The 1 Ton Swap...finally

[CartsXJ]

So after years and years of sourcing and gathering parts.....last year I finally decided to pull the trigger and start the +05 SD, 3FR/4RR link, coilover swap. Also it was pushed by a few other factors.....wheeling schedule opened up and the rear frame was starting to become religious (holy).....LOL!!! Sorry dad joke.

Started with putting it up on tall stands and pulling everything out. The goal was to set everything at projected ride height.

Once everything was pulled......frame rail repair and reinforcement was completed. I didn't grab any pics, cause I think everyone has seen that process.
Then I started mocking the big stuff in place.

 

[CartsXJ]

Using an Ironman4x4 gen 1 full crossmember for my bases, I started to place the axles with the links.

Then I started to think about wheelbase and wanting to keep the fuel out of the passenger compartment; kids, storage and potential state inspection issues. So after a to of research and phone calls, I deceide to design my own fuel cell around the new Ruffstuff tank skid. Next was full scale mockup and fitment.

 

[CartsXJ]

Then after a few phone calls to the big 3 aftermarket fuel cell manufacturers about doing a custom one with basically their existing parts.......I came up short. No one wanted to build it for me. So I proceded to source the parts myself and have a buddy at work, who TIG's aluminum everyday, put it together for me.

Then I fitted with the factory pump and in the skid

Made the skid to mimic TJ fuel tank/cell setups, for ease of service and such.

Then bolted it up

This fuel cell holds approximately 20 gallons and allows for up to 7" of rear stretch with a Ford 10.5 and Ruffstuff cover and uses the factory filler location.

 

[CartsXJ]

Then the fun part.........fitting a Fox 2.5 14" travel emulsion shocks. The biggest want for me was keep them below the hood line in the front. So this meant custom towers. Starting with the 12" Ruffstuff towers as a base........I proceeded to box them in some hopes of "sealing" off the engine bay from mud and debris from the tires. The Dodge VAN MC doesn't help things, LOL!!

So, here's what I ended up with from the top of the engine bay.

 

[CartsXJ]

Then I started flexing the front out to see if I have any bind and/or issues. So far only issue i have is the front driveshaft on driver full droop. Its either the axle yoke of the CV at the transfercase needs clearancing to gain a few more degrees. The front axle is pushed forward about 4". I have a completely flat pitman arm and have full lock to lock steering at all positions of the front axle. I am planning on fitting the Hydro Assist cylinder above the diff cover on the truss to the DS knuckle, which already fits....will have pics soon of that.

 

[CartsXJ]

Then I moved to the rear........at least the driver's side. My goal is to keep it as XJ looking as possible, everyone can cut to their hearts content....but I like to be different.

I did cut out the section of the floor and ran a piece of 3/16" plate across the top for the frame rail flanges to try and incorporate and share the load between both sides of the frame rail. I do plan on tying them and the fender tube into the current roll cage.

 

[twinhauler]

Looks nice

 

[Anak]

Love that tank.

Nice build.

 

[CartsXJ]

Thanks!

Been a long time coming and a lot of trial and error. Unfortunately I only get a few hours a week to work on it, family and kids, lol!!

But hopefully it will be under its own weight this fall.

 

[CartsXJ]

Was able to get a few hours in on Saturday. Got the PS coilover tower and Bumpstop mounts in along with tacking up the limit straps.

https://flic.kr/p/2qcmrHu

https://flic.kr/p/2qcmNsb

Also took inventory of the TK1 swaybar kit. Going with the under the rear seat mounting.

https://flic.kr/p/2qck984

 

[CartsXJ]

https://flic.kr/p/2qeV5Nz

Was able to spend a few hours last night getting the Swaybar mockup and measuring for links and placement. The rear suspension mockup is done and the rear axle can come out for final weld and assembly.

https://flic.kr/p/2qeV5NQ

Have to do some more cut and patch around the swaybar tube along with the rear wheel wells…but gaining.

 

[CartsXJ]

https://flic.kr/p/2qif7at

Was only able to get a couple of hours at the shop this week, and my son wanted to help. So I put him on beadlock duty. He got one together, lol!! Only 4 more to go.