Hi: If you opt to make some custom long arms yourself be prepared for some precision fabrication and welding-Here is a little example of what I have done using someone's plagiarized write-up..first I want to go on record and thank whomever was the original author and I apologize for some of the personal modifications I took the liberty to change on my personal set-up-
Long Arms
----------------------
6' of 1 3/4" X .25 DOM tube = $80.00
Item ID Items Price Quantity Total
TA-241 1.0" -14 tpi Tube Adapter
Thread Hand: Right Hand Thread
Tube Inner & Outer Diameters: Size 2: 1.25 in ID - 1.75 in OD - $1.00 $11.99 2 $23.98
:TA-241 1.0" -14 tpi Tube Adapter Tube Inner & Outer Diameters: Size 2: 1.25 in ID - 1.75 in OD
Ballistic Poly Bushing 2.63" w/ weldable housing
Ballistic Poly Bushing 2.63" w/ weldable housing
7/8" 14tpi Hex Tube Adapter
Tube Inner and outer diameters: 1.0 in ID - 1.25 in OD
Thread hand: Right Hand Thread $9.99 2 $19.98
URL=http://img36.imageshack.us/i/thumbsnailasp.jpg/]
[/URL]
Forged Chromoly 2.63" Ballistic Joint
Bearing thru hole: 9/16''
Stud diameter / Thread Pitch: 1.0" - 14 tpi
Thread direction: Right hand thread $42.99 2 $85.98
Cross member
3' of 2"x4"x3/13" rectangle tube = $10
--------------------------------------
Total =
The crossmember was made of a piece of 2"x4"x3/16" rectangle tube. I made brackets on each end that would allow the stock crossmember bolts to be reused as well as new bolts drilled through the qsuedo frame. The bolts that go through the frame should be sleeved to keep the frame from being crushed. but do have a strip of 3/16" plate on the other side to spread out the load.
*Pics of the cross member as well as the mounts here*
The lower arms were made of 1 3/4" dia x .25 walled DOM ( 2"x.25" DOM, optional was way overkill for my XJ ) -I would recommend modifying this next statement to,..
quote," 32" one end to the other,..etc.. ".." measure your own lower arm requirement from front axle eyebolt to frame side mount eyebolt,as these dimensions are going to be different for each vehicle lower arm setup On one end of the long arms use a tubing-notcher to cut the notch for the bushing holder. Use a 2.5" bi-metal hole saw and lots of cutting oil to cut trough the tube. Once done the ends clean up with a grinder.
Once the bushing sleeves were prepped I welded them onto the DOM.
Another way to get the bushing sleeves would be to buy the bushings -
My upper arms are simply some aftermarket adjustable ones that use the stock locations that cost about ninety-dollars.
Once the LCA mount is gone bolt up the long arm. At this point I needed to remove the other UCA so that I could set the caster. I used the jacks and the pipe wrenches to get the UCA off and then set the caster where I wanted it. I then took the mount that would be welded to the lower arm and bolted it to the upper arm. The upper arm only sits right on the lower arm at one angle. Just move it around till it isn't binding and weld it on.
Once one long arm is done remove the other LCA and fallow the same steps of mounting the arms.
HTH