Project Handicapped Access: 1 Ton Tubed XJ

[Mark817XJ]

Hi,

I've been here lurking for a while now, all while gathering parts and ideas. I'm almost to the point of cutting up my XJ so I figured I'd start this thread to list my plan and get input.

My plan so far:

1989 XJ-4D 95k on the odometer

1985 Ford Dana 60 Front DRW

• 35 Spline inner and outer shafts
• Drive Flanges
• Lockrite or equal locker
• 5:38's
• 1410 U-Bolt Yoke

GM 14 Bolt

• Stock shafts
• Blue Torch Disc Brake Brackets
• Chevy 1 Ton Front Disc, Rotor and Calipers
• Mini Spool
• 5:38's
• 1410 U-Bolt Yoke

Transfer Case stock 231 until I blow it up and or can afford an Atlas

Engine/Tranny - 4.0L w/ got propane kit and stock AW4. Way down the road I'd like to do a 5.3L/TH400/Atlas

Tube work will be 1.75"OD .120 wall DOM; I'll cut away all but the "frame rails," and firewall from the firewall back to right where the stock rear seat ends and the rear fender well begins. Engine will be caged and radiator moved to rear. I'll maintain a near stock wheelbase, maybe slightly streched but will only have two seats with small storage behind the seats. Dual propane cylinders over the rear axle.

3-Link with pan hard bar up front
Triangulated 4-Link Rear
Fox Air shocks on all 4 corners, size and version TBD
37" tires (currently have TSL's, will probably switch to red lables)

I'm sure I'm forgetting some but I'll update this coming weekend with pictures of progress to where I stand right now.

Currently I have both Axles, the 14-bolt is complete and ready to go minus the truss and I'm about to start the 60's overhaul.

Jeep, wheels and tires are here and I just finished my got trikes bender and ordered my dies.

Friday I'll be ordering Bend-Tech PRO and hopefully have some layout work done so that I can start laying out my links in the calculator.

More updates and pics to follow. Along the way please comment. This will be a slow build by most of your standards as I'm building as funds become available. I fund most of my hobby with side work and over time, which takes from build time.

EDIT: The thread title should have read Handicap Accessible, I'll be building this rig with one hand because thats all I have use of, along with the help of some close friends.

 

[Israel]

Why 1410 yokes?

 

[Jump This]

Full width I guess?

 

[Mark817XJ]

Why 1410 yokes?

I went with 1410's because as things progress I can see me keeping these axles and moving to a different platform. Maybe something faster or more radical and with a 1410 I won't have to upgrade down the road.

I know at the moment my transfer case is the weak link, hopefully an Atlas is in my not so distant future. Same with my locker and axle shafts. I went 35 spline even though I can only afford cheap shafts right now but down the road room for improvement is there. I needed a new yoke and for 89 bucks the 1410 was a great choice, IMO.

 

[Mark817XJ]

Full width I guess?

Not by choice, the front axle was a deal of a life time. I found someone looking to sell or trade it on C/L and made them an offer for an assortment of junk I had and they went for it. I scored the axle and 4 h1's for some reloading equipment that was given to me.

If I can find SRW hubs for a reasonable price I will convert it but in the mean time I planned in running H1's with stock offset up front and recentered H1's with a 4.5" backspacing in the rear.

The 60 is 77" wms and the 14bolt is 67" The two wheels will give me 9" and a spacer will get me even. I'll be wide but in Texas that isn't a huge problem.

 

[Mark817XJ]

Couple of other things I planned on but left off:

Full Hydro Steering
On-Board Air via AC Compressor

 

[Israel]

If I can find SRW hubs for a reasonable price I will convert it but in the mean time I planned in running H1's with stock offset up front and recentered H1's with a 4.5" backspacing in the rear.

There was a guy on Pirate4x4 selling a ton of Ford D60 hubs, knuckles, caliper brackets, etc. In his ad, he has a photo of at least 6 sets. You could hit him up for a good deal on SRW hubs.

