Birty Dastards Jeep Club

Tech Forum => Workshop => Topic started by: Warthog on May 01, 2010, 10:03:03 PM

Title: TJ Long Arm Project "Designed in the Pub, Built in a Shed"
Post by: Warthog on May 01, 2010, 10:03:03 PM
Asylum has a set of axles to chuck under his TJ. Dana 30 front 4:56 with a tru-trac in. At the rear is a Dana44 with and ARB, 4:56 of course :003:
The rear has been stripped of its stock up mounts and ready for 3 link (all removed by previous owner) So with some research, we have come up with a plan to get'em under his truck.

Plan is:
-Long-arm the rear axle. Tri-angulated uppers,  Lowers follow the path of the original axle mount.

-Front axle can go straight in without any mods at present. However a Radius armed front set-up using original axle mounts and long arm chassis mounts will follow.

First stage for the Bank Holiday, was to get the lowers done for the rear. The lower mounts on the axle, are still present. So lower arms made up, short arm brackets need to be removed ready to get an idea where the chassis mounts are to be located. We have numbers but, like to build in such away that makes the natural placements match the numbers :015: The TerraFlex "Belly-up" skid plate has to be modded to make room for the chassis mounts. So a temp support will be put inplace.

But Asylums Daily J'Eep is off the road. So first stage has been aborted for now :jpshakehead:

However we made up the lower arms today:

 2.5" JJ's at the chassis. Damn these things are hard to come by in the UK....At a good price! Asylum got raped for these 2 :jpshakehead:
(http://img.photobucket.com/albums/v11/Tenbulls/01052010455.jpg)

Mated to 40mm x 25mm tube 7.5mm Wall (Well drilled out soild EN12, the intentions were to go soild. But change my mind due to wieght. I know CDS would of been stronger due to the materials grain direction. But this material was available and at 7.5mm wall, Should suffice)
(http://img.photobucket.com/albums/v11/Tenbulls/01052010457.jpg)
 
65mm x 65mm x 50mm Bush housing. Glued to other end of tube, which will be at the axle.
(http://img.photobucket.com/albums/v11/Tenbulls/01052010468.jpg)

Adiprene L42* bushes with 16mm centres. Trying this material out for 2 reason. 1: I have enough for spares. 2: Have seen how much of a beating it can take.
Centres are 20mm conduit, easily sourced with enough clearance for 16mm bolts.
(http://img.photobucket.com/albums/v11/Tenbulls/01052010470.jpg)

Lowers are at 31.5" between centres.
(http://img.photobucket.com/albums/v11/Tenbulls/01052010469.jpg)

Lower arms ready for fitting :003:

*Adiprene® L 42 is a liquid urethane elastomer that yields high-quality vulcanizates of 80 durometer A hardness when cured with MBCA. Adiprene L 42 products have good tear strength, good abrasion resistance, and excellent flex life. They are very flexible at low temperatures having a torsional modulus of 10,000 psi (703 kg./sq. cm.) at -80°F (-62°C), and a brittleness temperature of -130°F (-90°C). Adiprene L 42 has been found suitable for the preparation of rolls, solid tires, diaphragms, boots, and for other applications where good flex life is needed. It should also be considered for making seals, bushings, and mountings for use at very low temperatures.






Title: Re: TJ Long Arm Project "Designed in the Pub, Built in a Shed"
Post by: xr6jeeper on May 02, 2010, 01:03:38 PM
Looking good, are you going to weld a small strap around the bush housing ?

Geoff.
Title: Re: TJ Long Arm Project "Designed in the Pub, Built in a Shed"
Post by: Warthog on May 02, 2010, 01:53:49 PM
Looking good, are you going to weld a small strap around the bush housing ?

Geoff.

Good idea :023:

Think it would make sense too. Would take some stress off the weld.

One area i think may fail are the original lower control arm brackets on the rear 44. Will be plating them for now though.

Will try and get as many images of the project upped. Bit slow starting at present. Any input welcome :greggmo:
Title: Re: TJ Long Arm Project "Designed in the Pub, Built in a Shed"
Post by: doublej on May 02, 2010, 03:06:52 PM
Any input welcome :greggmo:

how you guys starting when i have most of the parts...... lol
Title: Re: TJ Long Arm Project "Designed in the Pub, Built in a Shed"
Post by: Warthog on May 02, 2010, 03:31:52 PM
Any input welcome :greggmo:
how you guys starting when i have most of the parts...... lol
Hey, were just resourceful :003: You back on this Island mate?

Couple more images,
Clayt cleaned up the rear axle top mount locations:
(http://img.photobucket.com/albums/v11/Tenbulls/P1010463.jpg)
(http://img.photobucket.com/albums/v11/Tenbulls/P1010467.jpg)
Discs finally a rear axle that has disc brakes on :icon_super:
(http://img.photobucket.com/albums/v11/Tenbulls/P1010469.jpg)

This is what were using to mount the upper bridge for the top mounts on to, To me, it makes a good base for the top mount, nice and easy to mount. No funky coping/fitting needed on tube.
(http://img.photobucket.com/albums/v11/Tenbulls/01052010458.jpg)

GrindR-Fu by Asylum:

(http://img.photobucket.com/albums/v11/Tenbulls/01052010460.jpg)

Chucked onto the axle, ready for some metal glue and set to aprrox pinion hieght when done
(http://img.photobucket.com/albums/v11/Tenbulls/01052010462.jpg)

Slow progress at present, but it should pick up over the nxt weekends
Title: Re: TJ Long Arm Project "Designed in the Pub, Built in a Shed"
Post by: isle of man on May 02, 2010, 04:03:50 PM
I have some Clayton upper shock mounts going spare if you are going to relocate.
Title: Re: TJ Long Arm Project "Designed in the Pub, Built in a Shed"
Post by: wildwood on May 02, 2010, 04:05:55 PM
Very nice guys.... really like that last bit for the mounts.......

