PDA

View Full Version : Project: TJ rear leaf spring conversion



bburris
09-23-2003, 11:41 PM
Blake, Paul and I started the rear axle swap today. I got one side mostly unbolted, I'll get the other side done tomorrow. I also need to unbolt the rear tire carrier, since the spare is bending my tailgate, and take the crap-ass rear bumper off.

Here's how it sits at Paul's garage:
http://www.texasoffroad.net/albums/lonestar/axleswap/Jeep.sized.jpg

Here are my kustom (Paul) Blunt Motorsports shackle/frame bushings:
http://www.texasoffroad.net/albums/lonestar/axleswap/shackle_bushings.sized.jpg

Here's one of my rear ujoint caps...I haven't greased them in quite a while...
http://www.texasoffroad.net/albums/lonestar/axleswap/u_joint_cap.sized.jpg

I'll update with daily progress throughout the swap...

eight
09-24-2003, 09:04 AM
What axle is going in?

TXsizeK5
09-24-2003, 11:04 AM
8.8 ?

BMFScout
09-24-2003, 11:10 AM
i think the 8.8 he got for 30 bones is going in...
http://www.tamor.org/forum/upload/showthread.php?threadid=2442

BMFScout
09-24-2003, 11:15 AM
hey check this out, think that was a friday axle, or do you think it is a legit concern?

http://www.4x4wire.com/jeep/tech/axle/ford8_8/

TXsizeK5
09-24-2003, 11:59 AM
Hey what boneyard is that... is that in corpus? Man that's alot of cars, i gotta give that place a visit.

BMFScout
09-24-2003, 03:40 PM
it's in Dallas

BigRedFord04
09-24-2003, 04:17 PM
damn....if you're careful not to overheat the axle until it warps i dont see why it could be a "bad" thing to weld up the tubes like that. just extra insurance.

BMFScout
09-24-2003, 10:35 PM
kind of what i was thinking, don't think my mig could do that though, and it is pretty easy to warp one I would think

eight
09-25-2003, 09:10 AM
The pig is cast, it should be welded with stainless, but 7018 should be fine too. Or you can spool your mig up with the right wire and gas or just use the right flux core wire, TSC has all these different things and a guide to tell you which to use.

bburris
09-28-2003, 01:42 AM
We've made some more progress in the last couple of nights.

I finished holesawing the tub for the taillights...
http://www.texasoffroad.net/albums/lonestar/axleswap/MVC_706S.sized.jpg

shackle mounts to the frame with these:
http://www.texasoffroad.net/albums/lonestar/axleswap/MVC_714S.sized.jpg

http://www.texasoffroad.net/albums/lonestar/axleswap/MVC_715S.sized.jpg

bburris
09-28-2003, 01:43 AM
This was the point of no return. I sawzalled most of the LCA frame brackets off, then used the grinder to get them flush to the bottom of the frame.

http://www.texasoffroad.net/albums/lonestar/axleswap/MVC_717S.sized.jpg

The furthest set are YJ leaves, the closer set is an XJ leaf pack. I have been convinced to use the XJs so I can flip them front to back later when I want to extend my wheelbase a few inches.

http://www.texasoffroad.net/albums/lonestar/axleswap/MVC_718S.sized.jpg

Kustom leaf spring brackets courtesy of the professional machinest at Blunt Motorsports :flipoff2:

http://www.texasoffroad.net/albums/lonestar/axleswap/MVC_719S.sized.jpg

Here are the leaves mocked up and measured. We just need to get the other side welded in and then we can figure out what to do about shackles.

http://www.texasoffroad.net/albums/lonestar/axleswap/MVC_724S.sized.jpg

bburris
09-28-2003, 01:45 AM
and to anyone that is curious...yes it will be sitting ass high for a while - until I can redo the front suspension

Ben97XJ
09-28-2003, 09:58 PM
Why don't you just sell your crap and buy an XJ thats what your turning your rig into anyway!!!:D

bburris
09-29-2003, 01:20 AM
I enjoy having a real frame. You saw me wheel. I'd break an XJ in half.

bburris
09-29-2003, 01:22 AM
Originally posted by BMFScout
hey check this out, think that was a friday axle, or do you think it is a legit concern?

http://www.4x4wire.com/jeep/tech/axle/ford8_8/


When I get the axle back from the gear guy we're going to throw some stitch welds around the tube so I can prevent that from happening. Thanks for the article.

