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Old 02-02-2012, 02:43 PM   #61
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Quote:
Originally Posted by 06TJX View Post
Great build! I have been looking on threads all over the place to figure out the best way to approach a build like this. I am at a loss to buy the RE 5.5" lift or just build my own with DOM and heim joints. Figured it would be cheaper doing it this way but the RE kit bolts right in and is a tried and true product. If you had the money would you buy the kit or build your own? Can't wait to see the front done, this will be a beast!
Sorry for the slow response.

Sometimes I wish I went with a kit. Like the teraflex long arm or the Rock Krawler kit. Though I do kinda wish I went with a bolt on longarm frame mount from teraflex. Would have taken out all the guess work for finding all the right angles. Even getting a rear 4 link frame mount from gen right would have been good to. But they want 250 for just frame mounts. I got all my rear suspention mounts for that amount. Another thing I should have probably done was get adjustable upper mounts, so that I would be able to dial in my anti-squat.

Teraflex longarm bracket. Just wanted the bracket not the arms. My arms are stronger than these at 2" OD and 1/4" thick. My uppers are the same strength as these. If doing a triangulated rear you'll probably have to cut the rear upper mounts off and reweld them at more of an angle.


Genright rear 4 link mount.

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Old 02-02-2012, 03:06 PM   #62
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Though, the way I did it is the way I first invisioned. I'm only missing two things... well three things in my driveline that I wanted. Full float 9" with lockouts, high pinion front, and a 3 speed transfercase(big money). Ok so I really want a diesel jeep too but who doesn't(4bt turbocharged).

I'm getting my triangulated 4 link rear and 3 link front with all rebuildable adjustable ends and heavy duty control arms for less than what the kits would cost. Granted it does take more than 10x the time to install. You will end up spending more than you think and run into tons more problems than bolt on parts. I think it will be worth it when I'm all done. All built by me, designed by me, and installed by me. No one can accuse my Jeep of being a bolt together bought Jeep.

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'03 TJ Sport / D30/Ford9 / 35x12.5x15 KM2 / D window black steel 15x8 wheels / 3" custom long arm lift / SYE & 1350 DS / JKS BL / 1" MML / Smittybilt's front bumper, Tube fenders, Rocker guards, and rear bumper / High Rock Tire Carrier
Just bought a True Hi9 rear and a D44 front, both with ARB's and 4.88 gears!! Check out the build!
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Old 03-06-2012, 02:04 PM   #63
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Finally getting a little more done. Got around to replacing the front lower control arm bushings. Found out that they are Rancho control arms. I feel practically no difference in driveability after the new bushings went in. Even though the old ones were real bad, the metal sleeves could move around in the bushing. My front vibration must be coming from something else. Oh well, I have all new front axle parts going in at some point.

I finally wired up my fan switch so that I can bypass the fan controller. Did this after the second controller died. I also picked up a hobby box from radio shack to place all the relays and fan controller. Anyone want a schematic? I had to use 2 relays since the switch I had was only a 3 position center off SPDT. I wanted the center position to be auto, up to be off and turn on a dash light, down to be manually on. The wire have been wrapped after the pic and I plan on putting silicone on the ends. I think water killed my last two fan controllers. Sadly this box takes up all the room for my second horn I installed. Will have to find a new spot for it.


I also mounted my air compressor. It was real easy. Now I just have to plumb all the lines...


Next up fix my damn window that keeps falling down on the highway in 38 degree weather. I haven't had the door panel on it in months. Sometime soon, move axle shock mount back down to allow more uptravel. I need to outboard the shocks.

Also got great news a few weeks ago. My wife is pregnant! Also means I better finish it in the next few months or it won't be getting done in at least a year.
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'03 TJ Sport / D30/Ford9 / 35x12.5x15 KM2 / D window black steel 15x8 wheels / 3" custom long arm lift / SYE & 1350 DS / JKS BL / 1" MML / Smittybilt's front bumper, Tube fenders, Rocker guards, and rear bumper / High Rock Tire Carrier
Just bought a True Hi9 rear and a D44 front, both with ARB's and 4.88 gears!! Check out the build!
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Old 03-06-2012, 04:02 PM   #64
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Nice work man and congrats on the baby
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Old 07-13-2012, 08:44 AM   #65
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What part number did you use to hook up the rear 9" ebrake to your TJ ebrake. Alos what hardware did you use to bot your EB axles to your stock brake lines? I'm doing this swap too & I'm stuck on the brakes.

