09 wrangler one ton build

[Fnord5]

Definitely vented.
So to do the control arms, I'll set the jeep at ride height, and line up the pinion angle with the axle on jack stands, tack on the control arm mounts in the general ballpark. The control arms will have built in adjustment.

Then burn them on, and install the axle to find caster, tack the inner C's on and have a pro weld them up for me.

[Fnord5]

Picked up my rear today.
Going to shave it, add more trussing, and then control arm brackets. Pretty much built already, 4,56 gears and a Detroit locker, disk brake conversion, pinion guard and a great lakes off road diff cover.
Buddy was sick of me not picking it up and having it in his yard, so he knocked $300 off if I got it today. It was a bargain and a half.

[Fnord5]

After a rock bouncing, crazy trip through the Rubicon, time to fast track this build.
12" coilovers ordered for the front, rears on hold till finances catch up
Shaving the front only for now, till I regear and throw an air locker in back.
Got a quote for a re-tube, going with .500 wall DOM, the guy machines the inside of the tubes on the housing side to fit standard Dana 60 inner axle seals. Need to order the shave kit, new diff cover, cut it myself and have the guy doing the re-tube weld it up for me(I don't want to mess with welding Cast Iron.

He also makes custom axle shafts in house. Cryo-treated and everything.
Don't mind dropping some coin on these shafts as I'll never break them with my 208 horsepower.

[Billdacat]

Are you going to re-tube the rear axle??? Are you keeping it as a full-float?? What is your time frame for completion? If you can, please post up pictures of the re-tubing of the front axles??

[Fnord5]

Keeping the rear as is full float, 67.5 wms to wms.
Front is going to be 69.5 wms to wms.
If the guy doing the work will let me, and if I have the time, I'll take lots of pics.

Hope to have it done in a year or less.

[Fnord5]

Rear coilovers ordered.
Aside from control arms, brake lines, and a couple brackets, the rear is ready to go. Driveshaft will have to be ordered after everything else is done.

Going with 12" travel, 2.5" body, remote reservoir coilovers, dual rate springs(don't know what strength yet)

[Fnord5]

Small update.
Shave kit and diff cover are here, picked up a set of stainless polished mile marker lockout hubs, the ALL METAL ones (warn hubs have a plastic collar inside and are 4x as expensive)
Have all 4 coilovers, 12" travel with remote resivoir, 2.5" body front, 2" body rear.
Going to start with 200/250 rate springs, as a buddy has them and likes the way they work.

Need to order my inner "C's", kingpin rebuild kits, tone rings, caliper brackets, calipers and rotors,and all the bearings, then I can get the front assembled.(minus steering components)

Slowly coming together.

Need to figure where exactly I need the center section, so I can get the re-tube done. I may have to modify my oil pan to clear.

[Billdacat]

Ka-Ching$$$$$$$

[Fnord5]

Surprisingly, not into it for too much so far. I've gotten some screaming deals on parts, as a lot are used and/or sourced from friends.
Only about $2600 so far.

[Fnord5]

1600 more in parts for the front, not including steering linkage, or labor for the shave kit and re-tube.
Have to do custom axle shafts as well, cryo treated chromoly,

[Fnord5]

Just ordered 16 Metalcloak Duroflex joints, local company to me, I know the owner and a couple employees. Awesome company and pretty innovative too.

[Fnord5]

New plans.
Ditching the factory 4 link setup in favor of a centered 3 link rear, and driver offset 3 link front.
I was looking at a kit for my rear coilovers, and decided I hated how they did it (designed to avoid cutting into the body, at the expense of strength)
So I'm going to chop into my poor jeep and do this correctly..
Similar to this, but more towards the outside of the tub.

[wornoutoldwelder]

This thread is a yawner...Seriously lacking in pics and updates. 10 months along on the timeline so far and NO pics or discussion involving actual fab, just what parts you bought. Hell, even bolt on parts need bolted on and deserve pictorials, all the welding and fab involved scream for it.

I'm glad you into it and enjoy doing it, but share more than facebook type updates in a fab oriented forum. I'm CERTAIN you had issues sorting out parts selection and fab design and actual fab up, so where is all that?....

Do I sound like an azz? sorry if I do..

[Fnord5]

Not at all. And nothing in this build is going to be bolt on.
The reason for lacking pictures is that I have just been collecting parts, and refining my build plans.
Once I start the actual build, I'll have plenty of pictures.
Unless you'd like pictures of parts...

Size difference between stock axle, and 14 bolt.

[Fnord5]

$291 out the door for a 23 foot stick of 2.25 OD, .375 wall DOM.
Should be fine for control arms if I stick to fire roads....

[Fnord5]

Some more parts.
Getting closer starting surgery on my jeep!

[Fnord5]

The joints:

[Fnord5]

Bought a beater car so I can start this build.
Started the teardown today.
Going to cut all the old brackets off the frame tomorrow.

[Fnord5]

Finished up cutting off the old brackets and cleaning the frame.

[Fnord5]

My comp cut layout, couldn't cut due to rain.

[Fnord5]

Break in the weather, cut one side, not complete, but got that first "real cut" out of the way.

[Fnord5]

Cleared off the rear axle tubes of the old brackets, changed the mini truss for a different one with a pinion guard bridge.


MM211, maxed out, 220v, 030 wire and c25. Beveled the truss to get nearly full penetration.

[Fnord5]

Got my upper, axle side link mounted.
Ruff Stuff 1" bore 1.25" shank heim, 3/4 misalignment spacers.

030 wire, 6&90 on my MM 211.

[weldermike]

Looking good bud!

[Billdacat]

Nice..... Still following along. I know that it takes a **** load of time and money to do it right. I have a 4" lift going on my wife rig this weekend (if I can find the time) that I have been acquiring parts for over the last four years.