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Old 04-16-2017, 05:22 PM   #126 (permalink)
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Line Lock

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Old 04-16-2017, 05:29 PM   #127 (permalink)
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There are still a few details to button up. Main one being the driveshafts, but it's a runner, steers, and 95% of the wiring/hosing is zip tied in place and good to go.
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Old 04-17-2017, 05:00 PM   #128 (permalink)
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I keep drooling looking at this damn thing............

What brake lines and t did you use. About to plumb my brakes. I need to find another sd60 and go rear steer ugh.........
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Old 04-17-2017, 07:08 PM   #129 (permalink)
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Quote:
Originally Posted by offroadman83 View Post
I keep drooling looking at this damn thing............

What brake lines and t did you use. About to plumb my brakes. I need to find another sd60 and go rear steer ugh.........
I used some custom made stainless braided hoses and some prefab hoses (that were the exact length and ends I needed) from Pegasus. They are all -3 AN with a combo of banjo, metric, 1/8" NPT, and -3 AN fittings at different locations. The tees are just 1/8" NPT tees that I bought at Fastenal, then I welded tabs to them to bolt them to my ram mount. All 4 lines at the brakes are the exact same length, and the 2 coming from the master cylinder are the exact same length too. I did this so I could carry two spares to replace a multitude of hoses. I used one 3/16" nylon hose from the line lock to the rear tee that I made myself. I may end up swapping it out for a braided hose eventually but for now the nylon will work in that spot. I have all nylon hoses on my other Jeep and they work well. If you need specifics on lengths and fittings/part #'s, let me know and I'll post them all up.
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Old 04-17-2017, 08:03 PM   #130 (permalink)
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Quote:
Originally Posted by DZ Fab View Post
I used some custom made stainless braided hoses and some prefab hoses (that were the exact length and ends I needed) from Pegasus. They are all -3 AN with a combo of banjo, metric, 1/8" NPT, and -3 AN fittings at different locations. The tees are just 1/8" NPT tees that I bought at Fastenal, then I welded tabs to them to bolt them to my ram mount. All 4 lines at the brakes are the exact same length, and the 2 coming from the master cylinder are the exact same length too. I did this so I could carry two spares to replace a multitude of hoses. I used one 3/16" nylon hose from the line lock to the rear tee that I made myself. I may end up swapping it out for a braided hose eventually but for now the nylon will work in that spot. I have all nylon hoses on my other Jeep and they work well. If you need specifics on lengths and fittings/part #'s, let me know and I'll post them all up.
I'd hate to trouble you. ..just looks really clean and really want to do similar.

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Old 04-18-2017, 08:50 AM   #131 (permalink)
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I'd hate to trouble you. ..just looks really clean and really want to do similar.

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Not a problem. I'll put the info together soon and post it.

Edit:

Info listed below.

Last edited by DZ Fab; 04-18-2017 at 01:15 PM.
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Old 04-18-2017, 01:15 PM   #132 (permalink)
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Here is the info. I used the stock calipers and rotors from the axles. They came without them when I purchased, so I bought 4 from a local salvage yard for about half of what they cost new.


Qty.---Part #----------Vendor----Description

4------3-40-S-B------Pegasus---40 Inch Size 3 TFE Hose, Straight Female 3AN to 3/8" Banjo (CALIPERS TO TEES ON AXLES)

4------3250-02-03S--Pegasus---1/8" NPT Male - 3AN Male Steel Adapter (USED AT THE TEES ON BOTH AXLES)

2------HC002----------Pegasus--Custom order hose, #3 Stainless Steel Braided PTFE Brake/Clutch Hose, 78" long, 10x1.00 90 degree Convex Seat Male Steel x 1/8" NPT Male (MASTER CYLINDER TO AXLE IN FRONT, MASTER CYLINDER TO REAR LINE LOCK)

