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Old 03-28-2016, 07:16 PM
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FootSoldier's 2016 JKR Build

This is the start of our new 2016 JKR build and if you squint your eyes just right you can see our new Mojave Sand Jeep Wrangler as we wait for Chrysler to start building our Jeep!

Nonetheless, who says you need a Jeep to start a build? I might not have a Jeep to build on yet, but we can get started anyway. So, I started gathering all the parts that will be used in the base build process.

Maybe a little history first. We bought a used 2011 JKR about a year and a half ago we bought our first Jeep. Many here (in particular kjeeper) helped me endlessly, as I did the typical mods. I consider myself to be mechanically inclined, but this was all new to me. You can see in my sig line what stuff I did to the 2011.

We eventually decided we wanted a "forever" Jeep and I felt like I really wanted the newer motor/transmission in that forever Jeep and I wanted the traditional design, rather than whatever they end up producing trying to reach the CAFE standards. So, we ordered a new Jeep with all the options, less smokers package, two weeks ago. And the wait goes on...

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2016 JKR Mojave Sand--The Harbaugh Wolverine; RK 2.5 X-Factor, Falcon 3.3s, PoisonSpyder flares/liners, sliders, and cage, Revolution 4.88s and USA axles, Artec armored housings and HD X-member, Dynatrac BJs, Rock Hard full skids, ARB HD Diff covers, Off Camber Fab bumpers, Teraflex HD tire carrier, Warn Zeon 8S, AEV Saltas, 35" STT PROs, SPod/LED lights, Mopar/Dynatrac BBK, RCV axles, T6 Alum 1 ton TR/DL, PowerTank.

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Old 03-28-2016, 07:27 PM
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The build plan includes using the Rock Krawler 2.5" Max Travel lift from the 2011. All of the RK components. I'll also be reusing the Off Camber front and rear bumpers, and the rock sliders. Along with the Teraflex spare tire carrier, AEV wheels and BFG KM2s.

I am planning front diff mods using all Artec stuff where I can. Truss, inner C gussets, HD TB bracket, LCA skids, Johnny Joint bushings for the axle side UCAs and an ABR diff cover. On the rear diff I'll be doing Artec LCA bracket/skids, HD TB relocation bracket, and spring perches, along with an ARB diff cover.

I am going to vent the two diffs, transfer case and transmission through an ARB vent kit in the engine bay.

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2016 JKR Mojave Sand--The Harbaugh Wolverine; RK 2.5 X-Factor, Falcon 3.3s, PoisonSpyder flares/liners, sliders, and cage, Revolution 4.88s and USA axles, Artec armored housings and HD X-member, Dynatrac BJs, Rock Hard full skids, ARB HD Diff covers, Off Camber Fab bumpers, Teraflex HD tire carrier, Warn Zeon 8S, AEV Saltas, 35" STT PROs, SPod/LED lights, Mopar/Dynatrac BBK, RCV axles, T6 Alum 1 ton TR/DL, PowerTank.

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Old 03-28-2016, 07:36 PM
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Today I got some of the welding done on the Artec brackets as prep work so I can be ready for when the big stuff starts.

I worked a large part of my adult life in electrical construction years ago and took a couple welding classes back then to weld on construction sites. Eventually I went through my off road race car building days and that lead to buying a Millermatic 35 in 1980.

That wire feed built many a car, car trailer, utility trailer, and who knows what all? But that was many years ago. So when I started doing some of the mods on our 2011, I needed advice and drvn4life1972 got me lined out.

Now after a little practice and a tuneup for my gear, I am making welds I don't have to be embarrassed about. That's important to me, because I'm doing all of the work on our Jeeps and I want it right.

All that said, please remember, I never said I was a welder!

