09 wrangler one ton build - Page 3
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  1. #51
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    Oct 2012
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    Re: 09 wrangler one ton build

    So, minor setback.
    Built a "shoe" to flatten the bottom of my crossmember where the upper wishbone brackets are going.

    The main bracket runs right where the driveshaft will be after only 2" of up travel.
    So, I stalled out on the project trying to think of a solution.

    The more I looked at the shoe, the more I hated it.
    Looked like a redneck fix, even if I made it work.
    The cuts I did, didn't match the contours of the crossmember, and yea, just ugly. (Pic attached of it clamped in place)

    So, to get the flat bottom., and enough meat to mount the brackets on the face, I'm going to be cutting g the crossmember out completely, and replacing with 2x2x1/4 square tube with flanges on the ends to mount to the frame.

    This project is way more in depth than I expected.


    This is the shoe/brackets that are a $100+ fail
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  2. #52
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    Oct 2012
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    Re: 09 wrangler one ton build

    New crossmember and flanges
    Christmas and new years are taking priority, so I'll be working on it the next weekend after.
    Crossmember with new brackets and joints, just to see how the brackets fit
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    Foam core flange prototype
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    Got the flanges cut
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  3. #53
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    Oct 2012
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    Sacramento, California
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    Re: 09 wrangler one ton build

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  4. #54
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    Oct 2012
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    Re: 09 wrangler one ton build

    1/4' square tube gussets...because......gussets.
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  5. #55
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    Oct 2012
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    Re: 09 wrangler one ton build

    9/16 all thread to secure and align tabs with joints , 16" apart.
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    3/8 tabs beveled on both sides to about 1/16 for full penetration.
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  6. #56
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    Oct 2012
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    Re: 09 wrangler one ton build

    Welded up
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    Factory versus "full retard" control arm tube.
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  7. #57
    Join Date
    Mar 2006
    Location
    Yuma, Arizona
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    3,357

    Re: 09 wrangler one ton build

    Name:  retard.jpg
Views: 254
Size:  10.8 KB
    Lincoln Power Mig 350MP - MIG and Push-Pull
    Lincoln Precision TIG 275,Undercart cooler,Foot/Finger Amptrollers
    Lincoln Hobby-Weld 110v
    Lincoln SP-200 MIG and Hi-Freq Tig
    CK TIG TORCH, gas diffuser, pyrex cup
    Thermal Dynamics Cutmaster 101

  8. #58
    Join Date
    Oct 2012
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    Sacramento, California
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    1,065

    Re: 09 wrangler one ton build

    Quote Originally Posted by Joker11 View Post
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    What fun is doing things half retard?

  9. #59
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    Oct 2012
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    Sacramento, California
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    1,065

    Re: 09 wrangler one ton build

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  10. #60
    Join Date
    Mar 2006
    Location
    Yuma, Arizona
    Posts
    3,357

    Re: 09 wrangler one ton build

    Weld that bad boy up already!

    Sent from my SM-N900V using Tapatalk
    Lincoln Power Mig 350MP - MIG and Push-Pull
    Lincoln Precision TIG 275,Undercart cooler,Foot/Finger Amptrollers
    Lincoln Hobby-Weld 110v
    Lincoln SP-200 MIG and Hi-Freq Tig
    CK TIG TORCH, gas diffuser, pyrex cup
    Thermal Dynamics Cutmaster 101

  11. #61
    Join Date
    Oct 2012
    Location
    Sacramento, California
    Posts
    1,065

    Re: 09 wrangler one ton build

    Kinda the layout
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    The lo g left hand tube is going to be bent to form a wishbone, approximately where the level is then plated in the middle.
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  12. #62
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    Oct 2012
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    Re: 09 wrangler one ton build

    Quote Originally Posted by Fnord5 View Post
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    Had the tube beveled for welding.
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  13. #63
    Join Date
    Oct 2008
    Location
    New Jersey (yeah it sucks)
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    691

    Re: 09 wrangler one ton build

    What do you do to keep the control arm threads from distorting during welding??? Any plug weld from the side??? How do you position the arm for welding???
    When do you think the rig will be ready for wheeling?? Nice build!!!

  14. #64
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    Oct 2012
    Location
    Sacramento, California
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    Re: 09 wrangler one ton build

    I've coated the joint stud with anti-seize (loctite copper)
    Going to weld the circumference, then gently rotate the joint to make sure everything stays kosher as it cools.
    Haven't figured out how I'll position the arms, Probably make some v grooves in wood, grease them up slick, then rotate by hand as I weld.
    No plug welds, thought about it, but I honestly don't think it will be needed.
    Last edited by Fnord5; 02-21-2016 at 12:20 PM.

  15. #65
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    Oct 2012
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    Re: 09 wrangler one ton build

    This is about how it will sit.

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  16. #66
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    Oct 2012
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    Re: 09 wrangler one ton build

    More progress today.
    Tacked all my arms up, didn't do full welds because things change and schite happens.
    Will only have 3-4" of up travel before the center upper link hits, so I'm going to have to build yet another replacement crossmember.
    Coilovers have gone from inboard, to outboard, and now back to inboard for clearance.
    Still need my wishbone bent and notched so I can really center the axle.
    I'm ending up at 18" of stretch, where my original plan was only 8. Lol.
    Will be a beast of a jeep though.
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    Toolbox area gone. Ha!
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    Last edited by Fnord5; 02-21-2016 at 11:45 PM.

  17. #67
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    Re: 09 wrangler one ton build

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