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Old 01-22-2010, 10:43 PM   #1 (permalink)
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Just Another XJ Buggy Build

Well, I'm bored and I figured it's about time I posted this up here.

Yeah, it's just another college built rig, except not exactly a "budget" build

Never done anything REMOTELY close this amount of fab, so i've got a little bit of a learning curve to tackle

Been slowly collecting parts for a while and due to shoulder surgery october before last at the ripe old age of 21 progress started later than I wanted. Being a full time ME student at Colorado State University and working as a Tire Tech at Discount Tire takes a bit of time out of my week as well.

The rig was pristeen when I got it with ~65k on the odometer, but that didn't last long

Couple pics before the teardown:

Clean driveway shot right after it was done (highschool)


Carnage Canyon in Boulder


Indy in Penrose


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Old 01-22-2010, 10:44 PM   #2 (permalink)
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Yeah, I abused it to say the least...

It looked like this after a flop on Upper Helldorado...and the body damage only continued after that day:



So now to the present...keeping up with freinds buggys and other more equipped rigs has become quite the venture.

Specs on the build:

-HP60 from a '79 Ford F350
-14BFF from a mid '70's Chebby
-16" FOA Coilovers on all 4 Corners
-42" Iroks on 17" Black Steelies (weld on locks in the future)
-Double Ended Full Hydro
-Triangulated Four Link Rear
-Triangulated Four Link or 3 Link with Panhard Front
The list goes on...

Well last summer before last a buddy and I drove to nebraska to pick this up:


Whats that attatched to the front end!?


Got it all cleaned up and primed, and bottom of cover shaved to match D60:

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Old 01-22-2010, 10:44 PM   #3 (permalink)
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After a bit of work and a LOT of money...voila!


Specs:
-5.38's, Detroit, RockCrusher Cover, Dedenbear Knuckles, PSC High Steer Arms, H.A.D. Forged 1350 Yoke, Alloy USA inners/outers, Warn 35 Spline Hubs...basically the only things stock left on the axle are the housing, caliper brackets, and hubs...everything else is new.

As well, a box containing some more toys arrived


P.O.S. double ended Ful lHydro Setup

Well this is what it looked like after a day with the sawzall...still more to be cut off:







Got these winter before last...42x14R17 Iroks with about 70% Tread
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Old 01-22-2010, 10:47 PM   #4 (permalink)
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Well next was getting the frame rails sleeved...what a B*TCH.

Drilled out all the spot welds on the leafs hangers and the upper control arm mounts



Then got the rails all flap disc'd and cleaned up






Had to cut some lips off the inner part of the frame rails, weld them together and clean them up...that was oh SO fun





Once was that was all said and done...it was time to get material for sleeving. What I ended up with was...



4" x 6" x 1/4" box...

Yeah a little heavier and thicker than I would have liked to have gone, but it was cheap, and I will have a lot mounted to it, so the beef will help. Well, got to work on it cutting it in half...

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Old 01-22-2010, 10:48 PM   #5 (permalink)
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Several HF grinders lost the good fight cutting that sucker in half

Driver's side fitted up





Everything will be tacked up for the time being, then I'll drop everything and weld it up fully...

Now it was time to start on my Tranny crossmember
I've got 300ft. of 1.75" x .120" HREW to work with on this so most things will be made out of that. I won't lie, getting the logistics worked out on this thing was a nightmare, but I got it to work out.

Started with some tube, and this little sucker I whipped out



I don't have a lot of pictures of when I made this since I kept forgetting my camera, but I'll make sure to when I take it back off since much of the work can't be seen...

Crossmember:


Where bushing attaches to to bolt onto AW4 adapter:






The hex bolts on the bottom allow for the panels to be removed in order for access to the bushing bolt and adapter bolts.

Last edited by freerider15; 01-22-2010 at 10:48 PM.
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Old 01-22-2010, 10:51 PM   #6 (permalink)
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Yeah I know many will say I should have started over with a clean body, etc. etc. but that wasn't really an option. I needed the VIN so I could drive it on the street, and I can't afford I new rig. I don't want to build anything else either as there are more TJ's, CJ's, etc. on one tons than one can shake a stick at, I wanted something a little more original.


Back onto the building...

Did some more trimming and looked at tire placement








 
 
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Old 01-22-2010, 10:52 PM   #7 (permalink)
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Now onto the 4-link. I'll be going with a double-tri setup with 2.25" x .375" DOM lowers and 1.5" x .25" DOM uppers. I'll have a mix of Ballistic and Currie Joints in the 1.25" flavor on the lowers, and 7/8" ballistic uppers. Here's the numbers i will be running on the 4-link, they took me a while to get but AS goes up during bump, and drops during droop.




My workstation and mock setup. I'm using pieces of PVC for mock up arms and to make sure things work.


 
 
Started working on the frame side setup for the links. This was interesting to tackle to say the least. Started with one tube, which I then notched to move it as far back as possible to allow driveshaft clearance....and then cut away a bit more floor :lol:





 
Then I took some 3 x 3 x 3/16 and made the brackets.
 
 
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Old 01-22-2010, 10:53 PM   #8 (permalink)
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Added some bracing



 
 
It then occured to me one hit to where the notch in the cross tube, and i'll have a good and bent crossmember. So I added this...
 