Here's where I started:

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2016 JKR Mojave Sand--The Harbaugh Wolverine; RK 2.5 X-Factor, Falcon 3.3s, PoisonSpyder flares/liners, sliders, and cage, Revolution 4.88s and USA axles, Artec armored housings and HD X-member, Dynatrac BJs, Rock Hard full skids, ARB HD Diff covers, Off Camber Fab bumpers, Teraflex HD tire carrier, Warn Zeon 8S, AEV Saltas, 35" STT PROs, SPod/LED lights, Mopar/Dynatrac BBK, RCV axles, T6 Alum 1 ton TR/DL, PowerTank.

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Old 03-28-2016, 07:50 PM
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Let the fun begin!





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2016 JKR Mojave Sand--The Harbaugh Wolverine; RK 2.5 X-Factor, Falcon 3.3s, PoisonSpyder flares/liners, sliders, and cage, Revolution 4.88s and USA axles, Artec armored housings and HD X-member, Dynatrac BJs, Rock Hard full skids, ARB HD Diff covers, Off Camber Fab bumpers, Teraflex HD tire carrier, Warn Zeon 8S, AEV Saltas, 35" STT PROs, SPod/LED lights, Mopar/Dynatrac BBK, RCV axles, T6 Alum 1 ton TR/DL, PowerTank.

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Old 03-28-2016, 07:58 PM
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Like I said, not a welder but I was pretty happy with the work.



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2016 JKR Mojave Sand--The Harbaugh Wolverine; RK 2.5 X-Factor, Falcon 3.3s, PoisonSpyder flares/liners, sliders, and cage, Revolution 4.88s and USA axles, Artec armored housings and HD X-member, Dynatrac BJs, Rock Hard full skids, ARB HD Diff covers, Off Camber Fab bumpers, Teraflex HD tire carrier, Warn Zeon 8S, AEV Saltas, 35" STT PROs, SPod/LED lights, Mopar/Dynatrac BBK, RCV axles, T6 Alum 1 ton TR/DL, PowerTank.

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Old 03-28-2016, 08:01 PM
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Spring perches. This step isn't really necessary, but it has always bugged me that my rear springs are bent on the 2011 even though I had correction wedges under them. So, this time I am going to clock the perches so the spring are straight.

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2016 JKR Mojave Sand--The Harbaugh Wolverine; RK 2.5 X-Factor, Falcon 3.3s, PoisonSpyder flares/liners, sliders, and cage, Revolution 4.88s and USA axles, Artec armored housings and HD X-member, Dynatrac BJs, Rock Hard full skids, ARB HD Diff covers, Off Camber Fab bumpers, Teraflex HD tire carrier, Warn Zeon 8S, AEV Saltas, 35" STT PROs, SPod/LED lights, Mopar/Dynatrac BBK, RCV axles, T6 Alum 1 ton TR/DL, PowerTank.

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Old 03-28-2016, 08:05 PM
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And rear LCA bracket/skids. Artec stuff is so HD, I love it. But this step really wasn't necessary either...unless you try to rip them off the axle housing on a rock!











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2016 JKR Mojave Sand--The Harbaugh Wolverine; RK 2.5 X-Factor, Falcon 3.3s, PoisonSpyder flares/liners, sliders, and cage, Revolution 4.88s and USA axles, Artec armored housings and HD X-member, Dynatrac BJs, Rock Hard full skids, ARB HD Diff covers, Off Camber Fab bumpers, Teraflex HD tire carrier, Warn Zeon 8S, AEV Saltas, 35" STT PROs, SPod/LED lights, Mopar/Dynatrac BBK, RCV axles, T6 Alum 1 ton TR/DL, PowerTank.

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Old 03-28-2016, 08:07 PM
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Axle brackets welded and waiting for an axle to put them on! More waiting...

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2016 JKR Mojave Sand--The Harbaugh Wolverine; RK 2.5 X-Factor, Falcon 3.3s, PoisonSpyder flares/liners, sliders, and cage, Revolution 4.88s and USA axles, Artec armored housings and HD X-member, Dynatrac BJs, Rock Hard full skids, ARB HD Diff covers, Off Camber Fab bumpers, Teraflex HD tire carrier, Warn Zeon 8S, AEV Saltas, 35" STT PROs, SPod/LED lights, Mopar/Dynatrac BBK, RCV axles, T6 Alum 1 ton TR/DL, PowerTank.

