84 CJ8 4 link coil over project underway

[ttrdiablo]

Hey guys,

Sorry I've been MIA since Texas Twister. Well thanks to FoolInjected (TJO forum) I'm in the process of converting the Scrambler from spring over leaf spring suspension to a 3-link front + 4-link rear coil over suspension.

List:
Have - Front Dana 60 (locked 4:56 gears Disk brakes) & BTF arms.
Have - Rear 14 Bolt (locked 4:56 gears Disk brakes)
Stak II-speed transfer case
To be ordered - Staun Bead locks
Have - 39" Pitbulls
Have - 17" American racing wheels
To Do - Full Cage
Extend wheel base (approx 119)
Have - Custom dash + new gauges + paint
Have - Corbeau Seats
Have - 5 point harness
Missing - Front 3-links (Still need to design + locate)
Have - Rear 4-links (Still need to design + locate)
Have - Front Shocks
On order - Front Coils
Have - Rear Shocks
Have - Rear Coils
Have - AMC 360 V8 (Installed)
Have - PSC Hydrolic assist steering kit
Have - JY half doors (ready for paint - need to trade black canvas half top windows for black vinyl to match full vinyl soft top)
Have - TJ coil over brackets
Have - Ballastic Forged Heim Joints + link brackets

I've been collecting parts to get this project started and as time permits will post my progress. I really enjoy reading up on ya'lls projects myself so it's time I return the favor.

Despite the much needed rain, my buddy Mark and I made some good progress this weekend;

Mark got the frame cut off

I cut out the existing fender wells and new fender location


Mark welded in the new frame - Welding and bracing coming soon
(narrowed, angled in and as high as possible)


I notched the frame and Mark welded the TJ coil over upper brackets
(Angled by 10 degrees foward leaving just enough room for the rear bench seat)


I cut off several inches of the rear body
(Notched to allow frame to meet with bumper)

Mark and I started working on the bumper to close out the frame. Following are the cross members. Pending on winch and fuel cell.
(Recessed receiver - pin through backside, cut out for reverse tail lights, and notched corners)



Next on the to do list:
Weld on bumper
Frame cross members
brace frame joints
complete welding on frame

There is still obvioulsy lots to do. I'm so thankful to Mark for allowing me to take his garage hostage for this project.

[bigwalton]

Cool looking build, somehow I missed it til now. Any more progress?

[ttrdiablo]

Our buddy Richard from San Angelo dropped by this weekend to lend Mark and I a hand. Here are the progress pics;






NOTE: the added metal to prevent the receiver from hitting the gas tank is shoved to far by accident.




We accomplished to protect and mount the gas tank. Mark ran went around and completed the welding on the frame. The rear bumper was welded on and the cross member/winch mount was also welded into place. The lower link brackets were weled on to the axle. We almost completed the lower link brackets on the frame (no pics yet but these are going to be haus) We also started on the frame braces. Next step is to complete the brackets and links mock up. As well as the frame bracing followed by the fab of a gas tank skid plate (just in case).

Thanks to Richard for the hand and loaning us his Plasma cutter. Also a cont. thnx to Mark for doing all the welding for me.

[ttrdiablo]

Stauns just arrived!


Staun is running a buy 3 get one free. I was not going to buy them until towards the end of the project, but the price was right. Coild springs arrived as well (no pics yet) Links are currently at machine shop getting drilled and tapped and should be ava. next week and will be able to wrap up the rear suspension soon. Then it's off to the front suspension.

Mando

[bigwalton]

I've always thought that the Stauns would be the way I'd go if I was stepping up to beadlocks...4 for 3 is a nice deal Can't wait to see the rest come together!

[bigjeepnfool]

Double posted.

[bigjeepnfool]

Cool build thread......I will eventually link my jeep, so I would like to see what you come up with and how you like it. I can't tell from the pics but are there only 4 tabs holding the fuel cell in??? You may want to consider a couple of straps that run under the tank for support....I know my brother kept breaking tabs and tearing the fuel cell up on his before he strapped it. Keep up the progress and posting the pics....it helps keep you honest on a long project.

The only problem I've seen with stauns is they push on the sidewall when you are aired down and can cause the sidewalls to get punctured when you are up against a sharp rock as the tire is unable to flex with the staun pushing on the sidewall.

