LiLNickT's 3/4 Ton XJ Build

LiLNickT · Nov 3, 2010

I Thought i would start this build thread by giving some background on the jeep at hand as well as project goals.

To begin, here is the jeep. Its a 96 2dr, it had a Rubicon Express 4.5" Lift, dana 30 front, 8.25 rear both open with 3.07's. When i got the jeep it had the rack and bumpers.

These were taken the day i got the jeep....

For the first year i owned the jeep i made some small changes including, rocker guards made by a friend of mine who sold his xj and pulled them off before selling it as well as some 31" TSL's from my old truck. Then i added the lights to the roof rack and wired them through a trailer wiring harness. i utilized the 4 wire harness connectors to make the roof rack detachable without having to unwire the lights.

Here are a couple pics of the rack and lights.

Gotta get going to class right now, when i get back i will explain the project goals as well as show some progress on the current axle swap and suspension build project.

LiLNickT · Nov 3, 2010

Project Goals:

Must be safe
Must be stable in off camber and uphill climbs
Must be strong
Must be semi - streetable
Clear 38" Tires

With these few goals in mind i set out in doing some research on a subject i really didnt know much about. I finally decided after a few months, i wanted a 3 link front, 4 link rear. I wanted to run a dana 44 and a dana 60 axles from a 79 ford f-250 that i had sitting. From this point i started on my build with an idea of some of the fundamental design considerations like anti squat, roll axis, pinion angle change, amount of bump and droop...

So first things first, i needed a firm base to begin working from so i started with the frame plating.

Cleaning up the frame

here you can see some of the damage that was caused by welding my rocker guards on and then cutting them back off. Rust was also a problem in some areas on the "frame"

My buddy prepping the frame stiffeners. ( kinda looks like he crapped himself lol )

Next up is cleaning up the front area for the front frame stiffeners.

And then of course making some cardboard templates

LiLNickT · Nov 3, 2010

After we had some templates to work from, we started fabing up the stiffeners. They are made from 3/16" plate.

LiLNickT · Nov 3, 2010

And then we did the same with the rears.

After the frame was all plated, i worked on making a new crossmember, i also utilized this as a mounting location for my Lower Control Arm Mounts.
Its made from 1/4" plate and 2" - 1/4"wall square tubing.

Pretty beefy compared to stock... 65lbs vs 15lbs for the stocker

LiLNickT · Nov 3, 2010

After getting the Frame Side LCA Mounts, i started working on the 44. I started with the LCA mounts and proceeded to the truss work and then onto the UCA and Track Bar Mounts.

The UCA/Track Bar mount was one of the hardest things to figure out on this build. It was difficult to get the right suspension geometry and work around the hysteer set up.

LiLNickT · Nov 3, 2010

Here is a couple pics of the Frame Side UCA Mount

Then it was on to the rear end.

LiLNickT · Nov 3, 2010

Some more of the rear end.

After i got the suspension set up i worked on getting the shocks set up.
Here are the rears.

LiLNickT · Nov 3, 2010

Then it was onto checking some clearences with the body, i ended up having to do a tuck and fold on the rear quarters, and trimming a bunch out of the front end.

And then we did some painting... lots of painting...

LiLNickT · Nov 3, 2010

finally it was time to get it reassembled, bounce it around and check for more clearences, i also made some bumpstops and captured the springs. right now im in the process of finishing up the pitman arm, as well as mounting the winch and tweaking the body to make sure i dont have any rubs. Here are some more pics...

Ohh yeah and i grooved the TSL's too.

LiLNickT · Nov 3, 2010

This weekend will be the first time out and i am just finishing up everything to go wheeling today and tomorrow. i will get some pics of it out on the trail. i would like to thank my best friend Cory who has helped me immensely though this project. I didnt include a whole lot in the way of technical information, but instead alot of pictures. if you have any questions feel free to ask and i will address them.

whitexj98 · Nov 3, 2010

I like it! What are the axles geared to? open/locked? It looks like you pretty much made everything yourself, nice work!

LiLNickT · Nov 3, 2010

Here is a list of the Parts that i used to complete this build.

Front Coils - Rubicon Express 5.5" XJ Front
Rear Coils - Skyjacker 2.5" TJ Front
I captured the springs on the axle side with 4" od pipe, and the bump stops on the frame side are long enough to keep the springs from fall out.

Shocks - 14" Travel RS9000xl all 4 corners

Front Axle - 79 F-250 Dana 44 w/ Flat top Knuckles (4.10 Gears) Welded
Rear Axle - 79 f-250 Dana 60 FF ( 4.10 Gears) Ltd Slip

Links - 2.63" Balistic joints with 2"-1/4" wall Dom Tubing.

Steering - 1Ton TRE's, Ballistic Hysteer Arms, 1.5" - 1/4" Wall Dom tubing.
98 Durango Saginaw Box.
Pitman arm - Custom
I need to incoporate an assist ram and new ps pump.

Wheels - Trail Worthy Fab double recenterd Hummer wheels with PVC double beadlock inserts.

Tires - 38.5x16x16.5 Swamper TSL - Grooved

Brakelines from Poly Performance, Custom Length front and rear.

94xjstud · Nov 3, 2010

This looks really good. What size joints did you use for the uppers and lowers.

EDIT: oops i posted this right after you did

LiLNickT · Nov 3, 2010

I used the 2.63" Ballistic Joints for all the uppers and lowers as well as track bar. The links were made from 2", 1/4"wall DOM

ausi02 · Nov 3, 2010

How did you do the suspension geometry? Did you use a the calculator from Pirate or what?

LiLNickT · Nov 3, 2010

I used the suspension calculators from pirate.

Front End: 3 Link with Track Bar
Anti Squat - 72 or 91%
Roll Axis - 1.34*
Change in Pinion Angle - about 4*

Rear End - Double Triangulated 4 Link
Anti Squat - 62 or 77%
Roll Axis - 3*
Change in Pinion Angle - about 5*

Triangulation in Uppers - 46*
Triangulation in Lowers - 20*

LiLNickT · Nov 3, 2010

Future Plans:

Hydro Assist Ram
Custom Front and Rear Bumpers
Full Cage
Rocker Replacement
231/300 Doubler
5.38's and spools front and rear
Chop the Top
Tube Fenders
Front Suck Down Winch
Stroker

This evening or tomorrow i will be cutting some vents in the hood as well. i shot my #1 cylinder fuel injector at 208*F last night after it kept dying, thought it may be vapor locking... I shot my buddies TJ and it was 135*F. I will see how it does with the hood vents this weekend, if im still having problems i will probably mount an electric pusher fan where i cut the holes for the vents.

DeftwillP · Nov 4, 2010

So how semi-streetable is it?
Oh, and badass.

billyjp2 · Nov 4, 2010

What lenght of time did this build happen over?

jakeWI · Nov 4, 2010

wow! looks great! that is some serious flex

LiLNickT's 3/4 Ton XJ Build

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