Fredo
09-29-2003, 11:48 AM
You call that frame under your jeep a "real frame"?

J Cooper
09-29-2003, 03:21 PM
... why leaves? why go through all the trouble for just leaf springs... i mean theres nothing wrong with them, but why go backwards, why not a tj long arm kit or something?

bburris
09-29-2003, 06:38 PM
$

fbronco86
09-29-2003, 07:01 PM
jeeps have a frame. I thought that was sheet metal. haha

BMFScout
09-29-2003, 07:06 PM
just 4 bushings to wear instead of 8 (and they wear out pretty quick), the upper arm mounts for the TJ elongate if you actually wheel it, leaves are hella cheap, long arm and the like are not. Now he has to worry about spring wrap, but a wrap bar will take care of that. He doesn't have to drop 300 bones on a bracket kit to get the 8.8 in there. It is defintiely the low buck way to go, It should flex pretty similar to a 4"lifted TJ if he gets the packs set up right. I think the TJ system works ok, but the links are far too short, and it makes the front lift from what I have seen. I mean if you turn Lissa's one way or the other and hit the gas the tire will go sky high, that can't be good. I think the leaves will fix that without spending the big skrilla on a long arm.

Here is the most famous of this conversion, I think it is a good low buck fix anyway, go to the bottom and click on the TJ-7 link...
http://www.kilbyenterprises.com/

BMFScout
09-29-2003, 07:10 PM
Originally posted by fbronco86
jeeps have a frame. I thought that was sheet metal. haha
cause Bronco frames are the epitome of strength, ask Tate how many times has he BROKE his frame...

bburris
09-29-2003, 07:58 PM
Originally posted by Fredo
You call that frame under your jeep a "real frame"?

I'll try to get a pic of it sometime. It's more than enough for a 4000 pound Jeep, whereas the unibody crap under Cherokees and Grand Cherokees has to beefed up a whole lot to obtain the same weight to beef ratio.

J Cooper
09-29-2003, 08:49 PM
thats cool, i just thought he already had a 4" lift ... im all about the leaf spring... and yes they are cheap as it gets.

bburris
10-01-2003, 01:32 AM
Alrighty...have some **** done now. After almost a two day hiatus as a result of my eyes being non-functional we made some noticeable progress tonight.

Here's a pic of the spring main eye hanger.
http://www.texasoffroad.net/albums/lonestar/axleswap/DSC03474.sized.jpg

Here I am letting Blake know what I think. This was pre-eye injury. That was a ****ty Optometrist visit. He came at me with a drill...
http://www.texasoffroad.net/albums/lonestar/axleswap/DSC03482.sized.jpg

This was checking out how the shackle mounts were going to work out.
http://www.texasoffroad.net/albums/lonestar/axleswap/DSC03490.sized.jpg

Here's a fine example of Paul's porn-star style of welding.
http://www.texasoffroad.net/albums/lonestar/axleswap/DSC03493.sized.jpg

And Blake's stick welding practice. He sat for who knows how long being worthless playing with these pieces of metal. :flipoff2:
http://www.texasoffroad.net/albums/lonestar/axleswap/DSC03503.sized.jpg

bburris
10-01-2003, 01:33 AM
Here's the passenger side all ready for the first fitment of the axle.
http://www.texasoffroad.net/albums/lonestar/axleswap/DSC03515.sized.jpg

The XJ leaves flattened out...more than I wanted, so it'll need an add-a-leaf to keep them from getting negative arch.
http://www.texasoffroad.net/albums/lonestar/axleswap/DSC03516.sized.jpg