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Old 06-01-2016, 07:43 PM
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The new jeep has arrived and the build plan has changed a little because the buyer of the 2011 decided to take the lift as part of the deal.



So I started ordering Rock Krawler parts and ended up with their 2.5" X-Factor kit with Rancho XL9000 shocks. The building is underway.

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2016 JKR Mojave Sand--The Harbaugh Wolverine; RK 2.5 X-Factor, Falcon 3.3s, PoisonSpyder flares/liners, sliders, and cage, Revolution 4.88s and USA axles, Artec armored housings and HD X-member, Dynatrac BJs, Rock Hard full skids, ARB HD Diff covers, Off Camber Fab bumpers, Teraflex HD tire carrier, Warn Zeon 8S, AEV Saltas, 35" STT PROs, SPod/LED lights, Mopar/Dynatrac BBK, RCV axles, T6 Alum 1 ton TR/DL, PowerTank.

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Old 06-01-2016, 07:48 PM
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Removed rear axle housing to start work.

Cut off stock brackets and clean up the housing.



Mounting Artec LCA brackets, spring perches and TB bracket.





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2016 JKR Mojave Sand--The Harbaugh Wolverine; RK 2.5 X-Factor, Falcon 3.3s, PoisonSpyder flares/liners, sliders, and cage, Revolution 4.88s and USA axles, Artec armored housings and HD X-member, Dynatrac BJs, Rock Hard full skids, ARB HD Diff covers, Off Camber Fab bumpers, Teraflex HD tire carrier, Warn Zeon 8S, AEV Saltas, 35" STT PROs, SPod/LED lights, Mopar/Dynatrac BBK, RCV axles, T6 Alum 1 ton TR/DL, PowerTank.

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Old 06-01-2016, 08:07 PM   #11
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Great job!!
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Old 06-01-2016, 08:55 PM   #12
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Subbed! Can't wait to see this build! Love that color too
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Old 06-02-2016, 09:46 AM   #13
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Gonna be painful to watch now that I saw that Michigan cover.
#goBuckeyes!
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Old 06-25-2016, 12:59 PM
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The rear completed with new Artec spring perches, TB bracket, LCA/shock brackets, and an ARB diff cover.





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2016 JKR Mojave Sand--The Harbaugh Wolverine; RK 2.5 X-Factor, Falcon 3.3s, PoisonSpyder flares/liners, sliders, and cage, Revolution 4.88s and USA axles, Artec armored housings and HD X-member, Dynatrac BJs, Rock Hard full skids, ARB HD Diff covers, Off Camber Fab bumpers, Teraflex HD tire carrier, Warn Zeon 8S, AEV Saltas, 35" STT PROs, SPod/LED lights, Mopar/Dynatrac BBK, RCV axles, T6 Alum 1 ton TR/DL, PowerTank.

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Old 06-25-2016, 01:03 PM   #15
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Looks great dude


2 door Rubicon, 3.5" RockKrawler x-factor, 37x12.5x17 MTR's, Steer Smarts Yeti steering, Savvy aluminum half doors.
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Old 06-25-2016, 01:05 PM
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With the pinion angle set at -2* lower than the drive shaft angle, the spring perches and TB brackets are plumb and level, so no need for correction wedges and the springs don't bow. That part I really liked, but after completing this stage, I learned that I probably should have set them up with 1-2* rearward slope. Oh well, live a learn!
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2016 JKR Mojave Sand--The Harbaugh Wolverine; RK 2.5 X-Factor, Falcon 3.3s, PoisonSpyder flares/liners, sliders, and cage, Revolution 4.88s and USA axles, Artec armored housings and HD X-member, Dynatrac BJs, Rock Hard full skids, ARB HD Diff covers, Off Camber Fab bumpers, Teraflex HD tire carrier, Warn Zeon 8S, AEV Saltas, 35" STT PROs, SPod/LED lights, Mopar/Dynatrac BBK, RCV axles, T6 Alum 1 ton TR/DL, PowerTank.

