99 XJ DD & Weekend Warrior

[bmikes]

99 XJ DD & Weekend Warrior

Fab it!! Make that bad boy beefy!!

 

[NW99XJ]

Fab it!! Make that bad boy beefy!!

Well, I'm putting it together at least....IT'll be plenty beefy, 1.25" DOM with 1/4" wall.
.....I COULD have just ordered the raw tube from somewhere,
then brought it here (to work)...cut it to length, then reamed and tapped the ends...
BUT I would have had to buy the reamer, and tap (we dont have anything quite that big here)....and didn't want to bother with the added expense.
I have been sitting on a $100 JCR Credit for a while now, and figured this would be the perfect use for it.
Hell, that's $100 off the tubing, AND all the machining work is already done for me!

I WILL BE making my own poly bushing though for the PS TRE....
It'll look just like this:

 

[crazymoose1990]

I told you I had the reamer. And you could have had the ends drilled and tapped for 50.00

 

[NW99XJ]

I told you I had the reamer. And you could have had the ends drilled and tapped for 50.00

I'm talking about the straight reamer, to ream the inside of the tube to the proper max diameter of the thread.
And yea...I'll admit I forgot about you mentioning the $50 part.
In any case, if I WAS to have tapped the ends myself, the tools would have cost me $25 ea for the LH tap, RH Tap, and .8750 reamer.

No biggie.
I needed to use that JCR Credit anyways.

 

[crazymoose1990]

Thats what I'm saying knuckel head they are reamed, or drilled whatever you want to call it. then they are tapped for 50.00 you supply the DOM. Sheesh are we speaking engrish.

 

[NW99XJ]

Steering Upgrades (1-ton) March_2013

So after getting my Tie Rod ends in a timely fashion, and after much waiting for my bars. The Brown Truck came thru .....FINALLY!

Damn Right Made in USA!!!

I had been planning on just making one, but JCR was nice enough to just throw one in.....Bonus Poly Spacer FTW

I brought the rod ends in to work with me today, as I was expecting this delivery.
I quickly mocked up the layout and I like what I see!!!!

Pure Beef!!!!

I just got enough thread engagement to hold the stuff together for now. I'll get it all dialed in when I take the old stuff off. There will be PLENTY of thread engagement that's for sure.
I still need to source a couple Jam Nuts. 7/8"-18 is hard to find...not really an industry standard. I know Ballistic Fab has 'em, and I could prob talk JCR into sending me a couple if need be too. I'll need one for each end of the drag link, so that's going to be one left hand thread, and one right hand thread. But if anyone knows where to source these locally, please let me know

This isn't going to get installed right away either.
I'm going to do a Durango steering box swap, (most likely - also been contemplating a YJ box instead - one has a bigger bore, the other has a 4 bolt mount and fixed ratio)
Either way, I'll prob go with something like the C-Rok brace or TNT Customs 4 hole steering box plate as well.
If i went with the TNT one, I'd most likely do a YJ (4-hole) steering box vs. the Durango.
I'm also going to fabricate, or order up an actual steering box brace... one that will come from the opposite side of the unibody and go to the box itself.

The only other thing up in the air is going to be the track bar.....
And I wont know what I'm going to do with that until after all this is installed.
It's either going to work as-is (doubtful) or end up having to be cut and relocated to above the axle.
STAY TUNED!

 

[SPECFab]

Go to Tacoma screw and get the jamb nuts I've got them there and if they are not on they shelf they can get them pretty quick and ask for jamb nuts and they will get you the thinner nuts for it

 

[NW99XJ]

Go to Tacoma screw and get the jamb nuts I've got them there and if they are not on they shelf they can get them pretty quick and ask for jamb nuts and they will get you the thinner nuts for it

Thanks for that, I cant believe I didnt think of them before.
MSC, McMaster-Carr, and Fastenall were all a bust....unfortunately, so was Tacoma Screw.
They don't stock the 7/8"-18 jamb nuts, but COULD do a special order, IF I was willing to order the minimums from their vendor.
And since I have no need for 9 extra LH AND RH jam nuts of this size.... I have no other option than to go with the ONE online vendor I found that actually has these.
Order has just been placed with Ruff Stuff.....
I found them over at Ballistic, but for $2 more per nut....(no thanks)
I should have these next week at the latest.

Now all I have to do is source a Durango box....
I COULD go scavenge the junk yards, but I'd almost rather get a new or at least a reman one for peace of mind sake.
Problem is, even thru rockauto.com its over $200 w/a core. Local parts stores aren't any better.

Anyone have/know of a source?