I think that should hold up pretty well:thumbsup:
Might be slight overkill but oh fawkin well...


Starting on the truss for the 14 bolt...

 


My first real attempt at bending tube. I will say this, bending tube is hard to repeat when you've never done it before, and notching is pain in the A$$ and can be VERY time consuming. This shouldn't be as much of a problem as I get more experienced with it.
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Old 01-22-2010, 10:55 PM   #9 (permalink)
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Kinda Finishing up the 14B:

Top plate welded on...this is where the upper link mounts will be.








Oh, and dimple dies arrived!

Finishing up the truss:





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Old 01-22-2010, 10:56 PM   #10 (permalink)
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Lower link mounts top part:





Now to my subframe rails...theres a LOT of work into these. I'll try and let pics speak for themselves. The smaller holes are the 5/8" bolt through holes for the tranny crossmember and rear four link crossmember. The bigger holes will be welded, they are all 1.5" via holesaw.











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Old 01-22-2010, 10:59 PM   #11 (permalink)
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Top view of the rear crossmember as its coming along





Braced the top of the link mounts for some added strength









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Old 01-22-2010, 11:00 PM   #12 (permalink)
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Getting the bottom plating (1/8") started



More finished product...









Installed...





Starting on the upper link mounts....got the brackets all sketched and ready to be cut out...







Overall i'm pretty happy with how its turning out. I'm pretty picky with things so when they're not perfect it bothers me, but i'm accepting things not being perfectly symmetrical in areas as its hard to make them perfect with limited resources :thumbsup: Welds aren't as great as i would like them to be, but I just need to work on consistency a little more, haven't welded this much in a while.
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Old 01-22-2010, 11:03 PM   #13 (permalink)
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Axle side upper link mounts halfway done, still have to get them plated...


Frame side upper mounts...really pleased with how these turned out
















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Old 01-22-2010, 11:04 PM   #14 (permalink)
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Got em burned in...









Not too much flex steer





Next step was to get it rigged up and over to my place...then some more finishing such as removing all the shatty weld spatter

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Old 01-22-2010, 11:07 PM   #15 (permalink)
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looks freakin sweet man. can't wait to see more. i am also in the middle of a build with 42s. only got 18 months in to it now.
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Old 01-22-2010, 11:11 PM   #16 (permalink)
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Got some work done on the 3-link front...
Decided to make my own plate/sheet press...




Some mock up...






Frame side lower link brackets, not 100% complete









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Old 01-22-2010, 11:12 PM   #17 (permalink)
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Rear near full bump...



Then this craziest think happened...all this sheet metal and frame fell off :yes:







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Old 01-22-2010, 11:16 PM   #18 (permalink)
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First off I finished up some work on the rear 4-link, so other than getting the links 100% welded the rear 4-link is DOOOONE!

"Boxed" in the upper mounts:



Well I had started work on sleeving the rest of the "frame," which to say has/was a nightmare is an understatement. I can't count the number of times I had to play cardboard mock up to get things right...and I've still got some fixing to do. I'll kinda let the pics speak for themselves as usual.

Decided to gain a little clearance on the "frame," as it would help my lower link not too hit it:




Driver's side getting done:


This is what took for-fukking-ever, well at least part of it. Its a two peice sleeve for the frame rails, with the out edge being bent in my press to keep it down to two peices. I made these out of 3/16", not 1/4" like the rest of my sleeving.



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Old 01-22-2010, 11:17 PM   #19 (permalink)
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Installed and connected to the frame sleeves, but not yet fully welded on.




"Finished" products...though they're not truly finished since I had to modify them more since my lower link are hitting the recessed portion as seen in a couple pics. Overall i'm satisfied with them, but not 100% happy how they turned out.






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Old 01-22-2010, 11:19 PM   #20 (permalink)
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Oops...



And FINALLY...


Yeah...the tubing has some rust on it. Thats what happens when its been tarped up the best possible but sitting outside since the summer. FINALLY got it from my friends house I started working on the Jeep at to my place...never would have thought it that hard to get the tube moved a whole mile

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Old 01-23-2010, 12:15 AM   #21 (permalink)
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Damn dude I kind of feel like I'm reading my own life story here......Except I didn't cut quite as much off as you did!

You keep good track of build pictures. Hope to see this thing around town someday!
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Old 01-23-2010, 07:09 PM   #22 (permalink)
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vary sick build!! wish i had that kinda money to toss into my rig
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Old 01-23-2010, 08:33 PM   #23 (permalink)
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Picture fail!
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Old 01-23-2010, 09:08 PM   #24 (permalink)
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Me and you should be brothers.... damn, looks familiar except mine is an MJ.

Here's the BASE of my "back half":

Capped unibody rails & Upper Wishbone mounts:



Base just started:


More done:


Rear Lower link Mounts & Driveshaft hoop crossmember thingy:

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Old 01-23-2010, 09:13 PM   #25 (permalink)
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My front axle... (I wish I could have afforded knuckles and High Steer arms!!
I got the Rockcrusher cover and Drive Flanges though!!!

Copper Hammered finish:


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