-Will

[ttrdiablo]

Guys,

Sorry for the delay. With a few family events and the holidays things started to slow down a bit for me. (Sorry Mark for hogging up your garage). So the links are complete and installed. Check out the brackets. These links are brackets are pretty darn stout.

Rear view of links (sorry for the bad pic)


Driver side upper links



Passenger side Upper Links



Driver Side lower link


Passenger side lower link


Rear Upper links (perfect clearance)



Got all grade 8 bolts, nuts, washers, and lock washers. Ready to test the springs/articulation next.

One more thing: Look what Santa brought early: (coil over front shock hoop kit with limiting straps)


Will: Thanks for the feedback. As for the tank - I have a 1/4 aluminum skid plate that is going right underneath the gas tank (Sandwich the tabs) but I will look into strapping it as well as it sounds like a good idea for preventative future repairs (that is the goal on this build to minimize having to worry so much). The tank still has some plumming and re-engineering to go through so we'll address it then. Thnx again.

Happy Thanks Giving!

[bigjeepnfool]

Looks great!!!!! I Like the frame link brackets. Now, when do we get to see some video of it in action????

[ttrdiablo]

Hey guys,

I was finally able to get back to the project so here are a few details of what I've done so far as progress goes.

I worked on the Fuel cell guts. I got these fuel pick ups from Auto Performance Engineering. (MP-12 & MP-13) Some fittings, high pressure fuel line, hard line, and stainless steel hose clamps.

http://www.autoperformanceengineering.com/html/pickups.html
Here is a layout of the guts.

Here is an inside view of the guts inside (Passenger side)

Here is an inside view of the guts inside (Driver side). Note the return line (elbow not in pic yet) dropping right back on the fuel pick up.

Now that the guts are all mocked up, I was able to drop off the tank with Wayne (the aluminum welding pro) from Cactus Metals to weld the fuel pick up fitting, the return line fitting, Fuel and vent hose inlets, cut out and plate the existing Fuel pick up and return stock fittings. Should be ready in a few days.

I also picked up a 1/4" aluminum plate to function as the fuel cell skid plate. To conform to the frame we designed I took the skid plate to Taylor Machine to have it bent. Here is a pic of the tank and skid plate mocked up.


Here is a view from the drivers side. Hard to believe there is 17 gallons in there.


I also got around to working on the Rear Winch (3k lbs) above the rear axle, between the frame on a cross member with a pulley system. Still not finished but click here to view the Winch in action Video1 and Video2 This will allow me to squeeze the Scrambler into the garage as well as allow me to suck down the rear in a steep downhill situation.

I miscalculated the lower links by an inch so I was forced to make new links. They are finally in place and painted. Curently pending waiting on the Rear Scrambler crush corners and tube fenders. So more updates coming soon.:winke:

[ttrdiablo]

Things are starting to pick up. Here are a few more pics of some recent progress.

Here is the tank back from Cactus Metals.

The pick up Fuel fitting and Fuel Return fitting.

Wayne from Cactus Metals cut off the original fittings on top of the tank and added a plate. Those welds are sweet!

Check out the inside view of the corner I had Wayne cut out in order to add a Fuel fill neck and vent neck to the tank.

Here is a pic of the outside

Here is another view of the guts finally in place. Note the 90 degree elbow return line to drop back into a fuel pick up. Had to go around the fuel gage.

View of the frame cut out to sneak the fuel hoses

Here is a view with the hoses


Next Mark welded the BTF brackets in place for the limiting straps (18") and I drilled out the upper holes. (note: the jeep is raised to make room for my fat arse but will not sit this tall)

Here is the view from the rear. I finally completed the routing of the brake lines. Mark built some pretty kewl 1/4" thick brackets to hold the fitting in place and brake line are protected.


Removed the Dana 300 T-case (Up for sale!) and skid plate. Waiting on the Crush corners, fender, and tube fenders from T&T (Shipping this week!) More updates as they come up.

[bigwalton]

That tank is full of awesome.

[mysunnshine]

You might want to support that fuel pick-up. That'll vibrate and break eventually-

[ttrdiablo]

Thnx for the feedback. The internal fuel line is fixed and has worked in Mark's Jeep for 4 years with the same setup with no problems. Don't think it will be a problem.

[Randyzzz]