TEXAS TILT BABY!!! I guess I'll be going with a little more lift in the front...
http://www.texasoffroad.net/albums/lonestar/axleswap/DSC03518.sized.jpg

bburris
10-01-2003, 01:34 AM
This is a 28 spline 8.8 shaft in the 31 spline side gear. There's a BIG difference. I'm glad mine is 31 spline...
http://www.texasoffroad.net/albums/lonestar/axleswap/DSC03528.sized.jpg

Cool pic of Paul welding.
http://www.texasoffroad.net/albums/lonestar/axleswap/DSC03533.sized.jpg

Here I am hard at work... :flipoff2:
http://www.texasoffroad.net/albums/lonestar/axleswap/DSC03536.sized.jpg

Putting some paint over all the new **** so it won't rust too fast.
http://www.texasoffroad.net/albums/lonestar/axleswap/DSC03538.sized.jpg

BigRedFord04
10-01-2003, 01:46 AM
i've got some 31 spine side gears you can use for spares for the low low price of 1 beer each :cheers:

bburris
10-01-2003, 01:58 AM
It should be getting a free (plus the cost of a rebuild kit) Trac-Lock...

So I, too, will have some 31 spline side gears.

BMFScout
10-01-2003, 10:31 AM
looks great, did you take one eyed willie to the optometrist? :flipoff2:

I have found out the hard way twice to wear GOGGLES not glasses when grinding underneath a vehicle. The optometrist dremel tool thing with the rotary eye drill attachment sucks...

robertf03
10-01-2003, 12:08 PM
brett are you going to flip the leaf spring around to move the center pin back?

bburris
10-01-2003, 02:31 PM
Originally posted by BMFScout
I have found out the hard way twice to wear GOGGLES not glasses when grinding underneath a vehicle. The optometrist dremel tool thing with the rotary eye drill attachment sucks...

I had glasses AND a full face mask on, so I figured I'd be ok. I wasn't. Luckily the doctor used about a bottle of those eye deadening drops so I didn't feel anything while he was drilling. Then I started realizing just how deep he went about 20 mins later while my mom and I (completely blind at this point) were eating lunch. I thought french fries and fried shrimp would be safe until I mistook three shrimp tails for a handful of fries...


Originally posted by robertf03
brett are you going to flip the leaf spring around to move the center pin back?

I'll do that eventually. I wanted near-stock wheelbase for now because to flip them would mean I would have to cut the rear fenders, which would result in the 33s looking even smaller than they do now... Damn I need some new tires.

bburris
10-05-2003, 11:56 PM
Here's how the rear suspension looks. We ended up using a stock YJ shackle to get the angle right.

http://www.texasoffroad.net/albums/lonestar/axleswap/Mvc_768s.sized.jpg

Here's the front with a 38.5" Gumbo Mudder next to it. The tire only measures out to about 35-36" tall, but this was for reference. The Jeep still has about 7-8" to go up since the front axle is at full coil droop.

http://www.texasoffroad.net/albums/lonestar/axleswap/Mvc_770s.sized.jpg

TXsizeK5
10-06-2003, 10:42 AM
Yeah, my friends 38.5x15 ground hawg is almost identical to my buddies 36x14.50 tsl rad.

What're your plans to level out the front? Coil Spacers? You should go 3/4 eliptical in the rear :eek:

bburris
10-06-2003, 03:48 PM
those coils will make it sit level with the rear after the rear gets an add-a-leaf

redcagepatrol
10-07-2003, 07:08 AM
amazing how fast you can do this, took Nutz how long to do his front???

Chadnutz
10-07-2003, 07:51 AM
I'm not working on school days and I don't have enough money to get it on the trail until Christmas break anyway so why rush?

I have the most demanding semester so far right now. I spend at least 3 nights per week in open access labs. I have a boss that doesn't think twice about working me until 4am on a school night and I am busy from 6am-9pm almost M-Th.

