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Project FIGJAM

97K views 548 replies 93 participants last post by  SkysTheLimit 
#1 · (Edited)
To start things off lets do a little back story. Bought the jeep back when I was 16 when it was more or less stock other than a tired small block Chev. Over the past 7 1/2 years I slowly built it into a more capable PNW style trail jeep. The last year of jeepin it started to become a bit of a hassle with tons of little things breaking/wearing out and I started to worry almost everytime I was gonna be "that guy". Never in its life having a full tear down, it was starting to show its age and I did my best to keep it together by strapping the frame after it broke, tied cage into frame, redid the suspension, etc. Anyways, here's the old girl.

TBI 350
Dana 44's F/R
t18
4.27's w/lunchbox lockers
Dana 20
Spring under rear with yj's
Spring over front front with toyota rears
Chromoly shafts
Redhead steering box
36 tsl's

[/url]jeep fenders by Alex Velasquez, on Flickr[/IMG]

[/url]IMG_20170225_170455782_HDR by Alex Velasquez, on Flickr[/IMG]

[/url]FB_IMG_1491176877168 by Alex Velasquez, on Flickr[/IMG]

Here was its final resting place after cracking bellhousing and fed up with working on old grimy parts.

[/url]IMG_20170830_164249355_HDR by Alex Velasquez, on Flickr[/IMG]
 
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#210 ·
It's hard for me sometimes, to slow down and take my time.
Your "quick crossmember" for example. All it takes is a little extra time and dedication, and you end up with a very nice, "simple," piece.

I love your patience and artistic skill. Carry on!
 
#212 ·
You front double sheer and an knuckle tie it should add some strength, but I dont see it adding much if the big spacer isnt somehow tied into the knuckle....In a stress failure situation(which you are trying to eliminate) i see it just breaking the tie rod hole of the knuckle off.
 
#214 ·
The big "spacer" is more or less just a spot to attach the double shear tab for the end link bolt. The hi-steer arm it self is both keyed and 6 bolts so the amount of force to shear all that would be quite the impact. My concern was the single shear on the bolt, so with everything tied I'm hoping to have made the heim joint my weak spot since those are easy to carry spares of
 
#215 ·
Double shear tabs are on.

[/url]IMG_20180917_105438547 by Alex Velasquez, on Flickr[/IMG]

[/url]IMG_20180917_112541780 by Alex Velasquez, on Flickr[/IMG]

Cut it then needed to shrink radius some more. OCD kicking in haha

[/url]IMG_20180917_113403578 by Alex Velasquez, on Flickr[/IMG]

[/url]IMG_20180917_113914198 by Alex Velasquez, on Flickr[/IMG]

[/url]IMG_20180917_122933916 by Alex Velasquez, on Flickr[/IMG]

[/url]IMG_20180917_135159846 by Alex Velasquez, on Flickr[/IMG]

[/url]IMG_20180917_135957538 by Alex Velasquez, on Flickr[/IMG]
 
#216 ·
Also started on making a plate to tie sway bar tube into winch plate so its not just being held in place by the ends.

[/url]IMG_20180917_130801789 by Alex Velasquez, on Flickr[/IMG]

Quickest method for me was to rough cut with porta-band, grinder with flap disc to get close, then fine tune with file.

[/url]IMG_20180917_131125658_HDR by Alex Velasquez, on Flickr[/IMG]

[/url]IMG_20180917_132953857 by Alex Velasquez, on Flickr[/IMG]

[/url]IMG_20180917_133916361 by Alex Velasquez, on Flickr[/IMG]

All cleaned up and sprayed with WD

[/url]IMG_20180917_135215906 by Alex Velasquez, on Flickr[/IMG]
 
#217 ·
Driveline stuff

[/url]IMG_20180910_201311309 by Alex Velasquez, on Flickr[/IMG]

For those of you interested. Not very impressed with the Essentially Offroad kit, their yoke is on the left compared to WOD Spicer unit on the right.

[/url]IMG_20180911_163527053 by Alex Velasquez, on Flickr[/IMG]

[/url]IMG_20180916_162239010 by Alex Velasquez, on Flickr[/IMG]

Went with the Essentially Offroad driveline kit for the intermediate since I was using their carrier bearing setup. Both front and rear drivelines with be WOD

[/url]IMG_20180916_165215159 by Alex Velasquez, on Flickr[/IMG]

Mocking length with exhaust tube

[/url]IMG_20180916_165135466_HDR by Alex Velasquez, on Flickr[/IMG]

[/url]IMG_20180917_140221825 by Alex Velasquez, on Flickr[/IMG]
 
#218 ·
#222 · (Edited)
Correct. The sway bar tube itself still needs to be situated and fully welded on the sides first prior to tying into plate. Then it gets weird with the winch plate haha there's 2 outside welds that wouldn't be accessible with the sway bar mount in place. Dilemma is to weld the winch plate out of position (if I feel like I can make it look good) or wait until I pull everything apart and flip chassis on its side. There's a method to my madness most of the time haha only reason it's not fully welded right now is because of sequence of welding I gotta do
 
#226 ·
That makes sense, I appreciate the explanation. I'm always looking for the how's and why's to better understand how to not eff things up myself :D
 
#228 ·
I was able to squeeze in some weld time at lunch today to button up the sway bar arms. Honestly, Im not super stoked on how they came out, but powdercoat will cover up the flaws.