So with 4.56s let me guess??? 35s or 36s and 101-102" wheelbase?? :icon_twisted:

And will it be ready for Kirton at the next Bank Holiday? :icon_super:
Title: Re: TJ Long Arm Project "Designed in the Pub, Built in a Shed"
Post by: Warthog on May 02, 2010, 04:22:20 PM
I have some Clayton upper shock mounts going spare if you are going to relocate.


I'll leave that decision to Asylum? Those Bilstien 7100 would of been used though :hysterical:

Very nice guys.... really like that last bit for the mounts.......

So with 4.56s let me guess??? 35s or 36s and 101-102" wheelbase?? :icon_twisted:

And will it be ready for Kirton at the next Bank Holiday? :icon_super:

35's i think Wildwood. No stretch at the mo.

Ready for Kirton? Would be a "lastminute.com" if we are :003: Clayts, Daily has thrown a spanner in the works. Sooo the froader is now the Daily :banghead:
Doable, but with a few things missing! 35's, Rear Arb. Long Arm front end. Would be a good shake down run.............
Title: Re: TJ Long Arm Project "Designed in the Pub, Built in a Shed"
Post by: wildwood on May 02, 2010, 07:29:06 PM
So 35s and an ARB??? Mmmnnn just the spendy bits then eh...... :jpshakehead:

Talking of which just finished wiring all the switches for the winch arm and operate system front and back..... what a mind fuck for someone who doesn't do lecks... but it works....... all carling switches at the last minute so bloody lights everywhere. Also added up the low cost (not) build and bits....... arghhhhh don't do it. I've sold all that I stripped off and its still 'kin a lot  :icon_twisted:

Like what yer doing tho.   
Title: Re: TJ Long Arm Project "Designed in the Pub, Built in a Shed"
Post by: isle of man on May 02, 2010, 07:33:51 PM
Think I have a couple of Clayton 12" rear shocks but one has bust a seal (believe they are Walker Evens) needs rebuilding......Make me an offer!!!

*off to the garage to find them*
Title: Re: TJ Long Arm Project "Designed in the Pub, Built in a Shed"
Post by: isle of man on May 02, 2010, 07:49:10 PM
No luck drawn a blank (Waggers must of had them) but did come across a pair of 5" Clayton rear springs and a pair of used Bilstein 5125's
Title: Re: TJ Long Arm Project "Designed in the Pub, Built in a Shed"
Post by: MOCAJ on May 02, 2010, 07:54:37 PM
looking good clayt, spotted the ssbc disk conversion on the 44

sounds like im out of luck with the belly up, let me know dood  :greggmo:
Title: Re: TJ Long Arm Project "Designed in the Pub, Built in a Shed"
Post by: Warthog on May 02, 2010, 08:22:25 PM
So 35s and an ARB??? Mmmnnn just the spendy bits then eh...... :jpshakehead:

Like what yer doing tho.   

The ARB is in, ready to rumble. But no pipe work, compressor etc at present.

5 x 35's are a little out of budget until the suspension it done and tested. As much as Boggers would be the choice. Im affraid Simex are Favourites at present.

Think I have a couple of Clayton 12" rear shocks but one has bust a seal (believe they are Walker Evens) needs rebuilding......Make me an offer!!!
*off to the garage to find them*

Cheers IOM. However at present, we want to cycle the suspension once done. To see where were at on travel. But the decision to purchase would be upto Asylum.
Title: Re: TJ Long Arm Project "Designed in the Pub, Built in a Shed"
Post by: Bubba on May 02, 2010, 08:25:18 PM
spotted the ssbc very good stuff
Title: Re: TJ Long Arm Project "Designed in the Pub, Built in a Shed"
Post by: Asylum on May 02, 2010, 10:06:09 PM
Hey all,

Thanks for all your input and offers, like warthog said I dont really know what the full potential of this will be until its built and tested for some components to be purchased later. I have been squirreling a lot of bits away over time exactly for this project though and lack of progress today is my fault as I have man flu  :icon_oak: which we all know is the worst kind.......anyway warthog thinks I have a rare strane of illness found only in the remotest regions of the world.........grinderflu....... :hysterical: as he knows I hate the damn things.

MOCAJ as for the belly up plate I have deliberated hard on this and it is a tough one. At present we are planning to modify it only very slightly but once we delve futher and I have my everyday ride back on the road so my froader can start being dismantled, our measurements may lead to other avenues in which case you would have first offer mate.

Something we are trying to adddress with this build, is to make the suspension adjustable to balance weight off and in the vehicle. ie. me! but all on a budget!

Clayt
 :greggmo:
Title: Re: TJ Long Arm Project "Designed in the Pub, Built in a Shed"
Post by: greggmo on May 03, 2010, 10:17:11 PM
was that grinder runnin backwards :icon_eek: lookin good you guys.
Title: Re: TJ Long Arm Project "Designed in the Pub, Built in a Shed"
Post by: wrangler on May 04, 2010, 11:16:55 PM
was that grinder runnin backwards :icon_eek: lookin good you guys.

I was thinking the same thing, sparks going the wrong way.

Waggers
Title: Re: TJ Long Arm Project "Designed in the Pub, Built in a Shed"
Post by: wildwood on May 05, 2010, 10:50:57 AM
Have that problem a lot .............left handed :jpshakehead:
Title: Re: TJ Long Arm Project "Designed in the Pub, Built in a Shed"
Post by: Asylum on May 05, 2010, 02:42:56 PM
The bigger and more important issue rather than the grinder going backwards is that the grinder is turned on and I am using it!  :hysterical:
Title: Re: TJ Long Arm Project "Designed in the Pub, Built in a Shed"
Post by: JamesH on May 05, 2010, 05:37:41 PM
Where did you get your JJs from in this country?? I'm in need and would prefer a quick UK supplier. Thanks, JAmes
Title: Re: TJ Long Arm Project "Designed in the Pub, Built in a Shed"
Post by: isle of man on May 05, 2010, 05:52:51 PM
Try Jim at gigglepin..