Very nice build by the way!!!
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Old 07-13-2012, 11:18 AM   #66
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What part number did you use to hook up the rear 9" ebrake to your TJ ebrake. Alos what hardware did you use to bot your EB axles to your stock brake lines? I'm doing this swap too & I'm stuck on the brakes.

Very nice build by the way!!!

Thanks. I've been busy with a new job and the hours of commuting through DC. Not to mention getting ready for a baby in the house. The build has slowed down a lot.

I actually don't have a parking brake right now. Though I have all the parts to install 8.8 brakes on it, including custom Currie rotors with 5x5.5 bolt pattern. I need to get new axle bearings and take it to a shop to get the 8.8 backing plate on. As it goes on before the bearings and axle retainer. I am going to use ZJ parking brake cables which I heard would work. I got them at the house and they do match the 8.8 brakes and my stock e-brake hookup.

I am actually thinking about using a different caliper now. If you want the parts. I already have a caliper mount welded on my axle with a mount spacing of 7.05", which works with old 70's calipers. If I find an eldorado caliper with a built in e-brake that would save me alot of time as it is just bolt on and I would only have to fabricate a cable.

For the brake cables. I went with a chevy truck rear brake line from the frame to the axle. It is maybe 6" longer with the stock connections. Also you can use the brake hoses you have and drill out the caliper side to the correct diameter. That is what I did instead of trying to track down new hoses. My calipers took a 7/16"-20 banjo bolt, I used a step drill and it conveniently deburrs the hole after you get it to the right size.
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'03 TJ Sport / D30/Ford9 / 35x12.5x15 KM2 / D window black steel 15x8 wheels / 3" custom long arm lift / SYE & 1350 DS / JKS BL / 1" MML / Smittybilt's front bumper, Tube fenders, Rocker guards, and rear bumper / High Rock Tire Carrier
Just bought a True Hi9 rear and a D44 front, both with ARB's and 4.88 gears!! Check out the build!
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Old 07-13-2012, 11:21 AM   #67
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Oh i have done something semi recently. I welded on tabs to my tire carrier to mount my hi-lift jack on.



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'03 TJ Sport / D30/Ford9 / 35x12.5x15 KM2 / D window black steel 15x8 wheels / 3" custom long arm lift / SYE & 1350 DS / JKS BL / 1" MML / Smittybilt's front bumper, Tube fenders, Rocker guards, and rear bumper / High Rock Tire Carrier
Just bought a True Hi9 rear and a D44 front, both with ARB's and 4.88 gears!! Check out the build!
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Old 07-13-2012, 11:48 AM   #68
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I like your build man Do you DD your wrangler or have another car, I don't think i saw. I agree with you about the save money but lose time aspect. Thats fine with people who love to work on stuff and get the satisfaction of doing everything themself. The big issue is having another vehicle. Anyways, you have been doing some cool stuff, I'll check in. How far are you along on the build until completion would you say?
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Old 07-14-2012, 12:06 AM   #69
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Originally Posted by TheTJRod View Post
Thanks. I've been busy with a new job and the hours of commuting through DC. Not to mention getting ready for a baby in the house. The build has slowed down a lot.

I actually don't have a parking brake right now. Though I have all the parts to install 8.8 brakes on it, including custom Currie rotors with 5x5.5 bolt pattern. I need to get new axle bearings and take it to a shop to get the 8.8 backing plate on. As it goes on before the bearings and axle retainer. I am going to use ZJ parking brake cables which I heard would work. I got them at the house and they do match the 8.8 brakes and my stock e-brake hookup.

I am actually thinking about using a different caliper now. If you want the parts. I already have a caliper mount welded on my axle with a mount spacing of 7.05", which works with old 70's calipers. If I find an eldorado caliper with a built in e-brake that would save me alot of time as it is just bolt on and I would only have to fabricate a cable.

For the brake cables. I went with a chevy truck rear brake line from the frame to the axle. It is maybe 6" longer with the stock connections. Also you can use the brake hoses you have and drill out the caliper side to the correct diameter. That is what I did instead of trying to track down new hoses. My calipers took a 7/16"-20 banjo bolt, I used a step drill and it conveniently deburrs the hole after you get it to the right size.