***I AM NOT A TIG WELDER***

[/url]IMG_20180919_093306505 by Alex Velasquez, on Flickr[/IMG]

[/url]IMG_20180919_093458782 by Alex Velasquez, on Flickr[/IMG]

Have a total of 6 passes on each arm.

[/url]IMG_20180919_121000933 by Alex Velasquez, on Flickr[/IMG]

[/url]IMG_20180919_121005776 by Alex Velasquez, on Flickr[/IMG]

It was going halfway decent up until this point, then I started shaking like a dog shittin razor blades for only god knows why... :mad3:

[/url]IMG_20180919_121421028 by Alex Velasquez, on Flickr[/IMG]

[/url]IMG_20180919_143052852_HDR by Alex Velasquez, on Flickr[/IMG]

[/url]IMG_20180919_143105420_HDR by Alex Velasquez, on Flickr[/IMG]

[/url]IMG_20180919_144440185 by Alex Velasquez, on Flickr[/IMG]
 
#229 ·
After i threw a fit for a bit I calmed down and worked on the rig some more when i got home haha And I decided to work on something that could wait till the very end :D

[/url]IMG_20180919_171613854 by Alex Velasquez, on Flickr[/IMG]

[/url]IMG_20180919_175821026 by Alex Velasquez, on Flickr[/IMG]

[/url]IMG_20180919_180434064 by Alex Velasquez, on Flickr[/IMG]

[/url]IMG_20180919_175841040_HDR by Alex Velasquez, on Flickr[/IMG]

[/url]IMG_20180919_180033126 by Alex Velasquez, on Flickr[/IMG]

Tossed on Sway bar arms as well

[/url]IMG_20180919_180312060 by Alex Velasquez, on Flickr[/IMG]

[/url]IMG_20180919_180425911 by Alex Velasquez, on Flickr[/IMG]
 
#240 ·
Probably not the correct way to go about this, but it sorta worked. Still a little way to go

[/url]IMG_20180921_163710054 by Alex Velasquez, on Flickr[/IMG]

[/url]IMG_20180921_172944063 by Alex Velasquez, on Flickr[/IMG]

Then cycled the rear suspension some more to make sure everything clears. Coil/tire was my biggest concern and needed to move the mount in about a 1/2", but needed to clearance the tube so I could still get a nut on the bolt.

One of those things that turns out to be way more complicated than it needs to be. Anyways, pics will explain.

[/url]IMG_20180922_101504716_HDR by Alex Velasquez, on Flickr[/IMG]

[/url]IMG_20180922_101519798_HDR by Alex Velasquez, on Flickr[/IMG]

[/url]IMG_20180922_102122677 by Alex Velasquez, on Flickr[/IMG]

[/url]IMG_20180922_102607632_HDR by Alex Velasquez, on Flickr[/IMG]

[/url]IMG_20180922_113051017_HDR by Alex Velasquez, on Flickr[/IMG]

[/url]IMG_20180922_113058029_HDR by Alex Velasquez, on Flickr[/IMG]

[/url]IMG_20180922_113847864 by Alex Velasquez, on Flickr[/IMG]
 
#241 ·
Chopped down the passenger mount and go it situated where it needed to be. Fully flexed out I have about a 1/4" clearance between tire and coil with the current wheels. I have a set of aluminum beadlocks that I plan to run and they have less BS than what I'm mocking with.

[/url]IMG_20180922_124401170 by Alex Velasquez, on Flickr[/IMG]

[/url]IMG_20180922_124407510 by Alex Velasquez, on Flickr[/IMG]

Welded up drivers side

[/url]IMG_20180922_140243838 by Alex Velasquez, on Flickr[/IMG]

Added in support tube tying mount into top corner of cage

[/url]IMG_20180922_160911709 by Alex Velasquez, on Flickr[/IMG]

[/url]IMG_20180922_160904756 by Alex Velasquez, on Flickr[/IMG]

[/url]IMG_20180922_160818973 by Alex Velasquez, on Flickr[/IMG]
 
#242 ·
Fitting the tubes in the corner were actually pretty easy. The little coping guide was an absolute life saver.

[/url]IMG_20180922_154734562 by Alex Velasquez, on Flickr[/IMG]

[/url]IMG_20180922_160757767 by Alex Velasquez, on Flickr[/IMG]

Rough cut and rough fit

[/url]IMG_20180922_165051787 by Alex Velasquez, on Flickr[/IMG]

[/url]IMG_20180922_165125754 by Alex Velasquez, on Flickr[/IMG]

[/url]IMG_20180922_165132179_HDR by Alex Velasquez, on Flickr[/IMG]

All welded up

[/url]IMG_20180922_175359901 by Alex Velasquez, on Flickr[/IMG]

[/url]IMG_20180922_175349610 by Alex Velasquez, on Flickr[/IMG]

[/url]IMG_20180922_173510186 by Alex Velasquez, on Flickr[/IMG]

[/url]IMG_20180922_174557072_HDR by Alex Velasquez, on Flickr[/IMG]

[/url]IMG_20180922_174503667 by Alex Velasquez, on Flickr[/IMG]
 
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