Burrellsjeep Project: Eugene

Discussion in 'Build Threads' started by burrellsjeep, Apr 6, 2009.

  1. burrellsjeep

    burrellsjeep Breaking Stuff...

    Joined:
    Nov 19, 2008
    Location:
    Morganton NC
    Specs:

    97 TJ 2.5 liter AX5/231J
    3.5 Inch Teraflex Springs
    Custom 3 link Front,
    Custom 4 link
    Locked D30/ Locked 8.8
    4.88 Gears

    I build all my projects in my garage with a 110 volt weekend welder.

    Current Progress Pic 7/5/2017

    [​IMG]

    Plans

    This build is going to be a work in progress, Or a slow build.

    1. Upgrade Steering - DOM Heims - Done!
    2. 3 link the front - Done!
    3. Build Track Bar - Done!
    4. Build a truss for the D30 - Done!
    5. Cut Fenders - Build tube fenders -Done!
    6. 4 link the rear - Done!
    7. Full Roll Cage - Done!
    8. Built Front Bumper - Done
    9. Rock Sliders - Done
    I currently running 35s, and will stay there until I come across a front axle, Not really looking just if I happen to find one then I will address the D30, Until then I plan on trussing it and wheeling it. I plan to keep the 3.5 inch springs and just build a 3 link in the front and a rear 4 link.

    This is another poor mans non hardcore build, and your input is welcome.

    Links to some write ups of small projects on the jeep.

    Second Skin Dead Liner Install
    Cheapo Hand Throttle
     

    Attached Files:

    Last edited: Jul 5, 2017
  2. Ron

    Ron Dum Spiro Spero Moderator

    Joined:
    Apr 16, 2005
    Location:
    Sharon, SC
    That wasn't "backpack" Jason Hill helping with the liner install was it?
     
  3. burrellsjeep

    burrellsjeep Breaking Stuff...

    Joined:
    Nov 19, 2008
    Location:
    Morganton NC
    Steering Installation

    So here is what I am currently working on. I am building my steering from of 1 3/4 3/8 wall DOM tubing (7 feet of it) and 3/4 Heims. Here is what I started out with.
    Tubing
    ai298.photobucket.com_albums_mm279_burrellsjeep_002_1.jpg_f2763a53e1248c2dc5558ff522478719.jpg
    Heims
    ai298.photobucket.com_albums_mm279_burrellsjeep_004.jpg_9e1c7f6cac084b968339e48d7982e428.jpg
    Mocked together
    ai298.photobucket.com_albums_mm279_burrellsjeep_006.jpg_0ee90812c1371038d55bdc0df8468a4e.jpg
    I drilled my knuckles and pitman arm out to 5/8 (I got an Industrial grade 5/8 bit from a supply house well worth it) and I am using 5/8 bolts and 5/8 step down spacers at the knuckles and 5/8 high misalignments at the pitman arm.
    Here was my first design welded up
    awww_pirate4x4_com_forum_picture_php_0fa06e09058a376557f6d78329d7b7d0._.jpg
    ai298.photobucket.com_albums_mm279_burrellsjeep_004_1.jpg_c094f8e032f5f1e4c32493bcb5436f7a.jpg
    ai298.photobucket.com_albums_mm279_burrellsjeep_005_1.jpg_dab281d7df80b9210da18928c4d839a9.jpg
     
  4. burrellsjeep

    burrellsjeep Breaking Stuff...

    Joined:
    Nov 19, 2008
    Location:
    Morganton NC
    There was some roll in the steering do to heims, Very little but I wanted it tighter so I added a bushing.
    ai298.photobucket.com_albums_mm279_burrellsjeep_002_2.jpg_ec724b95d92386a7d413f55265f783a6.jpg
    After I got done with I just didn't like how the drag link ties into the tierod. I wanted a double sheer mount and I was concerned the two would bind. So I got some brackets and did it this way.
    Here are Brackets courtesy of Ballistic Fab
    ai298.photobucket.com_albums_mm279_burrellsjeep_003_1.jpg_e1068d922c9019af5861f539818afc1e.jpg
    And here is how it is now.
    ai298.photobucket.com_albums_mm279_burrellsjeep_008_1.jpg_dd4202a1a1529537a7899465b7e772f2.jpg
    ai298.photobucket.com_albums_mm279_burrellsjeep_007_1.jpg_a0fb643be4914d9a95e3c7845870206f.jpg
    ai298.photobucket.com_albums_mm279_burrellsjeep_009_1.jpg_288108fbe071eebd8ac8081e55880734.jpg
     
  5. burrellsjeep

    burrellsjeep Breaking Stuff...

    Joined:
    Nov 19, 2008
    Location:
    Morganton NC
    The one and only
     
  6. burrellsjeep

    burrellsjeep Breaking Stuff...