 

[SPECFab]

get a tight one out of the wrecking yard it is better than the crap rebuilds
a rebuilt box is just resealed with used gears so you could end up with a reman that is really bad

 

[dukie564]

I agree I'd pull one from a yard, rebuild it yourself, and throw it in. Parts store rebuilds are dicey at best, plus they seem to screw up the boxes also - you may get one with the incorrect ratio or even one that's the wrong box - they don't keep track of cores very well...

 

[TORX]

Sounds like you got the jamb nuts sourced, but for future reference try R&P 4WD in, Oregon City. When I was doing some research on building an inverted-t steering system R&P had everything I needed at the time. Including machining for steering links as well. Plus they're a cool locally owned 4x4 shop. :thumbup:

 

[NW99XJ]

Sounds like you got the jamb nuts sourced, but for future reference try R&P 4WD in, Oregon City. When I was doing some research on building an inverted-t steering system R&P had everything I needed at the time. Including machining for steering links as well. Plus they're a cool locally owned 4x4 shop. :thumbup:

Good to know Dustin, Thanks.....
I've met those guys a few times at some of the local shows....good people for sure.
I guess for some reason I had it in my head that all they did were axles and gear set-ups.

 

[NW99XJ]

Steering Upgrades (cont) March_2013

Just ordered a Durango Steering Box....
Fully rebuilt/reconditioned with 100% new O-rings and lip seals.
All new Teflon rings are added to valve(s)
Internals are surface honed to OE specifications or better.
Air leak tested for performance reliability.
Hydraulically Tested for Bypass/Hi-Pressure.
Road simulation tested.
Drag link load/shear tested.
Lifetime Warranty.
$125 shipped....

Should be here middle of next week at the latest.
Jam Nuts for the bars are on their way......
Now all that's left is the plate/spacer....and a brace.

 

[kndrewa]

Nice, I put a Durango box in mine too. Makes the steering wheel feel like a truck! Think I lost a bit of turning radius, though.

 

[blue2824]

Wow! Thanks for the write up. I just ordered (early this week) a 3.5" Rubicon short arm lift kit with full leafs and shocks from 4WD.com and it should be here tomorrow. I'm only on page 3 of your thread but it is perfect timing to come across this. All good info for a first lift. Not sure if I am going to do it or have John & Jason at Auburn Car Repair in Auburn, WA. do it for me. But if I do it you can bet I will be re-reading your posts.

Can't wait to get my '90 XJ's lift on! arty:

 

[kenny811]

Thanks for that, I cant believe I didnt think of them before.
MSC, McMaster-Carr, and Fastenall were all a bust....unfortunately, so was Tacoma Screw.
They don't stock the 7/8"-18 jamb nuts, but COULD do a special order, IF I was willing to order the minimums from their vendor.
And since I have no need for 9 extra LH AND RH jam nuts of this size.... I have no other option than to go with the ONE online vendor I found that actually has these.
Order has just been placed with Ruff Stuff.....
I found them over at Ballistic, but for $2 more per nut....(no thanks)
I should have these next week at the latest.

Now all I have to do is source a Durango box....
I COULD go scavenge the junk yards, but I'd almost rather get a new or at least a reman one for peace of mind sake.
Problem is, even thru rockauto.com its over $200 w/a core. Local parts stores aren't any better.

Anyone have/know of a source?

Did you think of or try Parkrose Hardware? The one on Sandy Blvd has to have to biggest selection of nuts & bolts ever. Check it out.

 

[NW99XJ]

Did you think of or try Parkrose Hardware? The one on Sandy Blvd has to have to biggest selection of nuts & bolts ever. Check it out.

YUP....All they had were the standard 7/8"-9 or 7/8"-14.....but not the fine pitch 18TPI that I needed.
Unfortunately, "close enough" doesnt count when it comes to threads.

 

[NW99XJ]

Wow! Thanks for the write up. I just ordered (early this week) a 3.5" Rubicon short arm lift kit with full leafs and shocks from 4WD.com and it should be here tomorrow. I'm only on page 3 of your thread but it is perfect timing to come across this. All good info for a first lift. Not sure if I am going to do it or have John & Jason at Auburn Car Repair in Auburn, WA. do it for me. But if I do it you can bet I will be re-reading your posts.

Can't wait to get my '90 XJ's lift on! arty:

Thats awesome!
The guys over at Auburn Car Repair are good people, they'll do top notch work for sure.
Thanks for the compliments and reading the build, one of the main points of doing all this is to pass on knowledge, and help others out. Glad some of this can come to some good use.
Good luck on the lift!

 

[NW99XJ]

SWEET!
Jam Nuts Are HERE!
Thank You RUFF STUFF!

 

[Mtb Jak]

Definitely let us know about the steering box! for that price looks pretty good..