Why do you even care?

eight
10-07-2003, 07:54 AM
I think everyone just likes to give you **** for entertainment.

redcagepatrol
10-07-2003, 08:03 AM
Originally posted by eight
I think everyone just likes to give you **** for entertainment.
Yeah, we really don't care but it's too easy to pick on you:D
we'll still buy you a beer for the effort:cheers:

Chadnutz
10-07-2003, 08:03 AM
I'm pretty sure of that. :flipoff2:

bburris
10-19-2003, 11:50 PM
Here's how the t-case came out. The 1350 flange looks really good up there. :D
http://www.texasoffroad.net/albums/lonestar/axleswap/DSC03584.sized.jpg

I got my package from High Angle a couple of days ago. :cheers:
http://www.texasoffroad.net/albums/lonestar/axleswap/DSC03588.sized.jpg

Here's a comparison of the stock shaft to Jess' 1350 CV shaft.
http://www.texasoffroad.net/albums/lonestar/axleswap/DSC03589.sized.jpg

Here's the shaft. I'm honestly not all that impressed by it. It's heavy, the packaging was OUTSTANDING, but it's just not all that impressive. It's just a driveshaft, and I honestly think most any local, reputable shop could build almost the same damned thing.
http://www.texasoffroad.net/albums/lonestar/axleswap/DSC03587.sized.jpg

Here's the beast bolted up and ready to propel my junk.
http://www.texasoffroad.net/albums/lonestar/axleswap/DSC03600.sized.jpg

bburris
10-19-2003, 11:52 PM
Here's the axle, ready to roll under the Jeep for it's final test fitting.
http://www.texasoffroad.net/albums/lonestar/axleswap/DSC03591.sized.jpg

axle going in
http://www.texasoffroad.net/albums/lonestar/axleswap/DSC03594.sized.jpg

Here's the pinion angle...
http://www.texasoffroad.net/albums/lonestar/axleswap/DSC03595.sized.jpg

bburris
10-19-2003, 11:54 PM
and here's the current ride height...little taller than we expected/wanted...
http://www.texasoffroad.net/albums/lonestar/axleswap/DSC03603.sized.jpg

and this is my reaction to the fact that it sits around 11" taller than a stock TJ... FAWK!
http://www.texasoffroad.net/albums/lonestar/axleswap/DSC03602.sized.jpg
(chop fodder)

bburris
10-24-2003, 02:57 AM
After thinking about things, I decided that the DOM I got was better suited for some homemade links, and I'll go ahead and use normal TREs for my steering.

Here's what we accomplished tonight before I got ****ty drunk...
http://www.texasoffroad.net/albums/lonestar/axleswap/LCA1.sized.jpg

http://www.texasoffroad.net/albums/lonestar/axleswap/LCA2.sized.jpg

http://www.texasoffroad.net/albums/lonestar/axleswap/LCA4.sized.jpg

http://www.texasoffroad.net/albums/lonestar/axleswap/LCA5.sized.jpg

bburris
10-31-2003, 02:29 AM
These are the lower link frame brackets. They're mostly 1/4" strap stock.
http://www.texasoffroad.net/albums/lonestar/axleswap/MVC_044S.sized.jpg

http://www.texasoffroad.net/albums/lonestar/axleswap/MVC_063S.sized.jpg

http://www.texasoffroad.net/albums/lonestar/axleswap/MVC_089S.sized.jpg

http://www.texasoffroad.net/albums/lonestar/axleswap/MVC_092S.sized.jpg

bburris
10-31-2003, 02:31 AM
I decided that I'd most likely bend the lowers (eventually) the way we had them made...so I sleeved them with 1.5" ID sch 40 pipe. They seem sufficient now. You can see the finished control arms in those last two pics.