4------466310--------Fastenal---1/8" F-NPT 150 lb Black Malleable Iron Pipe Tee (USED AT MIDDLE OF BOTH AXLES)

1------PBLK-----------Smiley's---SRP Plastic Brake Line Kit, Includes All Fittings (USED ONLY FROM LINE LOCK TO REAR AXLE)

1------N/A-------------N/A--------1/4" High Pressure Hydraulic Ball Valve (REAR LINE LOCK)

2------50785K41-----McMaster--High-Pressure Brass Pipe Fitting 90 Degree Elbow Adapter, 1/8 NPT Female x Male (USED AT BOTH TEES ON AXLES FOR LINES RUNNING FROM MASTER CYLINDER)

1------50785K81-----McMaster--High-Pressure Brass Pipe Fitting 45 Degree Elbow Adapter, 1/8 NPT Female x Male (USED IN FRONT OF LINE LOCK VALVE FOR ROUTING PURPOSES)

2------69850---------Fastenal----1/4" Male NPT x 1/8" Female NPT Brass Bushing (USED IN FRONT AND BEHIND LINE LOCK VALVE TO ADAPT TO 1/8" NPT)

1------BLF-36C-------Autozone--AGS M12x1.0 male to M10x1.0 female adapter (USED AT MASTER CYLINDER TO ADAPT TO BRAKE LINES. DRILLED OUT THE INVERTED FLARE WITH STANDARD DRILL BIT)

1------ M390426-----Amazon----Dorman M390426 New Brake Master Cylinder (RAM 2500 MASTER CYLINDER)
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Old 04-18-2017, 01:50 PM   #133 (permalink)
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Dang.............your the man...........awesome list!!
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Old 04-20-2017, 11:38 AM   #134 (permalink)
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Do you have any pictures of how you did the belly with no exposed bolts down below?
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Old 04-20-2017, 12:12 PM   #135 (permalink)
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Quote:
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Do you have any pictures of how you did the belly with no exposed bolts down below?
Here's a pic I had of the topside of the skid plate. I'll try to snap some photos of how it attaches.

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Old 05-01-2017, 12:44 PM   #136 (permalink)
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Btt............need More, more more lol
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Old 05-02-2017, 09:52 AM   #137 (permalink)
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Btt............need More, more more lol
Sorry for the lack of updates. I finished the Jeep and sold it.









Just kidding. I got it finished and drove it around the neighborhood the night before I was supposed to take it to Wolf Caves for the Crawl run. I found that the clutch was not fully releasing, and determined that I needed a throwout bearing with different spacing to allow full disengagement of the clutch. At that point I called it and decided not to go on the trip as it was 11 PM and I was only going to get to wheel 1 day anyways due to a wedding shower for a close friend. I had knocked out the list below in the 48 hrs. leading up to that point, which included Qty. 2, 12 hr work days, re-painting my garage door, and approximately 1-1/2 hours of sleep.

To Do List:
1. Purchase more 80W-90 gear oil. COMPLETE
2. Install and route crank case vent hose. Route around engine bay and down on passenger side near battery. COMPLETE
3. Install and route transfer case vent hose. Route over transfer case and down next to the slave cylinder. COMPLETE
4. Remove old steering wheel and install new wheel. Wheel is in downstairs closet. COMPLETE
5. Cut the zip ties that are not yet cut down on the hoses underneath Jeep in rear. COMPLETE
6. Install new yokes on transfer case. COMPLETE
7. Install 80W-90 gear oil in differentials and transfer case. COMPLETE
8. Install and route axle vent hoses. Route over case and down between diff cover and steering cylinder mount. COMPLETE
9. Charge ORI shocks on all 4 corners COMPLETE
1. Front Driver:
2. Front Passenger:
3. Rear Driver:
4. Rear Passenger:
10. Drill & tap slave cylinder for 1/4 NPT. CANCELLED
11. Mount switch panel TEMPORARILY ZIP TIED
12. Mount shift boot for transmission
13. Mount shift boot for transfer case
14. Bench bleed master cylinder COMPLETE
15. Tighten all brake line connections and bleed brake lines COMPLETE
16. Bleed clutch master cylinder COMPLETE
17. Install driveshafts COMPLETE
18. Install hood COMPLETE
19. Install windshield frame
20. Install skid plate
21. Fill parts box with spares, hoses, fluids, etc. COMPLETE
22. Get toolbox prepped COMPLETE
23. Get tire straps from downstairs closet COMPLETE