 

[Twisted_Dakota]

Can't wait to help start the build.

 

[Israel]

There was a guy on Pirate4x4 selling a ton of Ford D60 hubs, knuckles, caliper brackets, etc. In his ad, he has a photo of at least 6 sets. You could hit him up for a good deal on SRW hubs.

Here's a link. It looks like he only has one set of hubs left.

http://pirate4x4.com/forum/showthread.php?t=870031

 

[Mark817XJ]

Here's a link. It looks like he only has one set of hubs left.

http://pirate4x4.com/forum/showthread.php?t=870031

sweet, thanks.

 

[Mark817XJ]

Here's a link. It looks like he only has one set of hubs left.

http://pirate4x4.com/forum/showthread.php?t=870031

He has one set, I told him to name his price, hopefully I get them.

 

[Mark817XJ]

Hubs are on the way

 

[ROBZ95Xj]

There was a guy on Pirate4x4 selling a ton of Ford D60 hubs, knuckles, caliper brackets, etc. In his ad, he has a photo of at least 6 sets. You could hit him up for a good deal on SRW hubs.

X2 i got my srw hubs off pirate for $65 shipped from Cali, the deals are on there ya just gotta be on the lookout

i also see no point on the 1410 ujoints, 1350's will be plenty

 

[Mark817XJ]

X2 i got my srw hubs off pirate for $65 shipped from Cali, the deals are on there ya just gotta be on the lookout

i also see no point on the 1410 ujoints, 1350's will be plenty

Thats something to keep in mind for the front, the rear is puchased and installed. I check pirate often, suprised I missed these but I did get his last pair.

 

[Mark817XJ]

I've been doing more and more reading and I think I'm going to do a Dana 300; I want to build my own spacer/flip kit but have a few questions yall might be able to answer.

I have an 89 AW4 in the jeep right now, I'm assuming it has the 21 spline output, right? Will a newer AW4 be a bolt in replacement so I can gain the 23 spline output?

i've also read anywhere from a 3/8" to 1" thickness for the clocking ring, whats your opinion?

 

[Mark817XJ]

I've done some more reading and I think it will be more cost effective to go with the Novak 21 Spline input shaft for the D300, at $186 it is a given.

 

[whitneyj]

If the adapter is only $186 get it. Just FYI, the spacer is 7/8" thick if you don't machine either the AW4 adapter or the D300. If you do THEN it's 3/8".

 

[asp]

if your tranny is in perfect working order and your D300 needs help, the novak input shaft will work fine. i wouldn't bother tearing your D300 apart for a rebuild if it wasn't necessary. you might as well just find a 23 spline output aw4 for $50. if you're not in a rush, just browse the classifieds. they come up.

 

[Mark817XJ]

if your tranny is in perfect working order and your D300 needs help, the novak input shaft will work fine. i wouldn't bother tearing your D300 apart for a rebuild if it wasn't necessary. you might as well just find a 23 spline output aw4 for $50. if you're not in a rush, just browse the classifieds. they come up.

I'm contimplating getting a 4:1 kit for it so I might be in it anyway. Is there any difference in inputs to the AW4? Reason I ask is a buddy I know, I use that term losely, is swapping his renix 4.0 with a h.o. 4.0 and he says the transmission has a different input shaft and the bearing in the crank is a different diameter.

I've yet to put my eyes on it and I know I may not be using proper terminology but does that make sense? Would that be the thrust bearing?

 

[Mark817XJ]

I was playing with bend tech, just trying to get a feel for it and its interface, and came up with this.

I doubt I'll keep it in use but I will build it out of some 1.75x.120 CREW because I can get it cheap. It will make sure my CLR is calibrated correctly and to test out how I'm inputting my measurements into bend tech.

I'll start building it this weekend so I'll update then with several pics. It should accommodate a standard bolt pattern winch and fair lead. I will build two 1/4" mounts that will allow it to bolt to the stock bumper mounts and a 4th hole about 12" back towards the rear.