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Author Topic: 99 TJ one ton stretch/coilovers/doubler etc...  (Read 31411 times)

Offline mattamd_xp

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99 TJ one ton stretch/coilovers/doubler etc...
« on: July 24, 2011, 09:16:38 PM »
Decided that I should add a build thread over here for you guys to see how my Jeep is progressing (or not as it's been since May ::) )
Most of this work is stuff I did in April and May of this year, a couple of things I did in February/March, but I really didn't start hammering it until April. On to the progress...
I'll start with the steering box relocation/new front frame cross-member that I did over the fall/winter. It's patterned after the TNT customs kit.









The box is rotated flat and moved forward against the new smaller cross-member that should give me about 3" of front stretch.
1999 Jeep Wrangler 4.0 AX-15,NP231/D300 Doubler, front/rear stretch, (4) coil-overs, and D60's swap in progress...

Offline mattamd_xp

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Re: 99 TJ one ton stretch/coilovers/doubler etc...
« Reply #1 on: July 24, 2011, 09:17:10 PM »
Got the front axle brackets tacked in place to check my clearances


Trac bar bracket just clears the reinforcement I have from my steering stretch


And the view from behind the axle


Also got the front upper arm measured, cut and welded.




1999 Jeep Wrangler 4.0 AX-15,NP231/D300 Doubler, front/rear stretch, (4) coil-overs, and D60's swap in progress...

Offline mattamd_xp

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Re: 99 TJ one ton stretch/coilovers/doubler etc...
« Reply #2 on: July 24, 2011, 09:17:47 PM »
Got the hubs temporarily on to check the clearances with the tires mounted. Here's a pic of it at full stuff with the fender mocked up in place. Also started working on the coilover hoops and clearances, but I didn't get any pictures of those. Made some great progress in the last couple of weeks  :thumbu: Hoping to have the front buttoned up except for the steering this coming weekend. Then on to the transfer case cross-member and then the rear axle.


A couple of other views:





1999 Jeep Wrangler 4.0 AX-15,NP231/D300 Doubler, front/rear stretch, (4) coil-overs, and D60's swap in progress...

Offline mattamd_xp

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Re: 99 TJ one ton stretch/coilovers/doubler etc...
« Reply #3 on: July 24, 2011, 09:18:22 PM »
Spent a few hours in the garage after work today. Made a lot of progress, but unfortunately my camera battery is dead so you'll have to put up with cell phone pics for now. All of the front suspension brackets except for the frame end upper control arm mount are fully welded in!  :dance: Used the plasma cutter to make the upper coil-over mount tabs. Was going to use it to make the axle end ones as well, but had some in my parts box that ended up working out quite nicely.

Mocked up the front coilovers and cycled the suspension. Everything clears great and flexes like nobody's business! Didn't get any pics of that, but should have the front resting on it's own weight shortly.
Now for the pics. Maybe someday I'll get a 220 mig so I won't have to use flux core when welding 1/4". I've got a lot of cleaning to do prior to prime/paint.









1999 Jeep Wrangler 4.0 AX-15,NP231/D300 Doubler, front/rear stretch, (4) coil-overs, and D60's swap in progress...

Offline mattamd_xp

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Re: 99 TJ one ton stretch/coilovers/doubler etc...
« Reply #4 on: July 24, 2011, 09:19:13 PM »
Got some more work done on it, but can't post pictures from here at work  :bwall: Will try and get some posted tomorrow.

Here are some pictures of the progress I've made in the last couple of weeks.
Got the front resting on its own weight: In the picture I have the front held up with jackstands so it's a bit above ride height. I should have about 4" of bump with the setup I'm running on the coilovers. I'm still trying to decide if I should go with rod ends or tre's for the steering. It's going to be a DD after I'm done hopefully, so I want something that's reliable and strong. I could go with a high steer arm on the passenger side and put the drag link under it to clear the frame a bit better, or if I run rod ends, I was going to put the tie rod under the knuckle and the drag link over it drilling them out for 3/4" bolts. Any recommendations?

