluid. Change leaf springs and leaf u-bolts, get the previous set rebuilt for next time.

Thats from memory. A bunch of other things will come up as you go through the car. I spend a few hours a night on it, and a few long weekends (mine are all 3 day). I know a lot of the desert race teams go a lot further than I do, but their races are longer than ours.

 

[md21722]

Thanks! How do you "Repack and reset preload on front wheel bearings." The stock ones are sealed... what are you running where you can do that? Do you really trash a set of rear leafs in one race? What's involved in changing shock fluid? I know in some way nitrogen is involved? I have a tank for pressure testing its not that involved. I really enjoy this thread.

 

[cal]

Thanks! How do you "Repack and reset preload on front wheel bearings." The stock ones are sealed... what are you running where you can do that? Do you really trash a set of rear leafs in one race? What's involved in changing shock fluid? I know in some way nitrogen is involved? I have a tank for pressure testing its not that involved. I really enjoy this thread.

We don't run unit bearings, but rather a more traditional spindle and bearing setup. I don't have pictures of it all going together, its a really greasy job and I don't touch my phone while I'm doing it.

 

[cracker]

Spindles........Gods gift to axles and go fast.

 

[cal]

Spindles........Gods gift to axles and go fast.

More than 10 years we've been friends, and i can still never tell when you're being sarcastic and when you're not.

 

[GSequoia]

Can't be away from work that long right now.

They've finally caught on to just how little work you actually do?