http://gigglepin4x4-shop.co.uk/epages/eshop343529.sf/en_GB/?ObjectPath=/Shops/eshop343529/Categories/Suspension (http://gigglepin4x4-shop.co.uk/epages/eshop343529.sf/en_GB/?ObjectPath=/Shops/eshop343529/Categories/Suspension)
Title: Re: TJ Long Arm Project "Designed in the Pub, Built in a Shed"
Post by: daggie on May 05, 2010, 06:59:51 PM
Try Jim at gigglepin..

http://gigglepin4x4-shop.co.uk/epages/eshop343529.sf/en_GB/?ObjectPath=/Shops/eshop343529/Categories/Suspension (http://gigglepin4x4-shop.co.uk/epages/eshop343529.sf/en_GB/?ObjectPath=/Shops/eshop343529/Categories/Suspension)

Peter
thats not a bad price :icon_biggrin: and a lot less hassle :greggmo:
Title: Re: TJ Long Arm Project "Designed in the Pub, Built in a Shed"
Post by: Asylum on May 05, 2010, 08:50:39 PM
The last lot I got was from exact fabrication at £37.99 each inc vat but the 2 I needed for this urgently was from Devon 4x4 as they were the only place that had them in stock. http://www.devon4x4.com/products_a/c10026/johnny-joints/0.html (http://www.devon4x4.com/products_a/c10026/johnny-joints/0.html)

Title: Re: TJ Long Arm Project "Designed in the Pub, Built in a Shed"
Post by: Dave69 on May 05, 2010, 10:02:40 PM
no problem using a grinder left or right handed, but i have a problem being chased by one after it kicks and it then gets dropped
Title: Re: TJ Long Arm Project "Designed in the Pub, Built in a Shed"
Post by: doublej on May 05, 2010, 10:16:16 PM
guess now we need to make to build weekend dates........ when we building?
Title: Re: TJ Long Arm Project "Designed in the Pub, Built in a Shed"
Post by: JamesH on May 06, 2010, 04:31:16 PM
Thanks - Exact Fab seems to have closed, I guess I'll have to pay up with one of the others.
Title: Re: TJ Long Arm Project "Designed in the Pub, Built in a Shed"
Post by: Alucardtnuoc on May 06, 2010, 06:11:23 PM
no problem using a grinder left or right handed, but i have a problem being chased by one after it kicks and it then gets dropped

So, Dude, if you saw this coming toward you you would do what exactly?

Title: Re: TJ Long Arm Project "Designed in the Pub, Built in a Shed"
Post by: Dave69 on May 06, 2010, 10:08:03 PM
stand to the side and let it run down the track.
Title: Re: TJ Long Arm Project "Designed in the Pub, Built in a Shed"
Post by: Warthog on May 07, 2010, 01:45:55 AM
I think a thread on Grinder-Fu is needed?

L.I.J.O (Asylum) is moving the grinder back towards himself, while the disc rotation is spinning in the opposed direction.
Title: Re: TJ Long Arm Project "Designed in the Pub, Built in a Shed"
Post by: Dave69 on May 07, 2010, 09:25:00 AM
you might need to take on the teacher role there and show the best way is side to side not infront of you going away and back towards the stomach area
Title: Re: TJ Long Arm Project "Designed in the Pub, Built in a Shed"
Post by: doublej on May 07, 2010, 08:01:26 PM
sideways youwould have no real control if it did kick - there is no trick to it - it just takes hours of it in your hand till you are comfortable with the tool and know what it feels like.

when we building again mates?
Title: Re: TJ Long Arm Project "Designed in the Pub, Built in a Shed"
Post by: wildwood on May 07, 2010, 08:30:35 PM
Took the guard off mine the other day and .............. yes it caught the pinkie........ good thing is a 1mm cutting disc sears the flesh so that by the time the damage is done 'ya all healed up'


Don't recommend it tho :jpshakehead:
Title: Re: TJ Long Arm Project "Designed in the Pub, Built in a Shed"
Post by: doublej on May 07, 2010, 10:27:52 PM
stop being a baby wildwood i havent had guards on mine since they entered the shop - they get in my way more than do good.
Title: Re: TJ Long Arm Project "Designed in the Pub, Built in a Shed"
Post by: wildwood on May 07, 2010, 10:32:34 PM
I know its all your fault Double J ........... It was at yours that I first experienced 'no guards' and thought....'Mmmnnn that's easier to work with' :hysterical: :hysterical:
Title: Re: TJ Long Arm Project "Designed in the Pub, Built in a Shed"
Post by: king cj on May 07, 2010, 10:46:56 PM
sideways youwould have no real control if it did kick - there is no trick to it - it just takes hours of it in your hand till you are comfortable with the tool and know what it feels like.

when we building again mates?

must resist, must resist, oh fuck it i cant! :gay-flag-28:
Title: Re: TJ Long Arm Project "Designed in the Pub, Built in a Shed"
Post by: Tragic on May 08, 2010, 12:18:25 AM
I do this shit for a living, and have done for the last 20 odd years. Yeah, I've taken liberties with power tools and I have the scars to prove it :jpshakehead: I've also seen the damage a kicked-back and flailing angle grinder can do to the human body, no matter how comfortable the user was with it.












I keep the guards ON! They're there for a fucking good reason!!
Title: Re: TJ Long Arm Project "Designed in the Pub, Built in a Shed"
Post by: Lornaben on May 08, 2010, 02:13:11 AM
Gotta agree with Tragic, I been usin em for years with guards on and off. I've had several kickbacks but only one without the guard ....

I was very lucky in hindsight, it took the glove right off my hand and jammed itself ..... if it hadn't I'm pretty sure my kids wouldn't exist ....