 



Got the cable shifters setup on the doubler too. I had to modify the brackets a bit because I'm not running Duffy's doubler kit, but someone elses, so the clearances are a bit different around where the brackets mount. I also cut out a mount for the D300 that is the same as TMR's flipped D300 kit, but didn't get a picture of it yet. I love having a plasma though  :twisted:



Started cutting the floor for clearance of the t-cases. Still have a bit more to go marked out. It's a pain lifting the doubler setup in and out while laying on my back under this thing... I need a lift :drool:
1999 Jeep Wrangler 4.0 AX-15,NP231/D300 Doubler, front/rear stretch, (4) coil-overs, and D60's swap in progress...

Offline mattamd_xp

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Re: 99 TJ one ton stretch/coilovers/doubler etc...
« Reply #5 on: July 24, 2011, 09:23:29 PM »
That brings it almost up to day. I now have the doubler hanging off the tranny waiting for me to weld up the cross-member and I've cut the floor out to get a basically flat belly. I picked up a 14 bolt rear and stripped all the factory brackets off it. Gonna do disc brakes on it and hopefully get some brackets tacked up this week on it. Hopefully having you guys after me to get it wheeling will help me get it done sooner  ;)
1999 Jeep Wrangler 4.0 AX-15,NP231/D300 Doubler, front/rear stretch, (4) coil-overs, and D60's swap in progress...

Offline jason m

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Re: 99 TJ one ton stretch/coilovers/doubler etc...
« Reply #6 on: July 24, 2011, 09:35:39 PM »
Hey Matt Ive been watching your build over on Westen Mass 4x4, looks good.

I did this for my front and rear steer on my Jeep

Rear,


Still working on it but its a proven set up and I used a 5/8" bolt with Mis spacers.

Jason.
whats left of a 93YJ, 4.0/700r/241/HP60/coiled14bolt and beating it like it owes me money.

http://www.youtube.com/watch?v=1pfTVptGdGg

Offline Ian

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Re: 99 TJ one ton stretch/coilovers/doubler etc...
« Reply #7 on: July 24, 2011, 09:52:10 PM »
Looks good. Ditch the flux core.  You won't regret it.
i am an AMSOIL dealer! pm me for a quote

60 w/ minor bling 4.56, 14b ff rear w/detriot 4.56, atlas 2speed 5.0 4 custom link rear and 3link front, 110" wheelbase, pcs full hydro, fox 2.5's,  and 42" Irok stikies... and no clue

'00 tj (see above)

Offline Twisty

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Re: 99 TJ one ton stretch/coilovers/doubler etc...
« Reply #8 on: July 24, 2011, 10:09:28 PM »
I hate to be "that guy" but since you're using 110v flux core, be sure that.your upper ARM axle mount is on there well.  It sucks when they come off, and there is a ton of force going through them.   Look great! What is your eta for finishing?
88 MJ buggy, 4.0/AW4, 203/205, 3 link front/4 link rear on airshocks, 42" Iroks, full hydro

"Only wealthy men can afford to buy cheap things."

Offline mattamd_xp

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Re: 99 TJ one ton stretch/coilovers/doubler etc...
« Reply #9 on: July 25, 2011, 11:40:22 AM »
Looks good. Ditch the flux core.  You won't regret it.

I've only got a 110 mig, with flux core it burns much hotter and I can get more penetration on the welds, so I'm confident in them holding. I've swapped out 3 rear axles with custom brackets using the same welder/wire with almost 10,000 miles on them with no problems, so I'm not worried about the strength. I wish I had the money to pick up a new 220 mig with gas, but I'm having enough trouble coming up with cash for the parts I need right now. I've got some left of the 97 I'm parting out, so maybe if I can sell the rest of that I'll have enough to pick up a good 220... I've been welding with a 110 mig since I was 7 and my dad taught me on his '36 Ford project we were working on at the time, so I'm pretty confident in my welding abilities. I still have to pick up some 1/4" plate so I can build my front truss reinforcing the upper link mount and preventing the axle from flexing, should be able to pick it up this week and get that squared away. I wouldn't run the front as is without a truss taking stress of the front upper mount, not enough weld surface no matter how well it's burned in for me to trust it to hold if anything were to happen while I'm driving it down the highway.

