Winter Project - 2008

Frank Z · Jan 15, 2008

Since I finally got the motor for our Stratus rebuilt and running and finished a few other odds and ends it's time to get busy on the XJ.
The first things I want to get done are redesigning the crossmember/long arms, add frame stiffeners, and swap out the transmission too.
First up, what it looked like before getting started....

Rock sliders are off...

Me getting the long arms unbolted...

Crossmember/xfercase skid is out...

Started cleaning up for welding on some frame stiffeners....

Frank Z · Jan 17, 2008

Passenger side is done, drivers side goes on tomorrow.

Frank Z · Jan 18, 2008

Drivers side is done...

jragan · Jan 18, 2008

Looks nice, did you build the stiffeners?

Frank Z · Jan 18, 2008

Yeah, used some 4"x4"x3/16" wall box tubing.

Frank Z · Jan 20, 2008

Made a little progress today. Found out that the 98 transmission is set up a little bit different than my current 97 tranny. First up I had to remove the tailcone and swap the rear output speed sensor and rotor(changed from 1-pulse/rev to 4-pulse/rev.) You can see the 97 rotor on the bench beside the new tranny.

Seemed like a good time to replace the existing filter.

Yes I cleaned and reinstalled the magnets.

Daniel helped out today, couldn't have got the transmission in without his help (Thanks Son!!)

New transmission is now installed and the transfercase is back in palce as well. More work tomorrow as time allows.
Thanks for looking!

Caged94XJ · Jan 23, 2008

Frank how are you going to wheel that thing with it torn apart... :doh: Looks good Frank... Let me know if you need any help...

Frank Z · Jan 25, 2008

New crossmember is almost ready for primer and paint.
Started with this...

Now have this...

Still need to box-in the LCA mounts. Hopefully I can get it installed this weekend and fab up the new LA's.

Frank Z · Feb 3, 2008

Got a little more accomplished since my last post...

Found a neat website to print out templates for coping tubes. Tried it out on the LA's.

First pic is the template after printing and cutting.

After tracing the desired pattern and grinding the tube the end result was pretty darn good.

New crossmember is on too...

Longarms are done and installed...and the tires no longer rub!!

Stay tuned.:beer:

tayman · Feb 3, 2008

do you have any specs on your long arms? Any plans? I'm interested in building some very similar to what you have.

rcmf5525 · Feb 3, 2008

That is bad ass! I am thinking about fabbing a cross member as well. I can only hope it turns out that good. Keep the photos coming!

Stumpalump · Feb 3, 2008

Very impressive Frank! Those welds look a whole lot better than the ones I saw you do with a couple of batteries but those were quite impressive too! What didn't you like about your old long arm set up? And did you use you new home made bender to get that nice bend on your skid?

Frank Z · Feb 3, 2008

Thanks all! No spec's or dimensions to share, building evrything on the fly so to speak. The previous LA's were almost exactly the same but the frame ends were directly under the frame. This allowed the tires to rub and limited my steering. The new design moves the frame ends inboard slightly so that the arms are perpendicular to each other. Since I welded the frame stiffeners on, the original crossmember was 3/8" to narrow so a new one was fabbed up.

The hoop that forms the transfercase skid was a spare that I had in the garage.

The bender should be finished tomorrow and I'll use it to complete the new sliders...stay tuned.

outlander · Feb 3, 2008

Clean work there Frank.....
Got a link to the site that you printed the templates off of?And any info on that homemade bender also???

Were you worried about warping the unibody due to heat when you were welding these stiffeners up?

tayman · Feb 3, 2008

Thanks all! No spec's or dimensions to share, building evrything on the fly so to speak.

alrighty then! how about this..... what kind of joints did you use?

Frank Z · Feb 3, 2008

Here ya go...
http://www.metalgeek.com/cgi-system/php5.cgi/static/cope.pcgi

The ends on the lower arms are the Large TeraFlex Joints and OEM bushings on the axle side. Uppers use the Medium TeraFlex Joints.

I stich welded about 2-3 inches at a time on the stiffeners and allowed extra time for the metal to cool before welding in the same area.

The plans for the bender came from http://www.gottrikes.com/Tube_Bender.htm

tayman · Feb 3, 2008

awesome, thanks.

WVUwheeler · Feb 3, 2008

Look good, I just read your other post where you fixed up the TJ. Seems like you have been pretty busy this winter.

outlander · Feb 4, 2008

Thanks!
Good luck with the build....

Frank Z · Feb 4, 2008

Finally got around to installing an AEM cone filter, been putting that off for a while. No pics, but we've all seen cone filters before.:eeks1:

Yanked the Bushwhacker flares...

Getting started on cutting out the rockers...

My son Daniel got into cutting the rockers...

Then he used a flapper to smooth out the rough spots...

Initial fit of the new rockers/sliders...

The boy approves...

Winter Project - 2008

NAXJA Forum User

NAXJA Forum User

NAXJA Forum User

NAXJA Forum User

NAXJA Forum User

NAXJA Forum User

NAXJA Forum User

NAXJA Forum User

NAXJA Forum User

NAXJA Forum User

NAXJA Member

NAXJA Forum User

NAXJA Forum User

NAXJA Forum User

NAXJA Forum User

NAXJA Forum User

NAXJA Forum User

NAXJA Forum User

NAXJA Forum User

NAXJA Forum User

Similar threads