Leave the guards on  :banghead:
Title: Re: TJ Long Arm Project "Designed in the Pub, Built in a Shed"
Post by: Warthog on May 08, 2010, 12:50:45 PM
O.k

For all those whom want to use an angle grinder safely do so. For those who dont, carry on on, but be really really really careful :hysterical:

If anyone wishes to waste 10mins of there life below is a youtube clip of how to angle grind :icon_rolleyes:

How to use an Angle Grinder (http://www.youtube.com/watch?v=6bA4pQQ4i2I#lq-lq2-hq)

Now play safe children
Title: Re: TJ Long Arm Project "Designed in the Pub, Built in a Shed"
Post by: Bubba on May 08, 2010, 09:12:42 PM
is ther a how not to use one vid
Title: Re: TJ Long Arm Project "Designed in the Pub, Built in a Shed"
Post by: Warthog on May 29, 2010, 09:31:26 PM
Slow progress, would've like to got the lower mounts sorted but! Rain forced a Retreat to the garage for today.


Pinion Angle set-up
(http://img.photobucket.com/albums/v11/Tenbulls/1.jpg)

Start of Uppers crossmember.
(http://img.photobucket.com/albums/v11/Tenbulls/4.jpg)

Xmember glued into place for set-up (basic shape, will be fettled with at a later date) Should be 10 1/2" of separation between upper and lower links. Upper links are gonna be mounted on the front face of the xmember,
(http://img.photobucket.com/albums/v11/Tenbulls/2-1.jpg)

These Clarke Plasma Disc are crap! One cut through 50mm box and its done for :jpshakehead:
(http://img.photobucket.com/albums/v11/Tenbulls/3.jpg)

Chassis mounts mock up:

(http://img.photobucket.com/albums/v11/Tenbulls/30052010530.jpg)

(http://img.photobucket.com/albums/v11/Tenbulls/30052010531.jpg)


Title: Re: TJ Long Arm Project "Designed in the Pub, Built in a Shed"
Post by: Alucardtnuoc on May 29, 2010, 09:43:11 PM
Istead of meesing around with angle grinders to cut your steel, toddle off down to B&Q and get one of those Evolution Compound sliding mitre saw. They have a general purpose TCT blade that cuts through box section like butter. They cost about £90 and it is probably the most useful tool I have ever bought.

Will post photos of it and what I have cut with it if you are interested.
Title: Re: TJ Long Arm Project "Designed in the Pub, Built in a Shed"
Post by: Nexus on May 31, 2010, 11:03:33 PM
I have the an Evolution 10" Blade compound saw cost me £180 but its already saved me more than than that in time and accuracy, new blades are about £30, and it cut damn near anything.  Cut 3mm 50mm box no trouble and also 1/4" x 8" plate.

Cheers
Nick
Title: Re: TJ Long Arm Project "Designed in the Pub, Built in a Shed"
Post by: wildwood on June 01, 2010, 12:12:15 AM
Got an Evolution from Machine Mart on VAT fee day

Did my rock sliders with it. Cut the stuff for rear bumper before welding and have just cut about 100 metres of 20mm round bar and 6mm x 30mm flat bar for steel fencing all stuff that would not be accurate with a cut off disc.
Title: Re: TJ Long Arm Project "Designed in the Pub, Built in a Shed"
Post by: doublej on June 05, 2010, 07:12:17 AM
wheres my updates??????????????? i started at 530am today.....do you know where your Fu is at?
Title: Re: TJ Long Arm Project "Designed in the Pub, Built in a Shed"
Post by: Warthog on June 06, 2010, 11:35:10 PM
wheres my updates??????????????? i started at 530am today.....do you know where your Fu is at?

The FUooker hit me on the Head!
(http://img.photobucket.com/albums/v11/Tenbulls/8.jpg)

Asylums Jeep attack! 4 hours up A&E and a few staples and i returned for more :003:
Title: Re: TJ Long Arm Project "Designed in the Pub, Built in a Shed"
Post by: Warthog on June 06, 2010, 11:37:33 PM
Slow progress. But the axle is under and another wknd should finish the rear.


Chassis uppers and lowers
(http://img.photobucket.com/albums/v11/Tenbulls/5.jpg)

Uppers in Pro
(http://img.photobucket.com/albums/v11/Tenbulls/014.jpg)

Lowers tacked in place
(http://img.photobucket.com/albums/v11/Tenbulls/7.jpg)

(http://img.photobucket.com/albums/v11/Tenbulls/6.jpg)

Upper link on mount
(http://img.photobucket.com/albums/v11/Tenbulls/013.jpg)

Where we are at with the lowers and pinion.
(http://img.photobucket.com/albums/v11/Tenbulls/010.jpg)

(http://img.photobucket.com/albums/v11/Tenbulls/9.jpg)

Safety first
(http://img.photobucket.com/albums/v11/Tenbulls/011.jpg)

As i dont want this to happen again!
(http://img.photobucket.com/albums/v11/Tenbulls/8.jpg)
This Jeep owes me!

RAIN! Axles under and the truck wheeled to the side for next weekend!
(http://img.photobucket.com/albums/v11/Tenbulls/012.jpg)
Title: Re: TJ Long Arm Project "Designed in the Pub, Built in a Shed"
Post by: momos on June 06, 2010, 11:53:02 PM
omg yes i bet it was painful but how?
Title: Re: TJ Long Arm Project "Designed in the Pub, Built in a Shed"
Post by: Bubba on June 06, 2010, 11:54:00 PM
ouch that hurts just lookin at it
Title: Re: TJ Long Arm Project "Designed in the Pub, Built in a Shed"
Post by: isle of man on June 06, 2010, 11:55:36 PM
 :iagree:
Title: Re: TJ Long Arm Project "Designed in the Pub, Built in a Shed"
Post by: MOCAJ on June 07, 2010, 12:03:27 AM
ouch, be careful guys  :icon_eek:
Title: Re: TJ Long Arm Project "Designed in the Pub, Built in a Shed"
Post by: king cj on June 07, 2010, 12:53:39 AM
needs bigger tyres!
Title: Re: TJ Long Arm Project "Designed in the Pub, Built in a Shed"
Post by: Warthog on June 07, 2010, 01:06:50 AM
needs bigger tyres!
:

 :lol_hitting: :098:






Title: Re: TJ Long Arm Project "Designed in the Pub, Built in a Shed"
Post by: Asylum on June 07, 2010, 10:34:37 AM
needs bigger tyres!