Thanks for the info, I'm going to stick with the drums on the 9" but I'l try some chevy truck brake lines for the front and rear. sounds like it would work for the front, since I'l be use'n chevy calipers up front. I'm not sure if i'm going to run an e-brake right away.
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Old 07-17-2012, 10:58 PM   #70
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I like your build man Do you DD your wrangler or have another car, I don't think i saw. I agree with you about the save money but lose time aspect. Thats fine with people who love to work on stuff and get the satisfaction of doing everything themself. The big issue is having another vehicle. Anyways, you have been doing some cool stuff, I'll check in. How far are you along on the build until completion would you say?
I do DD my Jeep. Or well.. I did for a while. Then decided that getting a new car for the wife and driving her old one was cheaper than filling up every other day. Also my carpool guy appreciated the quieter smoother ride. Did I mention that my new job is 75 miles away on the other side of DC? Yea.. 1.5 to 2 hour drive one way, and that's on a good day.

I have really been putting off buying anything for the Jeep the past few months since I got the new job. Since we will have no money after the baby is born we have been trying to get everything for the house we have been needing to get. Also started filling the nursery.

I am going to be buying a few hundred for the Jeep soon though. I still need DOM tubing, some hub bearings, TRE's. I do want to get some new long travel shocks and shock towers but that might be a bit much for now.

I am definitely past the half way point. SYE, CV driveshaft, t-case mount, rear axle, exhaust. I now need to get the front axle, driveshaft (probably going with a u-joint adapter to 1330) and OBA system(all parts bought except for air tank). I do need to still fix a problem with my t-case. It doesn't shift out of 2Hi, I believe I need to shave my shift rod even though the instructions said I didn't on my year. I have read that some still had to shave it down or maybe I left that spring out. The front is going to take just as long as the rear even though I have a much better idea of what I am doing. I am going with a 3 link+trackbar setup but will have to balance the placement of all that to get as much uptravel as I can with no binding. Also I am wanting to stretch the front a few inches.

There are a number of other things that need to get done on it. But that doesn't count for the axle swap to be done.
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'03 TJ Sport / D30/Ford9 / 35x12.5x15 KM2 / D window black steel 15x8 wheels / 3" custom long arm lift / SYE & 1350 DS / JKS BL / 1" MML / Smittybilt's front bumper, Tube fenders, Rocker guards, and rear bumper / High Rock Tire Carrier
Just bought a True Hi9 rear and a D44 front, both with ARB's and 4.88 gears!! Check out the build!
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Old 12-25-2012, 02:30 AM   #71
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filling up every other day??? what MPG you get? I finished my build(for now). and I ended up building custom caliper mounts for the 9" to mount a K5 small caliper to it. I don't have an e-brake right now either I figer I'l get a drive line e-brake when I want one. I've been drive'n it around for a few weeks now and I've been getting 16.8ish MPG on 35x12.5, here is what mine looks likt now that its drivable and mostly done.
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Old 12-26-2012, 01:04 PM   #72
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filling up every other day??? what MPG you get? I finished my build(for now). and I ended up building custom caliper mounts for the 9" to mount a K5 small caliper to it. I don't have an e-brake right now either I figer I'l get a drive line e-brake when I want one. I've been drive'n it around for a few weeks now and I've been getting 16.8ish MPG on 35x12.5, here is what mine looks likt now that its drivable and mostly done.

Well I don't drive it anymore. I drive 145 miles a day and got around 16 mpg with the Jeep.

I would look at getting calipers with a parking brake built into them. I feel that a t-case parking brake would hang down more than I would want it to. I decided on just going with the TSM caliper (New Lg GM Rear Calipers). I have the big caliper with 7" bolt spacing.

I followed your build, I need to get around to outboarding my rear shocks.

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'03 TJ Sport / D30/Ford9 / 35x12.5x15 KM2 / D window black steel 15x8 wheels / 3" custom long arm lift / SYE & 1350 DS / JKS BL / 1" MML / Smittybilt's front bumper, Tube fenders, Rocker guards, and rear bumper / High Rock Tire Carrier
Just bought a True Hi9 rear and a D44 front, both with ARB's and 4.88 gears!! Check out the build!
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