    Joined:
    Nov 19, 2008
    Location:
    Morganton NC
    The track bar as you can see is a work in progress, as I will post up what i got so far tomorrow.
     
  7. burrellsjeep

    burrellsjeep Breaking Stuff...

    Joined:
    Nov 19, 2008
    Location:
    Morganton NC
    Track Bar

    Since I got the steering done, I needed a solution for the track bar, I was able to get some more 1 3/4 tubing (Actually enough to 3 link the front also). So I decided to build it just like my steering arms. I had to relocated the axle bracket in order to clear the steering.
    I ordered this bracket from Ruffstuffspecialties.com
    [​IMG]
    I moved it to the top of the axle and offset it 2.5 inches to match the factory offset. Here are some pictures of it tacked in place and mocked up.
    ai298.photobucket.com_albums_mm279_burrellsjeep_011.jpg_c955f22aa099ceb462c2f5444d4c144e.jpg ai298.photobucket.com_albums_mm279_burrellsjeep_012.jpg_4218b96a189b09429b8b4c0a2279abae.jpg
    Looks like it will work well, I just have to burn it in and gusseted up. I am going to use these to gusseted it. There 1/4 thick and from DIY4X.com.
    ai298.photobucket.com_albums_mm279_burrellsjeep_010_1.jpg_1101a08d55b64a3b4c0adc53ed33864f.jpg
    I have some material for a truss for the top of the D30, I will post that up tonight, Along with my plans for the truss I am building.
     
  8. adam greene

    adam greene Well-Known Member

    Joined:
    Sep 9, 2008
    Location:
    morganton
    looks good i wana no how that steering does. might get you to help me do mine lol.
     
  9. burrellsjeep

    burrellsjeep Breaking Stuff...

    Joined:
    Nov 19, 2008
    Location:
    Morganton NC
    I hope to get to try it out soon.

    Say the word we'll build them up.
     
  10. braxton357

    braxton357 Robot

    Joined:
    Apr 6, 2005
    Location:
    Morganton
    You didn't fawk around with that steering...I've seen monster trucks that don't have tierods that large. There's no binding anywhere with that diameter tubing?

    Now you just have to worry about tearing the steering arm or balljoints off that cheesy d30 knuckle. :flipoff2:

    Looks good though.
     
  11. burrellsjeep

    burrellsjeep Breaking Stuff...

    Joined:
    Nov 19, 2008
    Location:
    Morganton NC
    Hey don't hate on my D30 it's special :flipoff2:

    I will put a larger axle in the front one day, When I can decide what I want.

    I had to mount the tie rod under the knuckles due to the size, If I had put them on top they would bind like hell, Don't think I will have an issue with it getting bent being lower. Hey I got a great deal on DOM.

    I think I might mount some recovery points on the tie rod. :lol:
     
  12. burrellsjeep

    burrellsjeep Breaking Stuff...

    Joined:
    Nov 19, 2008
    Location:
    Morganton NC
    D30 Truss

    So here's my plan for the truss on the D30, I have some 1.75x2.75 1/4 inch wall square tubing, I am going to cut it on an angle. I plan on using it kinda like a large gusset to help with the tube flex the 30s are known for.

    This gives you the idea.

    ai298.photobucket.com_albums_mm279_burrellsjeep_Truss.jpg_0b5b2bc13c2ff11698a54175ae4d93ed.jpg

    I am going to mock it up in card board and see how it going to fit.
     
  13. braxton357

    braxton357 Robot

    Joined:
    Apr 6, 2005
    Location:
    Morganton
    How close will it be to the oilpan?
     
  14. burrellsjeep

    burrellsjeep Breaking Stuff...

    Joined:
    Nov 19, 2008
    Location:
    Morganton NC
    Its a 2.5 liter, So I got all kinds of room up front.
     
  15. burrellsjeep

    burrellsjeep Breaking Stuff...

    Joined:
    Nov 19, 2008
    Location:
    Morganton NC
    My buddy Justin (Who works for a large machine shop) is helping me with this build. He is a much better welder and I trust him to do the welding on anything that is tied to safety. I hope to be posting up his build in the near future. His rig is one of the impressive rides I have seen ever.


    Just wanted to give him his due.

    Thanks again.:beer:
     
  16. burrellsjeep

    burrellsjeep Breaking Stuff...

    Joined:
    Nov 19, 2008
    Location:
    Morganton NC
    I hope to get back to work on this asap,

    I have been trying to get it to start.

    I let the battery die, and now it won't fire, So I am trouble shooting that. As soon As it running I going to start on the truss and get the front buttoned up.
     
  17. burrellsjeep

    burrellsjeep Breaking Stuff...