It will get some mate but not untill budget permits!

We still havent identified which bit of the jeep actually struck warthog on the head!  :icon_eek: But there was alot of claret! :headhack:
Glad hes ok though.............after all, how else would I get my jeep mods finished! lol

I dont mean it mate! :greggmo:

Title: Re: TJ Long Arm Project "Designed in the Pub, Built in a Shed"
Post by: Dave69 on June 07, 2010, 08:38:36 PM
i'm amazed you didn't see ivory
Title: Re: TJ Long Arm Project "Designed in the Pub, Built in a Shed"
Post by: doublej on June 08, 2010, 08:46:27 PM
Glad hes ok though.............after all, how else would I get my jeep mods finished! lol
I dont mean it mate! :greggmo:

NO you dont mean it cause then you would have to drive farther to my house to make me do them.

so did any of those mounts help ya. that center one is too cool not to use mate. lol
Title: Re: TJ Long Arm Project "Designed in the Pub, Built in a Shed"
Post by: Warthog on June 12, 2010, 10:33:48 PM
Today:

Axle links set-up, ready for glue
(http://img.photobucket.com/albums/v11/Tenbulls/13.jpg)

Committed now, glued into place.
(http://img.photobucket.com/albums/v11/Tenbulls/14.jpg)

Upper and lower link bolt placement are near as parrallel to each other. 10 1/2" Separation, between uppers and lowers.
(http://img.photobucket.com/albums/v11/Tenbulls/15.jpg)

Done for now, bit of paint to stop the rust mite.
(http://img.photobucket.com/albums/v11/Tenbulls/16.jpg)

Centre point for links fall just pass the diff nose.
(http://img.photobucket.com/albums/v11/Tenbulls/17.jpg)

Well due to injury, Asylum was assigned "Fire Watch" He wouldnt let me gaffer tape a GrindR to his crutch :003:
(http://img.photobucket.com/albums/v11/Tenbulls/18.jpg)

Hopefully have it under the Truck Sunday.
Title: Re: TJ Long Arm Project "Designed in the Pub, Built in a Shed"
Post by: Asylum on June 13, 2010, 11:20:09 AM

Well due to injury, Asylum was assigned "Fire Watch" He wouldnt let me gaffer tape a GrindR to his crutch :003:
(http://img.photobucket.com/albums/v11/Tenbulls/18.jpg)

Hopefully have it under the Truck Sunday.

Thats my walking aid crutch, not crutch crutch just in case anybody questioned!  :hysterical:
Title: Re: TJ Long Arm Project "Designed in the Pub, Built in a Shed"
Post by: Warthog on June 13, 2010, 09:29:20 PM
Rear Links etc, all initailly complete. Some final welding and niggles to do.


Slave Driver with a Crutch  :headhack:
(http://img.photobucket.com/albums/v11/Tenbulls/20.jpg)

Uppers 33" long. One end will be fixed, the other end adjustable.
(http://img.photobucket.com/albums/v11/Tenbulls/19.jpg)

Under the truck.

(http://img.photobucket.com/albums/v11/Tenbulls/24.jpg)

At ride hieght the uppers are very close to paralle. Total lift on the truck will be 5" and have spring adjusters, at present its sitting on 4" Old Springs.
(http://img.photobucket.com/albums/v11/Tenbulls/21.jpg)

(http://img.photobucket.com/albums/v11/Tenbulls/26.jpg)

(http://img.photobucket.com/albums/v11/Tenbulls/27.jpg)

See the CAT for the exhaust in the distance? Gotta route that somehow to the back or side :hysterical:
(http://img.photobucket.com/albums/v11/Tenbulls/28.jpg)

(http://img.photobucket.com/albums/v11/Tenbulls/29.jpg)

(http://img.photobucket.com/albums/v11/Tenbulls/23.jpg)

(http://img.photobucket.com/albums/v11/Tenbulls/22.jpg)

(http://img.photobucket.com/albums/v11/Tenbulls/30.jpg)

Prop at max, with shoxs on their limit. Not sure if i like the idea of the shoxs bottoming out? Maybe limiting straps and longer shoxs would sort a few things out?

(http://img.photobucket.com/albums/v11/Tenbulls/25.jpg)


The man with the Crutch, is happy!

(http://img.photobucket.com/albums/v11/Tenbulls/13062010578.jpg)


Ehxhaust to do!

We've taken ages to get this far. But "Hey ho" were giving it a go....

On to the front very soon.

Off to visit, JJ and Co next weekend. Then back to it...
Title: Re: TJ Long Arm Project "Designed in the Pub, Built in a Shed"
Post by: isle of man on June 13, 2010, 10:14:00 PM
Great job...
Title: Re: TJ Long Arm Project "Designed in the Pub, Built in a Shed"
Post by: doublej on June 13, 2010, 11:50:10 PM
now why did it take me so damn long........
Title: Re: TJ Long Arm Project "Designed in the Pub, Built in a Shed"
Post by: Warthog on June 14, 2010, 02:16:56 PM
now why did it take me so damn long........

2 Holidays may of set ya back mate! You know? Those in that big SandBox :003:




Opened up a box, left in the Garage by Clayt :003:

(http://img.photobucket.com/albums/v11/Tenbulls/14062010600.jpg)


Hopefully, should be able to lash something together for an exhaust :017:

If anyone has ideas where to route an exhaust?




Title: Re: TJ Long Arm Project "Designed in the Pub, Built in a Shed"
Post by: isle of man on June 14, 2010, 04:37:31 PM
Just cut it and pont down - it's what you will do in the end the fooooooker just gets in the way.
Title: Re: TJ Long Arm Project "Designed in the Pub, Built in a Shed"
Post by: wildwood on June 14, 2010, 05:36:00 PM
like IOM says.......
You got no tank in the way so straight back and out........
or back and out the side high up behind the rear wheel flare...........
Title: Re: TJ Long Arm Project "Designed in the Pub, Built in a Shed"
Post by: Asylum on June 15, 2010, 10:47:17 PM
(http://img.photobucket.com/albums/v11/Tenbulls/28.jpg)
(http://img.photobucket.com/albums/v11/Tenbulls/30.jpg)

What Mark is asking is if you look at the 2 pics you can see that there is no room for a muffler after the cat and the distance between the underside of the tub and the top of the arms is minimal so somehow quickly going over the top arm to then run along the chassis is a head scratch?

