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Discussion Starter #1
I finally mostly consider my rig bad ass. I just finished the one ton swap and built mostly every piece, minus the actual brackets etc.
I had some help along the way here and had some good reception to what I was doing so I figured I would post the progress of my rig over the last ocuple years.
It started when I came home with this 2k xj on a rustys 6.5" lift and 33's for virtually no money.


It didnt take long before I had the goofy flares and shock boots off



Then I wheeled it. I installed an aussie locker in the rear and started wheeling.



Then I picked up some 35's and radius arms.



at the same time I installed 4.88's and a high pinion front.





I decided to lower it, and got it down around 4"
Then I wheeled it more





Then made stiffeners and plated my x member



I got a set of hoops from Tim and LII

 

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Discussion Starter #2
Then I decided 36" bias Iroks sounded like a good idea



I put in WJ knuckles and brakes and built x-over steering and wheeled it some more





until this happened

 

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Discussion Starter #3
I had been going back and forth for a while on axles. I already had a 10.25, and a KP 60. I ended up selling the 60 here undecided on what to do.
So when the pinion broke it was time. I found a BJ 60 on craigslist for 300$ so I went and snagged it.

I pulled it apart and got to work





Then I got an e-mail update from the NE for sale thread here. "TheFreek" had posted a dana 70 for sale, already geared and locked with discs. Just what I needed to save some time and money. So I sold the 10.25, and my 8.25 and made my way to PA to get it.





I picked up another set of iroks for a 17" rim for 200$



I started to get the brackets for the front mocked up



Then I got a nice order of parts from ruffstuff

 

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Discussion Starter #4
I started to get it all mocked up



Made some mid arms out of 2" OD 1/4" wall DOM



Then I tried to figure out what to do witht he uppers. With some guidance from the members here I decided to incorporate the track bar bracket and upper link mount into one






In the meantime I got the rear underneath and perches welded on

 

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Discussion Starter #5
Then I got the track bar mocked up. My goal was to keep all of the links straight. So I moved the frame mount as far forward as I could without hitting the draglink or pitman arm



Threw some 5150's in the rear



and bought one of my favorite tools ever. Yukon bearing puller.



So the front axle came back out to get final welded and geared.









 

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Discussion Starter #6
Then it went back in for the last time.



got new brakes



and new wheels



I shortened a front shaft, and used an old tom woods slip I had laying around



and started to mock up the drag link and steering







and got it back down on its own weight



 

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Discussion Starter #7
This past Sunday I got to take it out on its maiden voyage.









I have a few things left to do. Most importantly is hydro assist.
I will be using a surplus center 8" 1.5" bore 1" shaft cylinder. and 3/8" hoses.
From what I read in the assist thread its the most common. I was going to run the 3/4" shaft, but they dont make it with the swivel eye and its what I prefer to run, so thats why im thinking the 1" shaft.

Also on my list but not in the immediate future is a good set of radial tires. IF I buy new it will be mtr's because Im a goodyear dealer, but Ill look around for a good deal on a used set.

Some of the other specs;
95 f350 D60 front. Dual piston calipers. 5.13's welded
late 70's D70 rear. Detroit 5.13's, ruffstuff disc brackets, gm calipers etc.
Im currently using the stock 2000 MC and it works pretty well. Prop valve is gutted.
Lower links are 2" 1/4" wall
Upper is 1.750" 1/4" wall.
All ends are ruffstuff heims.

Next things on my list other than that are;
box rockers, which will also serve as a tie in to a hybrid cage.
Ill update as I go. I know you guys like to see a good start to a build thread though, I hope I did ok. If not




















:flipoff2:
 

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Ive your other thread in here. Looks like it came out really nice.

Make sure you add some support to the bottom of the frame where the panhard mount is welded on to get more weld area and box the rufftuff mount in.
I had mine just welded to the bottom the way it came and it ripped my frame beacause there wasnt enough contact area to weld to.

And the dodge 2500 mc upgrade is WELL worth it. You wont believe how good your brakes can work.

Got any pics of the upper control arm mount frame side?
 

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Discussion Starter #9 (Edited)
Ive your other thread in here. Looks like it came out really nice.

Make sure you add some support to the bottom of the frame where the panhard mount is welded on to get more weld area and box the rufftuff mount in.
I had mine just welded to the bottom the way it came and it ripped my frame beacause there wasnt enough contact area to weld to.

And the dodge 2500 mc upgrade is WELL worth it. You wont believe how good your brakes can work.

Got any pics of the upper control arm mount frame side?
The whole inside is welded to the frame. and there is another plate that is the height of the bracket, that is also welded to the inside of the frame. I didnt want to take any chance there. The plate thats welded to the frame is 3/16", welded full perimiter and has 4 5/8" rosettes. Im pretty confident in it, but you never know.
The upper link is actually on the x-member and uses the original lower mount from my radius arms. It is not perminent. But worked out with my time and budget concerns for now.
A new x mamber will come with the doubler or atlas, to be decided later.
you can kind of see it here


ah, here it is. This is with the old lower links hanging. But its where the upper is mounted now. Its only about 3" of frame side seporation. But its light years better than the radius arm setup was. When it gets a new x-mamber it will be up another few inches. It will be flat bellied then too.





and thanks. Im really happy with it so far. Only one wheeling trip in though
 

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I think im in love! Dont tell my wife...How close is the track bar mount to the diff during driver side uptravel?
 

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Discussion Starter #13 (Edited)
I think im in love! Dont tell my wife...How close is the track bar mount to the diff during driver side uptravel?
HAHA thanks man.

VERY close. Full bump its probably 1/16" from it. Where its bumped now its maybe 1/2-3/4" but I need a little more up.
 

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Discussion Starter #14 (Edited)
Im going to order my assist ram and hoses from surplus center this weekend.
Any issues with the stuff Im looking at?
8"x1.5"x1" shaft cylinder.
3/8 hoses. Im thinking 36" to be safe, but maybe 30's. I have to measure better.
I think Im going to use the ballistic tie rod clamp also, unless anyone else has another recommendation. i dont want the tabs welded to the tie rod, one turn on it changes the toe like 1/2-3/4". If I ever need to change it I want to make sure I can.
Im not sure yet but I think its going to get mounted off of the diff cover. I have to size it up once its here.
 

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Build is looking great...... Subscribed.
 

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Discussion Starter #17
Looks good Dan, If I was around last weekend when you called I would've been out there with ya, ohwell there's always next time!
Also I may have past over it but.. any ideas in a traction bar for the rear so you dont beat the leaves up too bad?
Going to get a kit from ruffstuff i think. I was going to order one from Tim at LII but I dont think he ever finished his XJ specific one. Ill have to see. But one or the other. It needs it.
 

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Discussion Starter #19
Got to wheel a bit today. Did some awesome lines. Waiting on a few pics still but heres what I got off of my camera.

















 

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Discussion Starter #20
couple more to do this spot more justice. Even this doesnt do it. The rocks were all covered in moss. Once the back tires hit the rock the back end slid over and almost smashed out the window, dented right behind it, put a good one in the hatch too.





 
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