XJ axle swap/build

Finally was able to clear my garage out today. Cut the TJ tub in half and it’s waiting to go to the scrap yard. Pulled the XJ in and was able to get the front axle dropped this evening. Next step is cutting frame side LCA mounts and trim some pinch seems for frame stiffeners and the SFR frame side link mounts.
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What frame stiffners are you running that need you to trim pinch welds/seams?

Are you just putting a jack under the transmission/transfer case when you fit everything up?
 
89Mock said:
What frame stiffners are you running that need you to trim pinch welds/seams?

Are you just putting a jack under the transmission/transfer case when you fit everything up?
Click to expand...


SFR frame side link mounts go around the unit body frame rails, and to run the stiffener you have to trim the drivers side pinch seam to get it to fit.

That is my plan so far, haven’t put too much thought into it yet, you have any suggestions?


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DocTremp said:
SFR frame side link mounts go around the unit body frame rails, and to run the stiffener you have to trim the drivers side pinch seam to get it to fit.

That is my plan so far, haven’t put too much thought into it yet, you have any suggestions?


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Click to expand...

Grind the frame rails clean, jack underneath to hold the stiffer up, a few C-clamps on the side to close the gap that way. Don't crush your fuel lines.
 
Phil said:
Grind the frame rails clean, jack underneath to hold the stiffer up, a few C-clamps on the side to close the gap that way. Don't crush your fuel lines.
Click to expand...


Thank you Phil! Do you remember what wire speed and voltage settings you used when you put yours on?


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Had to re do coil buckets and axle side track bar bracket today because I wasn’t sure that the track bar would clear the spring. I also added a spring retainer plate. Got to put the new welder to use and I am super happy with it. This is a before photo.


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Looks good. You might find that with a heim or tie rod end mounted to the hi steer arm, clearance may be slim to none with the track bar bracket. Hopefully it clears though
 
DocTremp said:
Thank you Phil! Do you remember what wire speed and voltage settings you used when you put yours on?


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Click to expand...

I did mine way back in the day when we used 3x3x3/16 angle steel for frame rail reinforcement...and we liked it!
 
Nates2000XJ said:
Looks good. You might find that with a heim or tie rod end mounted to the hi steer arm, clearance may be slim to none with the track bar bracket. Hopefully it clears though
Click to expand...


Checked with a tie rod and it was far from clearing. Cut the bracket off and I think it’s pretty close now. That’s at full lock.


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Haven’t been working on the Jeep very consistently because I’ve been doing projects on the new house. But in the last couple of weeks I’ve been able to make some progress on frame stiffeners. Right mid is basically done, left mid is 25% burned in, and right front is about 50%.
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What wire feed speed and voltage did you end up using? I burned my Ruffstuff frame stiffeners in recently and it was a 165 IPM setting and hot enough I could poke through the body if I stayed there too long. I had to move kind of fast as I could see the wire digging in and the weld pool melting into the metal with each loop. For more than one spot I went back and did a cover pass/reinforcement.
 
89Mock said:
What wire feed speed and voltage did you end up using? I burned my Ruffstuff frame stiffeners in recently and it was a 165 IPM setting and hot enough I could poke through the body if I stayed there too long. I had to move kind of fast as I could see the wire digging in and the weld pool melting into the metal with each loop. For more than one spot I went back and did a cover pass/reinforcement.
Click to expand...


These are the settings I have been using. I’ve burned through a few times but not as many as I thought I would to be honest.
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Nice welder.

Try turning down the wire feed speed. That seems really high if it is inches per minute. Plus a lower wire feed speed will lower amperage and heat in that area.
 
89Mock said:
Nice welder.

Try turning down the wire feed speed. That seems really high if it is inches per minute. Plus a lower wire feed speed will lower amperage and heat in that area.
Click to expand...


Thank you! It helps me look like I know a little bit about welding haha.

Yeah it’s .030 so I think that’s why the wire speed is so high.


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