We have started it up with just the cat and no back box and although it sounds nice would give you a headache with the rumblings and fums. Take into consideration my truck has no body lift also so the distance between upper arms and tub is very very minimal.

Any words of wisdom greatly appreciated!

I have seen some loop under the upper arm in pics but not sure thats a good idea?

cheers

clayt
Title: Re: TJ Long Arm Project "Designed in the Pub, Built in a Shed"
Post by: Nosebolt on June 15, 2010, 10:57:31 PM
have you considered rerouting from the manifold and taking it all outside the frame rail?
Title: Re: TJ Long Arm Project "Designed in the Pub, Built in a Shed"
Post by: Bubba on June 15, 2010, 11:29:26 PM
how about a stack
Title: Re: TJ Long Arm Project "Designed in the Pub, Built in a Shed"
Post by: Warthog on June 16, 2010, 01:32:33 AM
how about a stack

MMMMMMmmmmmm! I Like Stacks :icon_biggrin: Thing is where would a stack look right on a TJ?
Title: Re: TJ Long Arm Project "Designed in the Pub, Built in a Shed"
Post by: isle of man on June 16, 2010, 02:12:48 AM
Just cut it and point down - it's what you will do in the end the fooooooker just gets in the way.


I will take a photo of what I have done in the Morning...
Title: Re: TJ Long Arm Project "Designed in the Pub, Built in a Shed"
Post by: Asylum on June 16, 2010, 09:28:45 AM
Just cut it and point down - it's what you will do in the end the fooooooker just gets in the way.


I will take a photo of what I have done in the Morning...

Cheers Peter
Title: Re: TJ Long Arm Project "Designed in the Pub, Built in a Shed"
Post by: isle of man on June 16, 2010, 08:12:42 PM
OK here we have what is left of my exhaust - like you I wanted to keep the Mafia legal for road use and had the exhaust running out the rear as you would expect - after many "dings and dongs" straitening the pipe became a pain to say the least soooooo I cut the fooooooker off and this is what we have remaining.


(http://i106.photobucket.com/albums/m246/manxmafia/clay3.jpg)

(http://i106.photobucket.com/albums/m246/manxmafia/cla1.jpg)

(http://i106.photobucket.com/albums/m246/manxmafia/clay2.jpg)

Works for me.....
Title: Re: TJ Long Arm Project "Designed in the Pub, Built in a Shed"
Post by: Bubba on June 16, 2010, 08:16:52 PM
i dont know that will pass a yearly mot here on the mainland only thinkin aloud not trying to be the voice of doom

truck cab and stack is my fave idea
Title: Re: TJ Long Arm Project "Designed in the Pub, Built in a Shed"
Post by: king cj on June 16, 2010, 09:39:49 PM
stack up the windscreen piller like a snorkel job done :icon_eek:
side exit would work
Title: Re: TJ Long Arm Project "Designed in the Pub, Built in a Shed"
Post by: Nexus on June 17, 2010, 08:12:21 AM
Their could be a slight risk of killing yourself with carbon monoxide poisoning if you put it on the windscreen pillar and had the window open or roof down.

Cheers
Nick
Title: Re: TJ Long Arm Project "Designed in the Pub, Built in a Shed"
Post by: Warthog on June 17, 2010, 11:32:14 AM
I have plan :sign0151:

Title: Re: TJ Long Arm Project "Designed in the Pub, Built in a Shed"
Post by: JamesH on June 17, 2010, 12:12:39 PM
Rachel Bentley's TJ has the same system (I think she has the same long-arm kit as IOM).
Vince Bentley's XJ had major headscratching to get an exhaust to the rear with long-arm coil conversion - I believe he moved the shock mount locations to help.
Title: Re: TJ Long Arm Project "Designed in the Pub, Built in a Shed"
Post by: Asylum on June 17, 2010, 02:53:43 PM
(http://i94.photobucket.com/albums/l115/Asylum76/01-1.jpg)
(http://i94.photobucket.com/albums/l115/Asylum76/02-1.jpg)

I like this idea. Found on pirate. This guy has helped himself out by lengthening the wheelbase as well though, but looking in detail at his build I think it possible to follow the exhaust line from the cat toward the driveshaft and then once past the footwell tuck over the upper arm to then be free to run to the back without a back box or if back box needed then there is plenty of space as there is no feul tank in the way for one.

 :greggmo:

Although Warthog aint told me his idea yet so slightly scared!!!!

 :greggmo:
Title: Re: TJ Long Arm Project "Designed in the Pub, Built in a Shed"
Post by: isle of man on June 17, 2010, 07:03:33 PM
That will not work!!!
Title: Re: TJ Long Arm Project "Designed in the Pub, Built in a Shed"
Post by: Asylum on June 17, 2010, 08:08:21 PM
Bugger...........what have I not spotted?

