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
Attachment 1297011

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
Attachment 1302851
Foam core flange prototype
Attachment 1302861

Got the flanges cut
Attachment 1302871

Attachment 1310581

Attachment 1310601Attachment 1310591

1/4' square tube gussets...because......gussets.
Attachment 1335161

9/16 all thread to secure and align tabs with joints , 16" apart.
Attachment 1335641

3/8 tabs beveled on both sides to about 1/16 for full penetration.
Attachment 1335651

Welded up
Attachment 1336191
Factory versus "full retard" control arm tube.
Attachment 1336201

Attachment 1336221

Attachment 1337241

Quote:

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Originally Posted by Joker11

Attachment 1337241

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What fun is doing things half retard?:cool2:

Attachment 1337521

Weld that bad boy up already!

Sent from my SM-N900V using Tapatalk

Kinda the layout
Attachment 1349641
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.
Attachment 1349651

Quote:

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Originally Posted by Fnord5

Attachment 1337521

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Had the tube beveled for welding.
Attachment 1349661

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!!!

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.

This is about how it will sit.

Attachment 1350751

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.
Attachment 1351701
Attachment 1351711
Attachment 1351721
Attachment 1351731
Toolbox area gone. Ha!
Attachment 1351741

Attachment 1351751
Attachment 1351761

Just about done. Need a new ECU, some sensor brackets and a ton of detail/cosmetic work.
After playing with some springs, I got it to 43" up travel in the front, 42" in the rear

Attachment 1709834Attachment 1709835Attachment 1709836

Stupid phone put them sideways. :mad:

A two door that's got 3.5" more wheelbase than the 4 door
Attachment 1709974
Had to get creative with my trackbar in the front.
Attachment 1709976
The front is a mess, but it works a treat.
Attachment 1709977

New (reman) ECU ordered and on the way. Hopefully that clears up my check engine light so I can get it smogged and legal.

Corners drilled for mounting bolts, drilled and tapped for my taillights. Going to weld on some tabs to mount heavy rubber fender flares so when I rub trees they don't break Attachment 1710154
Attachment 1710155

18" limit straps installed on the rear.
Attachment 1710235

Armor mounted with success.
Problem with custom one off parts is they don't always fit like production, off the shelf parts with tons of R&D behind them.
No complaints though, 1/4" plate will do quite well.

Attachment 1710798
Attachment 1710799

Could someone rotate my pics for me?

You gota takes pics with your phone horizontally. That looks like a nice toy. Is it stick shift?