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Old 06-25-2016, 01:07 PM
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Then it was off to the front diff. I knew this would be much more challenging and I would have been sunk without the help of kjeeper10 and dvn4life1972. They helped me a ton!
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2016 JKR Mojave Sand--The Harbaugh Wolverine; RK 2.5 X-Factor, Falcon 3.3s, PoisonSpyder flares/liners, sliders, and cage, Revolution 4.88s and USA axles, Artec armored housings and HD X-member, Dynatrac BJs, Rock Hard full skids, ARB HD Diff covers, Off Camber Fab bumpers, Teraflex HD tire carrier, Warn Zeon 8S, AEV Saltas, 35" STT PROs, SPod/LED lights, Mopar/Dynatrac BBK, RCV axles, T6 Alum 1 ton TR/DL, PowerTank.

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Old 06-25-2016, 01:30 PM
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I don't have plans to run anything larger than the 33s, but since this is supposed to be the "forever" Jeep and I wanted to do the inner C gussets, I figured that now was the time to do an Artec truss as well.

So, I pulled the front diff assembly (never done anything like that before) and set up to start a bunch of welding like I have never done. I was VERY nervous about it, but got a lot of encouragement from dvn4life1972 and ScaldedDog.

Let the welding begin!
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2016 JKR Mojave Sand--The Harbaugh Wolverine; RK 2.5 X-Factor, Falcon 3.3s, PoisonSpyder flares/liners, sliders, and cage, Revolution 4.88s and USA axles, Artec armored housings and HD X-member, Dynatrac BJs, Rock Hard full skids, ARB HD Diff covers, Off Camber Fab bumpers, Teraflex HD tire carrier, Warn Zeon 8S, AEV Saltas, 35" STT PROs, SPod/LED lights, Mopar/Dynatrac BBK, RCV axles, T6 Alum 1 ton TR/DL, PowerTank.

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Old 06-25-2016, 01:39 PM
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I started by striping the diff housing and removing the ball joints and UCA bushings.

Then welded in the Artec inner C gussets.



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2016 JKR Mojave Sand--The Harbaugh Wolverine; RK 2.5 X-Factor, Falcon 3.3s, PoisonSpyder flares/liners, sliders, and cage, Revolution 4.88s and USA axles, Artec armored housings and HD X-member, Dynatrac BJs, Rock Hard full skids, ARB HD Diff covers, Off Camber Fab bumpers, Teraflex HD tire carrier, Warn Zeon 8S, AEV Saltas, 35" STT PROs, SPod/LED lights, Mopar/Dynatrac BBK, RCV axles, T6 Alum 1 ton TR/DL, PowerTank.

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Old 06-25-2016, 01:48 PM
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Then moved on to the Artec truss and Front TB bracket.





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2016 JKR Mojave Sand--The Harbaugh Wolverine; RK 2.5 X-Factor, Falcon 3.3s, PoisonSpyder flares/liners, sliders, and cage, Revolution 4.88s and USA axles, Artec armored housings and HD X-member, Dynatrac BJs, Rock Hard full skids, ARB HD Diff covers, Off Camber Fab bumpers, Teraflex HD tire carrier, Warn Zeon 8S, AEV Saltas, 35" STT PROs, SPod/LED lights, Mopar/Dynatrac BBK, RCV axles, T6 Alum 1 ton TR/DL, PowerTank.

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Old 06-25-2016, 02:17 PM
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After fitting (there wasn't much necessary) the truss onto the housing and cleaning the paint from everything, I tacked everything together and took lots of time welding up the truss together and to the axle tubes. I also decided to change out the rubber UCA bushings for Currie Johnnie Joints st this point, so I welded their kit into the truss.