 :017:
Title: Re: TJ Long Arm Project "Designed in the Pub, Built in a Shed"
Post by: Bubba on June 17, 2010, 08:10:08 PM
this may sound mad could you not use a cranked arm to clear
Title: Re: TJ Long Arm Project "Designed in the Pub, Built in a Shed"
Post by: Dave69 on June 17, 2010, 08:29:09 PM
would a body lift give you more options ?
Title: Re: TJ Long Arm Project "Designed in the Pub, Built in a Shed"
Post by: Warthog on June 18, 2010, 01:35:27 AM
Although Warthog aint told me his idea yet so slightly scared!!!!
:greggmo:

Have faith Brother! It only involves a small amount of GrindR Fu. Oh and a 'ittle bit a tin massaging >:D
Title: Re: TJ Long Arm Project "Designed in the Pub, Built in a Shed"
Post by: doublej on June 18, 2010, 10:07:51 PM
just exit it out just forward of the rear tyre.... you would only need 1 45* bend and you can give me the rest.......
honestly it would work mate. alot better and easier than what i have planed for the monkey. where did you get the pipes anyway?
Title: Re: TJ Long Arm Project "Designed in the Pub, Built in a Shed"
Post by: Warthog on June 19, 2010, 12:03:36 AM
where did you get the pipes anyway?

http://www.merlinmotorsport.co.uk/EXHAUSTS/c223/index.html?osCsid=f6f6e791df1fe7bd5685efa53aa0a2c9 (http://www.merlinmotorsport.co.uk/EXHAUSTS/c223/index.html?osCsid=f6f6e791df1fe7bd5685efa53aa0a2c9)
Title: Re: TJ Long Arm Project "Designed in the Pub, Built in a Shed"
Post by: Warthog on July 03, 2010, 10:50:09 PM
Upper and lower chassis mounts complete
(http://img.photobucket.com/albums/v11/Tenbulls/03072010632.jpg)

(http://img.photobucket.com/albums/v11/Tenbulls/03072010633.jpg)


Belly Plate on. Sorry Mocaj, the Terraflex plate is staying for now.
(http://img.photobucket.com/albums/v11/Tenbulls/03072010637.jpg)

(http://img.photobucket.com/albums/v11/Tenbulls/03072010636.jpg)

(http://img.photobucket.com/albums/v11/Tenbulls/03072010638.jpg)


Onto the Exhaust and Rear Disc brake set-up
Title: Re: TJ Long Arm Project "Designed in the Pub, Built in a Shed"
Post by: Warthog on July 04, 2010, 11:36:02 PM
A few bits progressed today:

Added a bit of strength to the lower mounts on the front axle


(http://img.photobucket.com/albums/v11/Tenbulls/04072010640.jpg)
(http://img.photobucket.com/albums/v11/Tenbulls/04072010641-1.jpg)

Exhaust mock-up in pro. Once happy with it, intended to weld into sections. Its gonna need some tweeking, but it somewhere handy.

(http://img.photobucket.com/albums/v11/Tenbulls/04072010660.jpg)

(http://img.photobucket.com/albums/v11/Tenbulls/04072010664.jpg)

(http://img.photobucket.com/albums/v11/Tenbulls/04072010667.jpg)

(http://img.photobucket.com/albums/v11/Tenbulls/04072010669.jpg)

Clayt wasnt ammused with the exit pipe though! :003:

(http://img.photobucket.com/albums/v11/Tenbulls/04072010671.jpg)

Rear disc brake conversion in pro:

2 types of mounting bracket to choose from. The SSBC brackets are the one to the right in the image below, not sure if the others are ssbc? Calipers are from something like a VW Golf 8V. Discs im unsure but investigating out of curiosity for spares.
 
I'll get some more images up at some point. This must be one of those mods, that every owner of a rear axled
Jeep with dumb brakes on would like to do?

(http://img.photobucket.com/albums/v11/Tenbulls/04072010650.jpg)
Title: Re: TJ Long Arm Project "Designed in the Pub, Built in a Shed"
Post by: doublej on July 05, 2010, 07:50:50 AM
i think this is what that rear axle needs warthog
(http://www.ballisticfabrication.com/assets/images/newbrackets/60truss.jpg)
basicly tieing the truss into the diff cover with a removable plate for when you need to take to diff cover off. it would add alittle more strength to the truss and the diff cover at the same time.
Title: Re: TJ Long Arm Project "Designed in the Pub, Built in a Shed"
Post by: Warthog on July 05, 2010, 10:19:08 AM
i think this is what that rear axle needs warthog
(http://www.ballisticfabrication.com/assets/images/newbrackets/60truss.jpg)
basicly tieing the truss into the diff cover with a removable plate for when you need to take to diff cover off. it would add alittle more strength to the truss and the diff cover at the same time.

Once the Axles out for Paint, there maybe a bit for strength added :icon_winkle: Wont be as pretty as that though :003:
Title: Re: TJ Long Arm Project "Designed in the Pub, Built in a Shed"
Post by: doublej on July 05, 2010, 08:53:39 PM
ooooohhh come on we can make it sexy........... come on
Title: Re: TJ Long Arm Project "Designed in the Pub, Built in a Shed"
Post by: Warthog on August 03, 2010, 01:04:52 AM
The rear disc brake conversion is a pretty much a bolt on mod. The calipers are MK3 Golf, not sure on
the discs though? Guess something jeepy anyone know?

(http://img.photobucket.com/albums/v11/Tenbulls/REardisc003.jpg)

(http://img.photobucket.com/albums/v11/Tenbulls/Reardiscs001.jpg)

(http://img.photobucket.com/albums/v11/Tenbulls/Reardiscs002.jpg)

Exhaust is done, the TJ sounds as quiet as a mouse (Boo!)

(http://img.photobucket.com/albums/v11/Tenbulls/Exhaust002.jpg)

(http://img.photobucket.com/albums/v11/Tenbulls/Exhaust003.jpg)

(http://img.photobucket.com/albums/v11/Tenbulls/Exhaust006.jpg)

The culprit of the quietness:
(http://img.photobucket.com/albums/v11/Tenbulls/Exhaust004.jpg)

(http://img.photobucket.com/albums/v11/Tenbulls/Exhaust005.jpg)


Front axle pinion bearings were shot and the oil seal had also failed. So fresh bearings and oil seal
were called for

Diff cover off, remove the retaining journals. Mark up the journals and assemble exactly as you removed.
(http://img.photobucket.com/albums/v11/Tenbulls/Removediff001_YUK.jpg)

Out it comes, no spreader plate special tool needed.
(http://img.photobucket.com/albums/v11/Tenbulls/Removediff002.jpg)

Remove pinion retaining nut. This is generally a stubborn bugger.
(http://img.photobucket.com/albums/v11/Tenbulls/Removepinion002.jpg)

Pinion out, here's the crush spacer that sets your bearing pre-load. Nissan Axles use these crush
spacers too. However a mod they do is to set the pre-load, then remove the crush spacer. Measure the
length of the spacer and replace it with a bush to the same length.

