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Thread: 09 wrangler one ton build

  1. #51
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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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    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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    Re: 09 wrangler one ton build

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  4. #54
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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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    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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    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
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    Re: 09 wrangler one ton build

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    Lincoln Power Mig 210MP MIG
    Lincoln Power Mig 350MP - MIG and Push-Pull
    Lincoln TIG 300-300
    Lincoln Hobby-Weld 110v Thanks JLAMES
    CK TIG TORCH, gas diffuser, pyrex cup
    Thermal Dynamics Cutmaster 101
    My brain

  8. #58
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    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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    Re: 09 wrangler one ton build

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  10. #60
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    Re: 09 wrangler one ton build

    Weld that bad boy up already!

    Sent from my SM-N900V using Tapatalk
    Lincoln Power Mig 210MP MIG
    Lincoln Power Mig 350MP - MIG and Push-Pull
    Lincoln TIG 300-300
    Lincoln Hobby-Weld 110v Thanks JLAMES
    CK TIG TORCH, gas diffuser, pyrex cup
    Thermal Dynamics Cutmaster 101
    My brain

  11. #61
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    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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    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
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    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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    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 11:20 AM.

  15. #65
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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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    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 10:45 PM.

  17. #67
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    Re: 09 wrangler one ton build

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  18. #68
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    Re: 09 wrangler one ton build

    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

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  19. #69
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    Re: 09 wrangler one ton build

    Stupid phone put them sideways.

  20. #70
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    Re: 09 wrangler one ton build

    A two door that's got 3.5" more wheelbase than the 4 door
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    Had to get creative with my trackbar in the front.
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    The front is a mess, but it works a treat.
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  21. #71
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    Re: 09 wrangler one ton build

    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 Name:  IMG_20200403_162449.jpg
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  22. #72
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    Re: 09 wrangler one ton build

    18" limit straps installed on the rear.
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  23. #73
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    Re: 09 wrangler one ton build

    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.

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  24. #74
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    Re: 09 wrangler one ton build

    Could someone rotate my pics for me?

  25. #75
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    Re: 09 wrangler one ton build

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

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