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Discussion Starter #1 (Edited)
Specs:

97 TJ 2.5 liter AX5/231J
3.5 Inch Tera Springs
Custom 3 link Front, Short Arm Rear (For Now)
Locked D30/Limited Slip 8.8

Pic In 2008


Current Progress Pic 6/19/2010



Plans

This build is going to be a work in progress, Or a slow build.

  1. Upgrade Steering - DOM Heims - Done!
  2. 3 link the front - Done!
  3. Build Track Bar - Done!
  4. Build a truss for the D30 - Done!
  5. Cut Fenders - Build tube fenders -Done!
  6. 4 link the rear (Gathering Parts)
  7. Full Roll Cage - Done!
  8. Built Front Bumper - Done
  9. Building Rock Sliders - in progress

I currently running 35s, and will stay there until I come across a front axle, Not really looking just if I happen to find one then I will address the D30, Until then I plan on trussing it and wheeling it. I plan to keep the 3.5 inch springs and just build a 3 link in the front and a rear 4 link.

This is another poor mans non hardcore build, and your input is welcome.

Links to some write ups of small projects on the jeep.

Second Skin Dead Liner Install
Cheapo Hand Throttle
 

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Discussion Starter #2
Steering

So here is what I am currently working on. I am building my steering from of 1 3/4 3/8 wall DOM tubing (7 feet of it) and 3/4 Heims. Here is what I started out with.
Tubing

Heims - Thanks Ruff Stuff

Mocked together

I drilled my knuckles and pitman arm out to 5/8 (I got an Industrial grade 5/8 bit from a supply house well worth it) and I am using 5/8 bolts and 5/8 step down spacers at the knuckles and 5/8 high misalignments at the pitman arm.
Here was my first design welded up


 

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Discussion Starter #3
There was some roll in the steering do to heims, Very little but I wanted it tighter so I added a bushing.

After I got done with I just didn't like how the drag link ties into the tierod. I wanted a double sheer mount and I was concerned the two would bind. So I got some brackets and did it this way.
Here are Brackets courtesy of Ballistic Fab

And here is how it is now.


 

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Discussion Starter #4
Since I got the steering done, I needed a solution for the track bar, I was able to get some more 1 3/4 tubing (Actually enough to 3 link the front also). So I decided to build it just like my steering arms. I had to relocated the axle bracket in order to clear the steering.
I ordered this bracket from Ruffstuffspecialties.com

I moved it to the top of the axle and offset it 2.5 inches to match the factory offset. Here are some pictures of it tacked in place and mocked up.

Looks like it will work well, I just have to burn it in and gusseted up. I am going to use these to gusseted it. There 1/4 thick and from DIY4X.com.
 

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Discussion Starter #5
So here's my plan for the truss on the D30, I have some 1.75x2.75 1/4 inch wall square tubing, I am going to cut it on an angle. I plan on using it kinda like a large gusset to help with the tube flex the 30s are known for.

This gives you the idea.



I am going to mock it up in card board and see how it going to fit.



Finishing up my front trackbar. Got some paint on it. I am welding the front track bar bracket on, Hopfully I will get the truss cut today and I can start the fitting process on it.

Trackbar Specs - 1.75 DOM 3/8 walled with 3/4 heims

 

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Discussion Starter #6 (Edited)
Side Note

I finally did my SYE and CV Drive Shaft, Like a dumb ass I wheeled 8.8 with the stock shaft and busted it due to binding, Sometimes I get in a hurry, I should done this a year ago. Got a ZJ shaft from my Brother in Law and had it cut down to size.

Nothing special to most, But to me it is.

A local shop CCC Truck parts did the shorting on it.They did an great job. Had them redo the whole thing, All new u joints, CV joint, shorten and rebalance. They even painted it. Paid like $170, Hell of allot better than $300 for a new one.

I dropped it off at eight and it was ready by noon. They kicked ass on it.




Tonite I hope to get the truss cut since it's going to interlock with the track bar mount, Then I can get all that welded in and then it might be mobile again. At least until I start the 3 link. (Which i have the parts just need the time)
 

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Looks good, but those Heims or rather the size of, makes god kill kittens.
 

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Holy hell batman !!! Do u really think u need it that beefy? I mean u got 35's and a D30... Have u flexed it yet looks as if your going to have some binding with the track bar..... Props for the beef on the tubing though
 

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Discussion Starter #10
Holy hell batman !!! Do u really think u need it that beefy? I mean u got 35's and a D30... Have u flexed it yet looks as if your going to have some binding with the track bar..... Props for the beef on the tubing though
It all clears barely,

I work next to a large machine shop, the tube was something they needed to clear out, so I got it for like nothing. I still have enough to link the front, As soon as the track bar is ready to go, I am starting the 3 link.
 

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Discussion Starter #11 (Edited)
Do you guys see any issues with making my front links out of 1 3/4 3/8 walled DOM with 3/4 heims on the frame side and a ballistic joint on the axle end?

I have read other builds with guys using them, I figure with the weight of my TJ, 4 banger and all, I should be ok
 

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I dig the steering beef. In the pic in post 5 you cant hardly see the axle tube because the tie rod is so dang big.:grinpimp:
 

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Discussion Starter #13
I dig the steering beef. In the pic in post 5 you cant hardly see the axle tube because the tie rod is so dang big.:grinpimp:
I have joked about hanging a recovery point from the center of the tie rod.:grinpimp:
 

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Discussion Starter #14
So here is what I decided on the links for the front.

I building the lowers out of the 1 3/4 inch 3/8 walled DOM, I using a Ballistic Joint welded to the Axle end, And I went with a Creeper joint threaded in the frame end, I going to tap the DOM for the 1.25 threads.

Here are ends I just bought from "Indy Will" on here.



On the upper link for the front I am going with a 3/4 heim on the Frame side and a poly bushing in the mount on the diff. I plan on using a summit joint in place of the bushing when the budget allows. But for now I will use the bushing. I haven't decided on the DOM for the upper, If I have left over of the 1 3/4 I will just use it, If not I may go with a 1.5 .250 DOM.
 

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Discussion Starter #15
Truss

Starting on the truss for the D30.

I using this 2.5 X 1.75 .250 square tube


I made a card board template to help me get it closer to the shape, I still going to have to shape it to fit.


Kids are in bed so I will have to cut in the morning.
 

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Discussion Starter #16
Truss

Well I got some work done on the front axle today, I got the track bar mount burned in, and the Truss cut and the front side of it welded on before I ran out of time.

I cut it with a saw sall and cut off wheel on my grinder, Man what a chore that was. But I got it done, I notched it around the track bar mount in order to help brace it to the axle, I am also going to add a gusset between the track bar mount and the truss, That should lock it all together.

I know my welds ain't purdy, I will clean them up
 

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Discussion Starter #19 (Edited)
Lower Link Brackets

I trying to decide on what to do for my lower link brackets in the front, I want to place them as close to the front of the skid as possible.

So should I just build some? If so what have you guys done?

Or should i just buy some?

I looking at using these from Ruff Stuff


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