    Joined:
    Nov 19, 2008
    Location:
    Morganton NC
    **Updates**

    Well turns out I have a bad computer in the TJ, Been chasing that problem so I hadn't worked on much else until today.

    Well I finished removing the 2 inch spacer lift, getting me back down to the ride height I am looking for.

    Having it at ride height I can my measure for my rear driveshaft, It ended up 18.5 inches from Center of Cap to Center of Cap. I getting a ZJ CV shaft cut down.

    I have it back to the stock wheel base maybe a inch or two longer. This will be where it stays.
     
  18. burrellsjeep

    burrellsjeep Breaking Stuff...

    Joined:
    Nov 19, 2008
    Location:
    Morganton NC
    Got my Driveshaft back from CCC Truck parts today,
    They did an great job on it, Had them redo the whole thing, All new u joints, CV joint, shorten and rebalance. They even painted it. Paid like $170, Hell of allot better than $300 for a new one. Got the ZJ shaft free from my brother in law.

    I dropped it off at eight and it was ready by noon. They kicked ass on it.

    Great job thanks.

    ai298.photobucket.com_albums_mm279_burrellsjeep_006_4.jpg_2b5382a6b00352e072acf1fa7f83a656.jpg ai298.photobucket.com_albums_mm279_burrellsjeep_005_2.jpg_909e9e5f1d5ea63d12d1fb0ab0845586.jpg

    Look them up if you need driveshaft or drive line work done.


    CCC Truck Parts / Joint & Clutch Service
    1112 1ST Avenue S W
    Hickory, NC 28602
    (828) 328-5705
     
  19. burrellsjeep

    burrellsjeep Breaking Stuff...

    Joined:
    Nov 19, 2008
    Location:
    Morganton NC
    Finishing up my front trackbar. Got some paint on it. I am welding the front track bar bracket on, Hopfully I will get the truss cut today and I can start the fitting process on it.

    Trackbar Specs - 1.75 DOM 3/8 walled with 3/4 heims

    ai298.photobucket.com_albums_mm279_burrellsjeep_009_2.jpg_bbaf5f56e7a8182474fbb466ea399881.jpg
     
  20. burrellsjeep

    burrellsjeep Breaking Stuff...

    Joined:
    Nov 19, 2008
    Location:
    Morganton NC
    Question

    Do you guys see any issues with making my front links out of 1 3/4 3/8 walled DOM with 3/4 heims on the frame side and a ballistic joint on the axle end?

    I have read other builds with guys using them, I figure with the weight of my TJ, 4 banger and all, I should be ok
     
  21. burrellsjeep

    burrellsjeep Breaking Stuff...

    Joined:
    Nov 19, 2008
    Location:
    Morganton NC
    So here is what I decided on the links for the front.

    I building the lowers out of the 1 3/4 inch 3/8 walled DOM, I using a Ballistic Joint welded to the Axle end, And I went with a Creeper joint threaded in the frame end, I going to tap the DOM for the 1.25 threads.

    Here are ends I just bought from "Indy Will" on Pirate.

    [​IMG]

    On the upper link for the front I am going with a 3/4 heim on the Frame side and a poly bushing in the mount on the diff. I plan on using a summit joint in place of the bushing when the budget allows. But for now I will use the bushing. I haven't decided on the DOM for the upper, If I have left over of the 1 3/4 I will just use it, If not I may go with a 1.5 .250 DOM.
     
  22. burrellsjeep

    burrellsjeep Breaking Stuff...

    Joined:
    Nov 19, 2008
    Location:
    Morganton NC
    Truss

    Starting on the truss for the D30.

    I using this 2.5 X 1.75 .250 square tube
    ai298.photobucket.com_albums_mm279_burrellsjeep_004_3.jpg_901bb6d5b38c586c2eac4c2431ec9be2.jpg

    I made a card board template to help me get it closer to the shape, I still going to have to shape it to fit.
    ai298.photobucket.com_albums_mm279_burrellsjeep_001_3.jpg_aa594b0225dbea15647f875d1d3969ea.jpg

    Kids are in bed so I will have to cut in the morning.
     
  23. 92yotaman

    92yotaman Active Member

    Joined:
    Nov 5, 2008
    Location:
    boone, nc
    im no expert, but i think that will do just fine
     
  24. burrellsjeep

    burrellsjeep Breaking Stuff...

    Joined:
    Nov 19, 2008
    Location:
    Morganton NC
    Thanks,

    i was unsure and you know if your not sure go larger, So I ordered the Crawler Joints, I just feel better with the 1.25 shank on the lowers as apposed to the 3/4 shank.
     
  25. braxton357

    braxton357 Robot

    Joined:
    Apr 6, 2005
    Location:
    Morganton
    How much of that rectangle tubing do you have? And if you want to come plasma it, I'm at the house today.
     

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