I have the new throwout bearing, but haven't had time to pull the trans and swap them out though. In the meantime, we purchased a new house, are in the process of selling our old home, and I've been completely occupied with working on the new house and preparing the old house for the sale. Hoping to get around to pulling the trans this upcoming weekend though, so hopefully I'll have good news to report soon.
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Old 05-02-2017, 11:17 AM   #138 (permalink)
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Scared me for a second! Can't wait to see pictures of this thing out on the trail! Hell maybe I'll get mine wheeling ready and see it in person hopefully.

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Old 05-02-2017, 03:22 PM   #139 (permalink)
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Did you make it to wolf caves? Didn't see you out there, it was a blast, wheeled with the crawl guys for a couple of hours, definitely a cool bunch
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Old 05-03-2017, 06:03 AM   #140 (permalink)
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Did you make it to wolf caves? Didn't see you out there, it was a blast, wheeled with the crawl guys for a couple of hours, definitely a cool bunch
No, I didn't make it after all. Hopefully in the next couple of months I'll make a trip somewhere.
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Old 05-03-2017, 10:54 PM   #141 (permalink)
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Any plans to cover the rear steer valve in case of a hose failure?
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Old 05-05-2017, 08:43 AM   #142 (permalink)
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Any plans to cover the rear steer valve in case of a hose failure?
No sir. I will probably add protective hose sleeves at some point, but that's it.
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Old 05-08-2017, 09:48 AM   #143 (permalink)
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Update. The new throwout bearing worked like a charm. I started breaking the Jeep down to pull the trans at 2 PM yesterday. Finished putting it all back together around 8 PM and drove it to my new house. It was a good feeling.
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Old 05-08-2017, 03:32 PM   #144 (permalink)
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I bet that is a great feeling! I can't wait to drive mine again. I'm so close and feel so far.

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Old 05-15-2017, 02:27 PM   #145 (permalink)
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Finally some daylight pics. Drove it around this weekend and it drives great. Hoping to take a trip to Hidden Falls next month for a break-in run.

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Old 05-15-2017, 02:33 PM   #146 (permalink)
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Old 05-15-2017, 02:37 PM   #147 (permalink)
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Old 05-15-2017, 02:44 PM   #148 (permalink)
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Old 05-17-2017, 03:58 PM   #149 (permalink)
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Can't wait for the wheeling pics!!!!!!
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Old 05-23-2017, 06:22 AM   #150 (permalink)
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I was reluctant to buy a dual fill kit for the struts, but ended up biting the bullet and am glad that I did. I bought the ORI dual fill kit, and used it last night. Charging and adjusting pressures on them was super simple. Took me about 45 minutes to do all 4 and that included relieving the pressure I had put in them beforehand. Right now I'm sitting at about 6" of up travel front and rear, with 150 psi in the lowers in front, and 160 psi in the lowers in the rear. I figured I wanted a little more pressure in the rear to help with stability. I took it on a drive around the neighborhood, and it is very stable around corners, even with the spool in the rear. It is a little bit bouncy right now, but I'm going to just keep driving it for a while before messing with it to see if they start to smooth out after a few runs. I didn't have anywhere to flex it out completely, but did find a couple spots and it felt like it will flex very well when off road.

An added bonus is that it still fits in the garage without sucking down the suspension at all.

Last edited by DZ Fab; 05-23-2017 at 06:23 AM.
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