After reading a lot online about the metal make up of the cast center section of the housing (is it cast steel or not? do you need to pre-heat or not?) I decided to put some large tack welds in place between the cast section and the truss, let then let the whole thing set over night and see if anything cracked after cooling?

Now, I am doing this work on the driveway in Arizona when the work setting under direct sun will hold 120* on it's own for hours. I checked the tacks at about 10:30PM and no cracks! So I thought I'd be good-to-go without a preheat process. I was worried about damaging the inner axle seals.

The next morning when I was prepping to weld, I found a couple small cracks on two different tack welds. So I decided I had to fire up the torch and preheat.

I also used an inexpensive infared temp gauge to monitor temp and heated everything up slowly to about 300*, then started welding. There's not much direct contact to the cast section to weld, so it didn't take long.

Once it was all welded, I checked the temp and didn't find any areas over about 350*. I then wrapped the whole thing up in two welding blankets and a wool blanket nice and tight, setting in the direct sun, where I left it until the next morning.





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2016 JKR Mojave Sand--The Harbaugh Wolverine; RK 2.5 X-Factor, Falcon 3.3s, PoisonSpyder flares/liners, sliders, and cage, Revolution 4.88s and USA axles, Artec armored housings and HD X-member, Dynatrac BJs, Rock Hard full skids, ARB HD Diff covers, Off Camber Fab bumpers, Teraflex HD tire carrier, Warn Zeon 8S, AEV Saltas, 35" STT PROs, SPod/LED lights, Mopar/Dynatrac BBK, RCV axles, T6 Alum 1 ton TR/DL, PowerTank.

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Old 06-25-2016, 02:19 PM   #22
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Impressive my brother. Good move on the Currie bushings .. One of the best changes i made.


2 door Rubicon, 3.5" RockKrawler x-factor, 37x12.5x17 MTR's, Steer Smarts Yeti steering, Savvy aluminum half doors.
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Old 06-25-2016, 02:28 PM
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After the unveiling, I found no cracks! Then I cleaned everything up with a wire wheel and got it painted up.

Since I was going to be having everything pulled apart, I had decided I wanted to install HD ball joints when it went back together, so I went with Dynatrac Pro Steer. Wow! What quality.

Installed ball joints, Johnnie Joints, bump stops, and topped it off with an ARB diff cover. Ready to go!





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2016 JKR Mojave Sand--The Harbaugh Wolverine; RK 2.5 X-Factor, Falcon 3.3s, PoisonSpyder flares/liners, sliders, and cage, Revolution 4.88s and USA axles, Artec armored housings and HD X-member, Dynatrac BJs, Rock Hard full skids, ARB HD Diff covers, Off Camber Fab bumpers, Teraflex HD tire carrier, Warn Zeon 8S, AEV Saltas, 35" STT PROs, SPod/LED lights, Mopar/Dynatrac BBK, RCV axles, T6 Alum 1 ton TR/DL, PowerTank.

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Old 06-25-2016, 02:33 PM
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Reassembly of the front end with Rock Krawler 2.5" X-Factor lift kit.





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2016 JKR Mojave Sand--The Harbaugh Wolverine; RK 2.5 X-Factor, Falcon 3.3s, PoisonSpyder flares/liners, sliders, and cage, Revolution 4.88s and USA axles, Artec armored housings and HD X-member, Dynatrac BJs, Rock Hard full skids, ARB HD Diff covers, Off Camber Fab bumpers, Teraflex HD tire carrier, Warn Zeon 8S, AEV Saltas, 35" STT PROs, SPod/LED lights, Mopar/Dynatrac BBK, RCV axles, T6 Alum 1 ton TR/DL, PowerTank.

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Old 06-25-2016, 02:34 PM
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Quote:
Originally Posted by kjeeper10 View Post
Impressive my brother. Good move on the Currie bushings .. One of the best changes i made.


