Thought i'd share the new rig..

maybe i'm crazy, but i think he used .25"... could have been on part of it and not all? i'm sure 1/8 is fine now that i think about it, i had 250lbs easy on my surco rack that mounted to the factory rails for my entire xcountry trip and it did budge.
 
1/8" would be plenty IMO, 1/4" wall would be overkill. Think about sliders, most people build those out of 3/16" and they'll take the weight of the Jeep crashing down on them.
 
Yup 1/8" would be plenty for the square tubing.

Hell you could probably get away with less.

You sure you don't want it out of round tubing? I'm sure you could pursuade someone to bend you up something out of 1.75" since it's a fairly common size.
 
XJLI said:
maybe i'm crazy, but i think he used .25"... could have been on part of it and not all? i'm sure 1/8 is fine now that i think about it, i had 250lbs easy on my surco rack that mounted to the factory rails for my entire xcountry trip and it did budge.
Click to expand...

I dont think i would have 250 on the rack, unless i need to put some fuel/water cans up top for some reason.

CTeunuch said:
1/8" would be plenty IMO, 1/4" wall would be overkill. Think about sliders, most people build those out of 3/16" and they'll take the weight of the Jeep crashing down on them.
Click to expand...

Understood..

Saw your bud has a Clayton rear LA setup for sale.. wish i could jump on it.

MoparManiac said:
Yup 1/8" would be plenty for the square tubing.

Hell you could probably get away with less.

You sure you don't want it out of round tubing? I'm sure you could pursuade someone to bend you up something out of 1.75" since it's a fairly common size.
Click to expand...

How much less? The local steel place also has 0.083 listed. http://www.metal-stock.com/index.php?id=CarbonSteelTubing&t=5

I'd really like square or rectangular tubing, would be easier for me on light tabs/shovel/axe mount etc. I'll see if the dealer is able to bend it..

I also had a link to a place that would do bends and ship them out. No idea what their prices are, gonna see if i can find it.

This is similar to what i want.

Hannibal-packed-on-roof.jpg
 
My vacation to Montana is over, the house work is done for now, my sidework didnt show for today. Think i'll get the front axle repainted and prepped for install.
 
Hit it with wire wheels, cleaned with Final wash and hit with a few coats of spray bomb. Had every intention to POR it but got lazy..

Looking for 4 1.25" wheel spacers if anyone has them..

axlepainted002.jpg
 
I bought some POR15 for my floors because of the surface rust starting, also had to buy the cleaner and the surface prep solution prep, Ended up being $$$
 
The above never happened... tossed the wheels back on and went to Montana.

Just got the Jeep reinspected and made an appt with Joe at Endless Mountain Fab to weld up my axle bracket kit. I put it on jackstands tonight to start cleaning it up and grinding all the old bracketry off it.

Checked the fit of the brackets i picked up.. the radius is off. Thinking these were cut to 8.8 tube dia as it's the most common ZJ axle swap. I did order a 2.75" diameter for the XJ D44 but things happen... no biggie.

This is too much of a gap at the ends i'd imagine? Guess i'll spend some time with a grinder, or maybe a drill press and holesaw?

Bracketfit.jpg
 
OK cool. I'll take my time and get them fitting better.

Andy, i wanna do it so Joe doesnt have too... and i can obviously use the experience!

Colin..looks like 1/4"
 
Last edited:
OverlandXJ said:
OK cool. I'll take my time and get them fitting better.

Andy, i wanna do it so Joe doesnt have too... and i can obviously use the experience!
Click to expand...

With the way you enjoy using your Jeep, the peace of mind when your "overlanding" in the middle of nowhere will pay dividends. We only have to worry about getting dragged 1 mile tops out of the woods... and can walk out if really needed. When your 30 or more miles from the closest gas station and one of those brackets goes *tink" at the weld.... you may have a rough next few days.
 
The correct way to do it is definitely to make it fit better.

But I'm just saying my traction bar bracket fitment was pretty much like that after I cut it off to reuse it when I put it on the passenger side. I just burned it in (3/8" thick).

It held my entire rear axle from folding out when I snapped both leaf springs :laugh:
 
Andy in Pa. said:
With the way you enjoy using your Jeep, the peace of mind when your "overlanding" in the middle of nowhere will pay dividends. We only have to worry about getting dragged 1 mile tops out of the woods... and can walk out if really needed. When your 30 or more miles from the closest gas station and one of those brackets goes *tink" at the weld.... you may have a rough next few days.
Click to expand...


Ask MOFO about walking 40+ miles out of a break on the trail in Utah... not something i wanna try.
 
If I were welding it for myself, I'd probably just use it as-is.

If I were giving it to someone else to weld for me I'd probably make it fit a little better.
 
Thats the way i see it to Chris..

Remember back when i was rushing around getting the XJ ready to run out to Utah.. then ended up in hospital? I was chasing a noise that led to me rebuilding the transfer then replacing the axleshaft bearings. Still had a noise on right turns.

I knew the race i pulled from that location was a bit sloppy, which led to the LocTite bearing adhesive discussion earlier. Pulled the axleshaft and found the new bearing (maybe 25 miles) had failed. What would cause this? I can also feel a few metal slivers where this loose part of bearing was turning on the end of the tube.. just beyond where the race would bottom out.

We pressed the bearing on properly by the inner ring. Now i'm concerned i'll need a new housing..

44bearingfailure.jpg
 
Ughh..

Want to thank Keith (MDXJ) for calling me and pointing out what a dumb ass i am. The bearings were pressed on backwards..

Theres a $120 mistake...
 
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