I like that setup Jason, I've been thinking of running something like that or just doing an inverted T with Chevy TRE's as my build is low enough that there won't be much of an angle and with a straight tie rod I shouldn't have any problems... I like the double shear setup though.
1999 Jeep Wrangler 4.0 AX-15,NP231/D300 Doubler, front/rear stretch, (4) coil-overs, and D60's swap in progress...

Offline jeepgod

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Re: 99 TJ one ton stretch/coilovers/doubler etc...
« Reply #10 on: July 25, 2011, 01:06:46 PM »
if you have been welding since you were 7 years old you need a new teacher! i could point out things wrong with your welds just by looking at them for 10 seconds. the easiest thing to see is that you are NOT getting penetration. your welds are "laying on top" of the 2 pieces that you are welding together, the welds should "flow". this is a tell tale sign of not enough penetration, i.e. heat (read 110 mig is not strong enough) you could try to pre heat the metal to get better penetration.

the simple fact of the matter is if you don't have the proper tools you shouldn't be building this. twisty is speaking from experience
as far as your past axle swaps still holding . . . . . i honestly think you are lucky if this is the quality of work done on them.

i know you are reading thinking "jeepgod is a d!!ck" but i am not trying to be one just pointing something out.
DISCLAIMER: 90% of the time the things i write on this forum are meant as a joke! Please be advised that these jokes are not meant to upset or hurt any one individual. if i offend you i am sorry. the other 10% of the time i am serious. if you are unsure pm me and i will be glad to explain.  thxs

Offline mattamd_xp

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Re: 99 TJ one ton stretch/coilovers/doubler etc...
« Reply #11 on: July 25, 2011, 05:47:07 PM »
if you have been welding since you were 7 years old you need a new teacher! i could point out things wrong with your welds just by looking at them for 10 seconds. the easiest thing to see is that you are NOT getting penetration. your welds are "laying on top" of the 2 pieces that you are welding together, the welds should "flow". this is a tell tale sign of not enough penetration, i.e. heat (read 110 mig is not strong enough) you could try to pre heat the metal to get better penetration.

the simple fact of the matter is if you don't have the proper tools you shouldn't be building this. twisty is speaking from experience
as far as your past axle swaps still holding . . . . . i honestly think you are lucky if this is the quality of work done on them.

i know you are reading thinking "jeepgod is a d!!ck" but i am not trying to be one just pointing something out.

The first two passes under neath the top pass are where the penetration is  ::) I know the limits of the 110 and this is definitely at it's max, but it's all about the prep of the joint. I wish I could get pictures while I was welding so you could see the backside of the brackets that are fused to the axle from the bead in the front... I understand what you're saying about how they look, 110 flux core looks like crap no matter what you do until you clean them off. Some of that is the flux/surface contamination that hasn't been cleaned off. If my 1st bead doesn't leave a heat effected zone of at least double the material thickness, I'll redo it. I'd love a 220 mig if you've got one you're looking to give away  ::)

Any questions as to what can be done with a flux core 110, check out slinky blue balls on pirate for a pretty decent rig that was by someone without the "proper tools"
1999 Jeep Wrangler 4.0 AX-15,NP231/D300 Doubler, front/rear stretch, (4) coil-overs, and D60's swap in progress...

Offline Ian

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Re: 99 TJ one ton stretch/coilovers/doubler etc...
« Reply #12 on: July 25, 2011, 06:04:45 PM »
Any questions as to what can be done with a flux core 110, check out slinky blue balls on pirate for a pretty decent rig that was by someone without the "proper tools"

fun facts to know and tell:
that rig almost was aquired by a nejz member. a club member offered more then it ended up being sold for......

iirc kirby used a 220 hobart
i am an AMSOIL dealer! pm me for a quote

60 w/ minor bling 4.56, 14b ff rear w/detriot 4.56, atlas 2speed 5.0 4 custom link rear and 3link front, 110" wheelbase, pcs full hydro, fox 2.5's,  and 42" Irok stikies... and no clue

'00 tj (see above)

Offline mattamd_xp

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Re: 99 TJ one ton stretch/coilovers/doubler etc...
« Reply #13 on: July 25, 2011, 06:12:20 PM »
Any questions as to what can be done with a flux core 110, check out slinky blue balls on pirate for a pretty decent rig that was by someone without the "proper tools"

fun facts to know and tell:
that rig almost was aquired by a nejz member. a club member offered more then it ended up being sold for......

