KOH Stock Class - Really Stock LJ Build

[FC4X4]

It's like Christmas around here...


The new 22 gallon Jaz Products fuel cell with 2 1/2" fast-fill & -10an vent.


The Powertank KOH Racer's Package... two 5lb bottles, regulator, hose, bracket & tire repair kit.


A case of Royal Purple for the diffs.


Yukon Dana 60 Superjoints.

[FC4X4]

I finally had a chance to unpackage my Bulldog Alpha 9300lb winch today as well. I'm looking forward to running this thing... the only thing faster is supposed to be the old school Warn 8274. This beauty came with the mounting plate, 100ft. synthetic rope, Hawse fairlead, and remote. I put it all on the scale and it came in at 90lbs even. I like the threaded connection for the remote so hopefully it won't come loose like my old Mile Marker... I also like that the power and ground cables already come sheathed.

[FC4X4]

We had a big day today. A couple buddies came up from Farmington on their day off and helped out.

We replaced the worn-out stock motor mounts with some MORE Bombproof motor mounts with a 1" motor lift. We also used their Bombproof Block Brackets which take advantage of eight threaded holes in the stock block as opposed to the three holes the stock brackets utiliize.


The stock block brackets.


MORE Bombproof Block Brackets.


The stock motor mounts.


MORE Bombproof 1" Motor Lift Mounts.

[FC4X4]

We're also using Mountain Offroad's TJ/LJ Dead Pedals.




We also got the 1" body lift installed today with all-new polyurethane bushings. We'll be using MORE's frame tie-in kit to tie the A-pillar into the LJ's frame through the stock drain-hole location.

[FC4X4]

We also got started on the cage today.

[griportip4x4]

Looking good Bigelow is a great person to work with!

[FC4X4]

Today's progress so far... just brushed up on the bending and notching threads since I was starting to pull my hair out.

[DOUG38S]

Keep it going get it done!

[sallys xj]

looks great so far..keep up the good work..Feb is around the corner...

[Mtn Valley Homes]

[QUOTE Feb is around the corner...[/QUOTE]

No Pressure!

[Bowzer5]

Who did you order your fuel cell from? I have been waiting for a couple weeks on mine from summit. About to call jegs and anyone else that may have one sitting around, need to get my plumbing done!

[FC4X4]

Got mine direct from Brad at Jaz Products... took about a week and a half, but we had a custom (larger) vent fitting installed as well.

Good luck!

[DOUG38S]

Originally Posted by Bowzer5

Who did you order your fuel cell from? I have been waiting for a couple weeks on mine from summit. About to call jegs and anyone else that may have one sitting around, need to get my plumbing done!

Drive over to summit and pick it up!

[Bowzer5]

Originally Posted by DOUG38S

Drive over to summit and pick it up!

Supposedly out of stock and I moved to Nebraska recently . . . I'm going to call around. Thanks for the help.

[gustav129]

Originally Posted by FC4X4

Today's progress so far... just brushed up on the bending and notching threads since I was starting to pull my hair out.

Attachment 643290

That's a weird cage design. I may be new to the idea of racing KOH, but every other sanctioned racing series I've been involved in the past 10 years, requires the main hoop behind the driver to be one piece. Your's is three pieces.

Since that's the main hoop is the main point of protection.......

[Mad Dog 1]

Originally Posted by gustav129

That's a weird cage design. I may be new to the idea of racing KOH, but every other sanctioned racing series I've been involved in the past 10 years, requires the main hoop behind the driver to be one piece. Your's is three pieces.

Since that's the main hoop is the main point of protection.......

I beleive the tech requirements for Stock class are a little more flexable.

Rig looks great, look forward to seeing you out there

[gustav129]

Originally Posted by Mad Dog 1

I beleive the tech requirements for Stock class are a little more flexable.

Rig looks great, look forward to seeing you out there

Looked through 2011 rules, and it doesn't have any info in regards to a main hoop, so it's just weird to me. It is what it is.

I can't wait to see the rig complete.

[FC4X4]

Yes, the cage is a little un-conventional. I have no doubt, however, when completed with all the required gussets, that it will protect Doug and I from any serious rollovers.

While I am not claiming it is anything like the Savvy LJ cage build, I don't think they are using a one-piece main hoop either.

[FC4X4]

Pics of today's progress:

[Phat95YJ]

Looks good man, I'll be rooting for ya!

[deuce]

Subscribed

[Hoose]

Looking good!! See ya on the lake bed.

[FC4X4]

Thanks to everyone for their encouragement. I have a lot to do, but we'll be there!

Next, many thanks to my wife who has been more than supportive of my long days and nights in the shop.

Thanks also to ToyCrwlDevlp for pitching in a couple of long days to get the cage almost finished. Too bad we ran out of wire for the MIG welder at 9:30 tonight.

Here's the progress photos on the cage.


We got some triangualtion and gussets going today. We still need to get the B-pillar triangulation in, as well as the seat-belt bar, rear frame tie-ins, and the rest of the trick tabs for the roof and firewall.


We got the door bars and the seats in.


I am really happy with how the rear deck portion of the cage came out. It looks very strong and is going to provide some good mounting options for the spare tire, Artec quart-crate, and Powertank.


Here is the rear firewall. I picked up a piece of scrap diamond-plate from my father in-law for free. I took a picture of the template I made to fit the firewall on the first try... no cut & fit, cut & fit here. I made the template, cut the diamond-plate and it fit first try. You simply cut some Masonite to the approximate shape you're trying to match... then hot-glue smaller tabs of Masonite all the way along the perimeter to match the contours and notches. This is way easier than cardboard.

[Phat95YJ]

That cage looks nice! keep up the good work man.

[FC4X4]

I need some help figuring out how to re-route the PCV/CCV Valves so that when I am driving on my side (or upside down) that I don't pull oil into the air intake. I searched and read up on the 20 or so threads that cover this issue, but I will be honest that I don't know exactly what to do that also incorporates a catch-can into the system. How do I plumb this?

I used to have a '95 YJ with a 4.0L engine and capped the PCV system. That didn't work too well; eventually I started blowing oil out of the distributor and oil pan gaskets. I don't want to repeat that here.

Here is a picture of the stock routing on the 2006 LJ. There is one PCV that vents to the air-intake tube and one that connects directly to the intake manifold.



What is the correct way to delete both of the paths for oil to enter the intake, allowing the engine to breathe properly, while incorprating a catch can and a vent that will pass tech? Here is the catch can I will be using.



I purchased two of them. I figured I would install one at the back of the Jeep for the rear axle and one at the front for the PCV, transmission, and front axle. I don't really understand how I am supposed to route the hoses though. It seems like if the catch cans are vented, that they would still leak if rolled over. HELP!