2 door Rubicon, 3.5" RockKrawler x-factor, 37x12.5x17 MTR's, Steer Smarts Yeti steering, Savvy aluminum half doors.
Thanks Ken! Couldn't have done it with you and the guys here at Wrangler Forum!

Steve
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2016 JKR Mojave Sand--The Harbaugh Wolverine; RK 2.5 X-Factor, Falcon 3.3s, PoisonSpyder flares/liners, sliders, and cage, Revolution 4.88s and USA axles, Artec armored housings and HD X-member, Dynatrac BJs, Rock Hard full skids, ARB HD Diff covers, Off Camber Fab bumpers, Teraflex HD tire carrier, Warn Zeon 8S, AEV Saltas, 35" STT PROs, SPod/LED lights, Mopar/Dynatrac BBK, RCV axles, T6 Alum 1 ton TR/DL, PowerTank.

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Old 06-25-2016, 03:18 PM   #26
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Awesome build so far! Definitely the smart way to do things - starting from the ground up.
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Old 06-25-2016, 04:02 PM
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2016 JKR Mojave Sand--The Harbaugh Wolverine; RK 2.5 X-Factor, Falcon 3.3s, PoisonSpyder flares/liners, sliders, and cage, Revolution 4.88s and USA axles, Artec armored housings and HD X-member, Dynatrac BJs, Rock Hard full skids, ARB HD Diff covers, Off Camber Fab bumpers, Teraflex HD tire carrier, Warn Zeon 8S, AEV Saltas, 35" STT PROs, SPod/LED lights, Mopar/Dynatrac BBK, RCV axles, T6 Alum 1 ton TR/DL, PowerTank.

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Old 06-25-2016, 04:21 PM   #28
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Old 06-25-2016, 04:47 PM
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The lift install portion is pretty much done now, but it seems like there are always lots of little primping things to do. I spent time getting the sway bar links cut to the lengths I wanted and playing around with the e-brake cables in the rear trying to get them secure, yet still flexible enough to reach the fully dropping axle.

I decided to try a Rough Country 7000 steering dampener, but the jury is still out on that one. A Fox unit may be in my future?

The front pinion angle was a PITA, but I finally got in dialed in to about +1.8* which should put me at about 4.2* caster angle. We'll see after a trip to the front end rack?

All in all, I am very happy with how everything has come together so far and the Jeep drives very well.





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2016 JKR Mojave Sand--The Harbaugh Wolverine; RK 2.5 X-Factor, Falcon 3.3s, PoisonSpyder flares/liners, sliders, and cage, Revolution 4.88s and USA axles, Artec armored housings and HD X-member, Dynatrac BJs, Rock Hard full skids, ARB HD Diff covers, Off Camber Fab bumpers, Teraflex HD tire carrier, Warn Zeon 8S, AEV Saltas, 35" STT PROs, SPod/LED lights, Mopar/Dynatrac BBK, RCV axles, T6 Alum 1 ton TR/DL, PowerTank.

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Old 06-25-2016, 04:52 PM
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Here's how it sets today:





This pic is for my Buckeye friends!


I did add a Teraflex 1" spring spring spacer in the rear because I felt like the rear looked like it was sagging a tad. By removing the OEM pad and replacing it with the Teraflex 1", I gained about a strong 1/2". Just right!
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2016 JKR Mojave Sand--The Harbaugh Wolverine; RK 2.5 X-Factor, Falcon 3.3s, PoisonSpyder flares/liners, sliders, and cage, Revolution 4.88s and USA axles, Artec armored housings and HD X-member, Dynatrac BJs, Rock Hard full skids, ARB HD Diff covers, Off Camber Fab bumpers, Teraflex HD tire carrier, Warn Zeon 8S, AEV Saltas, 35" STT PROs, SPod/LED lights, Mopar/Dynatrac BBK, RCV axles, T6 Alum 1 ton TR/DL, PowerTank.

https://www.wranglerforum.com/f314/f...d-1666418.html
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