(http://img.photobucket.com/albums/v11/Tenbulls/Pinion_crush_spacer.jpg)

Remove oil seal flange:
(http://img.photobucket.com/albums/v11/Tenbulls/Oilsealremove.jpg)

Drift the old bearing shells out of the diff housing. KEEP THE SHIMS AND REFIT, WITH NEW SHELLS (in
bering shell)

Fit new shells
(http://img.photobucket.com/albums/v11/Tenbulls/Bearingouterrace.jpg)
 
(http://img.photobucket.com/albums/v11/Tenbulls/Innerbearingouterrace.jpg)

Pull off old inner race from pinion and refit new. I used the old crush space and some 1" 3/4 pipe to
press into place.
(http://img.photobucket.com/albums/v11/Tenbulls/Fitnewpinioninnerracetoshaft.jpg)

New bearing on pinion and a fresh crush spacer;
(http://img.photobucket.com/albums/v11/Tenbulls/Pinionwithfreshbearingandcrushspacer.jpg)

Place the outer bearing race into the nousing and then re-fit the oil thrower. Then onto a fresh oil
seal:

(http://img.photobucket.com/albums/v11/Tenbulls/Oilsealfitting.jpg)

(http://img.photobucket.com/albums/v11/Tenbulls/Oilsealseated.jpg)

Pinion shaft in and ready for tightening. The bearing needs a rotation preload of 3-5Nm, this basically
means that the nut needs to be done up to somewhere between 240-260Nm! Bloody tight....

(http://img.photobucket.com/albums/v11/Tenbulls/TorqueupthepinionMax260NmsCrushspacer_.jpg)

(http://img.photobucket.com/albums/v11/Tenbulls/Roling_Torque.jpg)

VIDEO OF ROLLIN TORQUE
(http://img

.photobucket.com/albums/v11/Tenbulls/th_24072010049.jpg) (http://smg.photobucket.com/albums/v11/Tenbulls/?action=view&current=24072010049.mp4)

Replace bearing journals and torque them up
(http://img.photobucket.com/albums/v11/Tenbulls/Installandtorqueupdiff.jpg)

Front Axle done.
(http://img.photobucket.com/albums/v11/Tenbulls/Frontaxle.jpg)


Rear axle ready to chuck under:

(http://img.photobucket.com/albums/v11/Tenbulls/AxleTweak002.jpg)

A little extra fab to appease JJ

(http://img.photobucket.com/albums/v11/Tenbulls/Axletweak001.jpg)


Axle under and brake lines etc fitted.

(http://img.photobucket.com/albums/v11/Tenbulls/02082010808.jpg)

(http://img.photobucket.com/albums/v11/Tenbulls/Brake_line.jpg)


Asylum fitted these funky things? They give around a 2" lift but are adjustable for more.

(http://img.photobucket.com/albums/v11/Tenbulls/akos002.jpg)

(http://img.photobucket.com/albums/v11/Tenbulls/Akos003.jpg)


Onto setting up the axle alignment and seeing how it all works.....


Front axle will get radius arm links sometime in the future. So at present its like a Half long arm

mutant jeep..
Title: Re: TJ Long Arm Project "Designed in the Pub, Built in a Shed"
Post by: Asylum on August 04, 2010, 10:26:33 AM
Anbody know what weight oil is best to run for an ARB? Also same question for a truetrac?

Cheers
Clayt
 :greggmo:
Title: Re: TJ Long Arm Project "Designed in the Pub, Built in a Shed"
Post by: normalbloke on August 04, 2010, 11:09:55 AM
I had a convo with Detroit about this and they recommend a regular EP90 for the trutrac and the full locker. I believe Mark Gasser used to recommend a 75/140, but I have no information as to why. I know which is easier to find on a weekend, and if Detroit say EP90, that is good enough for me.
Title: Re: TJ Long Arm Project "Designed in the Pub, Built in a Shed"
Post by: wildwood on August 04, 2010, 12:02:36 PM
Yup agree
Been running EP90 for 8 years with Lockrite and ARB........OK so far :icon_super:

I am well impressed guys.......... looking good.......... also impressed with the 'Masterclass" in axle stuff. Axle tech is my 101 at present.

You going to be ready for Kirton on August Bank Holiday?
Title: Re: TJ Long Arm Project "Designed in the Pub, Built in a Shed"
Post by: doublej on August 05, 2010, 08:37:07 PM
just grab some anti friction additive to it and youll be good to go.
Title: Re: TJ Long Arm Project "Designed in the Pub, Built in a Shed"
Post by: Asylum on August 17, 2010, 10:21:25 AM
You going to be ready for Kirton on August Bank Holiday?

Am hoping so, got a few niggles to sort out, mostly brakes, oh and change the height of the sankey hitch as it now sits way to high!!! Doh!

There may be a trip to help JJ out this weekend so gonna be a busy prep week before!

Cheers for the replies on oil.........as I thought but good to check, thanks all  :greggmo:
Title: Re: TJ Long Arm Project "Designed in the Pub, Built in a Shed"
Post by: willo on February 28, 2012, 10:32:07 PM
Holy Thread revival :icon_eek:

How have these control arms held up?, Has the truck done much rock based stuff?

Just wondering as I need to select some tube for my arms that are soon to be fit on my TJ
Title: Re: TJ Long Arm Project "Designed in the Pub, Built in a Shed"
Post by: doublej on March 09, 2012, 03:56:02 PM
Clayt has been slacking in the use of his jeep for awhile. I can remember what size tube they used but I want to say 6mil lowers is a good starting place. I over build things that i dont want to bend so I would sleeve them with something - another tube, tbar ect ect