iirc kirby used a 220 hobart

220 after he built his axles. He started in SC with a 110 mig and didn't get a 220 until way into the build. Here's a quote from him:
"I use a 125 hobart flux core which I actually ran over 2 years ago when the lead came out and it was sitting in the passenger seat, flew out and got run over by a 37 irock. I had to rewire some [censored] and so a little body work on it but it still works great. ya, its a piece of [censored]...but to prove my welds are good, I ripped a hole in my frame where the trac bar mounted and it peeled the frame away beyond where the weld was. I put plenty of weld surface on all the things that count, like axle brackets etc.

My little garage is a piece of [censored], but for $30 a month and being in college it isnt bad. I pretty much use an angle grinder, mini fridge for beer, shitty drill press and the 125 hobart for everything I do...and trust me, I use wayyyyyy more than $30 a month in electric alone (dont tell my apartment manager)"

from this page: http://www.pirate4x4.com/forum/showthread.php?t=551947&page=14

Not saying at all that I prefer to use a 110 flux core over a nice 220 welder, but I make do with what I have right now. I've been looking at 220 migs recently, but the guy that is supposed to buy my half-doors that I have for sale hasn't shown up yet = no funds for new tools after I bought the Powermax 45 in April
« Last Edit: July 25, 2011, 06:15:00 PM by mattamd_xp »
1999 Jeep Wrangler 4.0 AX-15,NP231/D300 Doubler, front/rear stretch, (4) coil-overs, and D60's swap in progress...

Offline jeepgod

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Re: 99 TJ one ton stretch/coilovers/doubler etc...
« Reply #14 on: July 25, 2011, 06:15:08 PM »
if you have been welding since you were 7 years old you need a new teacher! i could point out things wrong with your welds just by looking at them for 10 seconds. the easiest thing to see is that you are NOT getting penetration. your welds are "laying on top" of the 2 pieces that you are welding together, the welds should "flow". this is a tell tale sign of not enough penetration, i.e. heat (read 110 mig is not strong enough) you could try to pre heat the metal to get better penetration.

the simple fact of the matter is if you don't have the proper tools you shouldn't be building this. twisty is speaking from experience
as far as your past axle swaps still holding . . . . . i honestly think you are lucky if this is the quality of work done on them.

i know you are reading thinking "jeepgod is a d!!ck" but i am not trying to be one just pointing something out.

The first two passes under neath the top pass are where the penetration is  ::) I know the limits of the 110 and this is definitely at it's max, but it's all about the prep of the joint. I wish I could get pictures while I was welding so you could see the backside of the brackets that are fused to the axle from the bead in the front... I understand what you're saying about how they look, 110 flux core looks like crap no matter what you do until you clean them off. Some of that is the flux/surface contamination that hasn't been cleaned off. If my 1st bead doesn't leave a heat effected zone of at least double the material thickness, I'll redo it. I'd love a 220 mig if you've got one you're looking to give away  ::)

Any questions as to what can be done with a flux core 110, check out slinky blue balls on pirate for a pretty decent rig that was by someone without the "proper tools"

but you are not "slinky balls"  ::)


and you are not correct about flux-core always looking like crap! just your welds look like crap! i knew you would come back here and try to defend your welds but the truth is they are not good welds!

oh and fyi your "prep" sucks!!  metal should be clean! your metal looks like its been sitting outside for a few months, or did you weld it up all nice and cool it off by leaving outside ::)  in fact your links look like poop pipe, another fine example of the quality you are doing to this jeep.

sorry dude but you will never convince me that they way you are doing this work is adequate or done well for that matter. i find it better to error on the side of caution rather than
Quote
my 1st bead doesn't leave a heat effected zone of at least double the material thickness
i guess you have x-ray vision.?

DISCLAIMER: 90% of the time the things i write on this forum are meant as a joke! Please be advised that these jokes are not meant to upset or hurt any one individual. if i offend you i am sorry. the other 10% of the time i am serious. if you are unsure pm me and i will be glad to explain.  thxs


 



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