CNC4x4 club build

BRUISER

silent.. but deadly
Moderator
Joined
Mar 17, 2005
Location
Raleigh
Every year CNC has wrenching days where we ask members to come together and help other member or new members either fix or add stuff to there rigs.

We have done cages, lifts, suspension, etc. pretty much almost every part that you can think off.

Well this year we are stepping up our game. We have a club member that would do anything for anyone so we are gonna give back to him.

We will be using my shop for the build with all others putting in time and muscle :)

Day 1 started yesterday Dec 10 2016. Jack and his dad showed up with a pile of parts and his jeep. His jeep is built very well but he wants to take it to the next level.

We have a deadline of April 1st 2017. Which is good cause that means I don't have to be in the garage every night :)





Shop ready to be filled with parts and the jeep.




Crate of axles.


Jeep full of parts
 

BRUISER

silent.. but deadly
Moderator
Joined
Mar 17, 2005
Location
Raleigh
More parts









Jack very excited to get started :)



Put jeep on lift and pulled off the tires. Then we sprayed all bolts/nuts with WD and PB so when we do our tear down it will go smoothly.



It may not be the fastest build but it will be cool.
 

BRUISER

silent.. but deadly
Moderator
Joined
Mar 17, 2005
Location
Raleigh
The list:

Dana 60's from dynatrac front and rear
All new suspension with ORI's
All new steering - and it steering with joy sticks
Gen right fuel tank
New fenders
And of course 40" tires
 

XJsavage

Warlock of Zante plantation
Joined
Aug 15, 2009
Location
South Carolina
Awesome!!! I would love to lend a hand in this if time and travel permits!
 

/dev/yj

Ralph Graw
Joined
May 19, 2005
Location
Raleigh, NC
Jack is one of those guys that when he's wheelin' there ain't no handicap. Heck, in general for that matter! If folks haven't seen the hoist and steering setup, it allows Jack to be one of the hardest rock crawlers in the club! And, one of the nicest most giving people you'll ever meet.

Nice Ken! He's gonna love it! :driver:
 

BRUISER

silent.. but deadly
Moderator
Joined
Mar 17, 2005
Location
Raleigh
Today we had our official first wrench day

We took out the axles, all suspension parts, and gas tank.

Next we strip the frame and then we can get started.



















 

/dev/yj

Ralph Graw
Joined
May 19, 2005
Location
Raleigh, NC
Sweet! Wish I could have actually helped but cool to see the progress. Jack's gonna love it. :)


Sent from my iPhone using Tapatalk
 

BRUISER

silent.. but deadly
Moderator
Joined
Mar 17, 2005
Location
Raleigh
Today we cut off all the old suspension brackets. Installed 1" Daystar body lift and a genright 23 gallon fuel tank and skid.











 

BRUISER

silent.. but deadly
Moderator
Joined
Mar 17, 2005
Location
Raleigh
because you cant ever have enough pics.. Here are some that Jack took sunday.. and a much better writeup then I do :)


Sunday, January 16, 2017


This was “officially” the second build day on the Jeep. Work started promptly at 9AM. The plan for the day was to remove all unnecessary suspension brackets and mounts, smooth out the frame, install the body lift, bolt in the new gas tank, and possibly remove the front fenders.


The first lesson of the day came early. As Ken was using the plasma cutter to remove old suspension parts, Jack Sr was using the air grinder to wire brush the frame. Well, the air compressor could not keep up with both tools at the same time. So, Jack Sr proceeded to remove the Anti-Rock sway bar.


Lucas showed up and took to smoothing the frame with the electric drill and sanding disks. The cutting and smoothing process took several hours. Next, we unpacked the SWAG weld-on body mounts. Since the build calls for a 1” body lift for the gas tank install, we decided to unbolt the body from the frame and insert the body lift blocks. The plan is to cut off the existing mounts one at a time and weld on the new mounts one inch higher. Lesson number two: it's easier to lift the body off the frame when you unbolt all the body mount bolts. We missed the two bolts on the rear crossmember. Lesson number three: the back half of a stripped down Jeep, on a frame style lift, is very light! Tie/strap the body down before lifting the body to insert the taller blocks.


Just before lunch, Ron joined the forces. After lunch – pizza from Salvio’s. Good stuff! We unpacked the new gas tank, which will allow the Dana 60 rear axle to be pushed back 5”, and installed fuel pump.


Lesson number four: what seems simple and straightforward isn't always so. The tank install appeared to be a direct bolt in. Not the case. The front mounting tabs required drilling the frame at the location of a crossmember. Drilling from the inside of the frame to the outside of the frame was not an option. First, we had to transfer the mark from the inside to the outside of the frame. Next, the challenge was to drill straight through the frame and hit the mark on the inside. Not so easy. The passenger side was slightly off the mark and took some time to lineup the holes. Lessons learned from the passenger side were applied to the driver side and we found success on the first try!


Holding the tank up and bolting it in place sounds easy; especially with four guys. Well, not so much, this took us the rest of the afternoon. The back of the tank lines up on the factory studs and the original nuts were used to secure the back of the tank, no problem. The next hour plus was spent devising ways to fish the supplied bolt through the newly drilled hole. Existing holes were used to assist in the process. Success was achieved by taping some welding wire to the bolt and pulling the bolt through the hole with the wire. Home free now, right? Wrong! We must have used every combination of tools in Ken’s toolbox. We had swivels, extensions, crows foot wrenches, off-set wrenches, shorty wrenches, and every other combination of ratchet and wrench we could think of. Finally, a combination that worked was discovered! The other side took ten minutes.

Lesson five: pay attention to hang wires and hoses. In hast to bolt the tank in place, we neglected to attach all of the electrical connections and hoses to the top of the tank. So, we had to partially unbolt the tank and drop it down. Luckily for us, Lucas has skinny arms. He was able to reach up over the tank and connect the unattended wires and hoses. We did have to spend some extra time on the one electrical connection. Over time, the plug has become brittle and the safety latch was broke on one side. The connection did not want to stay together. Ken used a zip tie to hold the latch in place. When then retighten all the bolts on the gas tank, put away tools, and called it a day.


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/dev/yj

Ralph Graw
Joined
May 19, 2005
Location
Raleigh, NC
because you cant ever have enough pics.. Here are some that Jack took sunday.. and a much better writeup then I do :)


Sunday, January 16, 2017


This was “officially” the second build day on the Jeep. Work started promptly at 9AM. The plan for the day was to remove all unnecessary suspension brackets and mounts, smooth out the frame, install the body lift, bolt in the new gas tank, and possibly remove the front fenders.


The first lesson of the day came early. As Ken was using the plasma cutter to remove old suspension parts, Jack Sr was using the air grinder to wire brush the frame. Well, the air compressor could not keep up with both tools at the same time. So, Jack Sr proceeded to remove the Anti-Rock sway bar.


Lucas showed up and took to smoothing the frame with the electric drill and sanding disks. The cutting and smoothing process took several hours. Next, we unpacked the SWAG weld-on body mounts. Since the build calls for a 1” body lift for the gas tank install, we decided to unbolt the body from the frame and insert the body lift blocks. The plan is to cut off the existing mounts one at a time and weld on the new mounts one inch higher. Lesson number two: it's easier to lift the body off the frame when you unbolt all the body mount bolts. We missed the two bolts on the rear crossmember. Lesson number three: the back half of a stripped down Jeep, on a frame style lift, is very light! Tie/strap the body down before lifting the body to insert the taller blocks.


Just before lunch, Ron joined the forces. After lunch – pizza from Salvio’s. Good stuff! We unpacked the new gas tank, which will allow the Dana 60 rear axle to be pushed back 5”, and installed fuel pump.


Lesson number four: what seems simple and straightforward isn't always so. The tank install appeared to be a direct bolt in. Not the case. The front mounting tabs required drilling the frame at the location of a crossmember. Drilling from the inside of the frame to the outside of the frame was not an option. First, we had to transfer the mark from the inside to the outside of the frame. Next, the challenge was to drill straight through the frame and hit the mark on the inside. Not so easy. The passenger side was slightly off the mark and took some time to lineup the holes. Lessons learned from the passenger side were applied to the driver side and we found success on the first try!


Holding the tank up and bolting it in place sounds easy; especially with four guys. Well, not so much, this took us the rest of the afternoon. The back of the tank lines up on the factory studs and the original nuts were used to secure the back of the tank, no problem. The next hour plus was spent devising ways to fish the supplied bolt through the newly drilled hole. Existing holes were used to assist in the process. Success was achieved by taping some welding wire to the bolt and pulling the bolt through the hole with the wire. Home free now, right? Wrong! We must have used every combination of tools in Ken’s toolbox. We had swivels, extensions, crows foot wrenches, off-set wrenches, shorty wrenches, and every other combination of ratchet and wrench we could think of. Finally, a combination that worked was discovered! The other side took ten minutes.

Lesson five: pay attention to hang wires and hoses. In hast to bolt the tank in place, we neglected to attach all of the electrical connections and hoses to the top of the tank. So, we had to partially unbolt the tank and drop it down. Luckily for us, Lucas has skinny arms. He was able to reach up over the tank and connect the unattended wires and hoses. We did have to spend some extra time on the one electrical connection. Over time, the plug has become brittle and the safety latch was broke on one side. The connection did not want to stay together. Ken used a zip tie to hold the latch in place. When then retighten all the bolts on the gas tank, put away tools, and called it a day.


View attachment 240271 View attachment 240272 View attachment 240273 View attachment 240274 View attachment 240275 View attachment 240276 View attachment 240277

Love it! Glad you're enjoying the process Jack!


Sent from my iPhone using Tapatalk
 

BRUISER

silent.. but deadly
Moderator
Joined
Mar 17, 2005
Location
Raleigh
work is moving along slowly and will be ramping up quickly now that we are back from KOH.

we replaced the motor mounts with new 1" lifted one, took the old fenders off and installed new gen right battery boxes and started prep for new fenders. we also installed a new PSC steering box with a poison spyder steering box skid.

next I will be working on cleaning more of the old stuff off the frame and prepping for new 4 link mounting brackets. we also unboxed everything which was a lot of fun and felt like Christmas.

@livetorun
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BRUISER

silent.. but deadly
Moderator
Joined
Mar 17, 2005
Location
Raleigh
Progress. All body mounts done. Entire frame clean, axles in place.

Thanks to Dave,Ron,Randal and the Kacks for helping today



























 

BRUISER

silent.. but deadly
Moderator
Joined
Mar 17, 2005
Location
Raleigh
Worked on jeep again. Front axle in place. Front frame mounts in place. Made temp links and temp steering. We are making progress











 

BRUISER

silent.. but deadly
Moderator
Joined
Mar 17, 2005
Location
Raleigh
Made more progress today. Thanks to all the helpers

My helper and myself.




Mr. safety




Setting pinion angle






















 
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