Here's the axle end with a polyurethane bushing in it.
http://www.texasoffroad.net/albums/lonestar/axleswap/MVC_084S.sized.jpg

Here's the pass. side lower in place and welded up.
http://www.texasoffroad.net/albums/lonestar/axleswap/MVC_093S.sized.jpg

bburris
10-31-2003, 02:32 AM
Here's a random pic of the rear axle that Blake took...poor driveshaft wants to be hooked up...
http://www.texasoffroad.net/albums/lonestar/axleswap/MVC_085S.sized.jpg

I got a spare D30 shaft and Madzooki tacked the caps in...these things are going to be fun to break... :laughing:
http://www.texasoffroad.net/albums/lonestar/axleswap/MVC_079S.sized.jpg

bburris
10-31-2003, 02:35 AM
Here's my cleaned up D30 short side spare shaft next to Blake's D60 short side shaft... Just thought ya'll might enjoy a comparison pic.

Cody_91YJ
11-04-2003, 12:43 AM
lookin good

bburris
11-05-2003, 02:44 AM
Thanks Cody!


We got it on four tires tonight. We have to do something about upper spring plates and we need to bleed the brakes.

Here's how the lower arm with the upper mounted to it turned out.
http://www.texasoffroad.net/albums/lonestar/axleswap/Mvc_122s.sized.jpg

Damn it's been a while since it sat down...I'm friggin' happy :cheers:
http://www.texasoffroad.net/albums/lonestar/axleswap/Mvc_121s.sized.jpg

http://www.texasoffroad.net/albums/lonestar/axleswap/Mvc_120s.sized.jpg

http://www.texasoffroad.net/albums/lonestar/axleswap/Mvc_119s.sized.jpg

AgDieseler
11-05-2003, 11:00 AM
attaboy

TXsizeK5
11-05-2003, 11:49 AM
Looks nice!

Now you just need some 35's :cheers:

Violentv8toy
11-05-2003, 02:05 PM
I say 37s...lookin good. Those front rear spring mounts look exactly like mine.

:cheers:

bburris
11-05-2003, 05:46 PM
I'm getting some 36" TSL/SXs from a guy on the LoneStar board.:cheers: :D

bburris
11-07-2003, 01:25 AM
guess who drove their Jeep tonight...?:flipoff2:

WHOOOOO HOO!

TXsizeK5
11-07-2003, 01:31 AM
Awesome... how does it drive? I see a beach run on the 15th, eh?

bburris
11-07-2003, 03:24 AM
Haha...I already exploded Jess's Spicer long life 1330 u-joint on the 8.8 :D

No, I don't know what happened, but the burnouts and "axle wrap testing" I was doing may have had something to do with it.

It drives...ok. There are shakes and wobbles that I haven't figured out yet, but I still need to do a lot of adjusting. The control arms need a little fine tuning, and the steering REALLY needs some help. I had to take the stabilizer off for the TJ steering to fit on the XJ axle...:rolleyes:

I'm waiting on a track bar, then it may be a little better...the front axle is cocked an inch or two to the driver's side, but it all hooked up, so I was stupid and went ahead and drove it.

AgDieseler
11-07-2003, 11:29 AM
details details. why worry? WFO, right?

eight
11-07-2003, 11:35 AM
My guess.

Pinion's allready pointed up for the CV shaft, soft springs wrap, pinion gets too high, joint binds, something bad happens.

TXsizeK5
11-07-2003, 11:42 AM
Are you using the 57" ford springs?

bburris
11-07-2003, 02:22 PM
Yes, David...WFO. I swapped the u-joint out in Circle K parking lot and kept on going. It spit another cap out on the way home so I salvaged one off the busted joint and babied it home. I just got up, so now I need to go get another collection of 1330 joints for the weekend.


Originally posted by eight
My guess.

Pinion's allready pointed up for the CV shaft, soft springs wrap, pinion gets too high, joint binds, something bad happens.

Good guess, but we've already checked it for all those problems. The pinion was pointed at the t-case, then 5* down. The springs relly don't wrap at all, it's really wierd. If I drop the clutch or power brake it the whole Jeep jumps up a few inches front and rear, then bounces up and down a few times and rolls forward. I had everyone at the meeting watching the pinion angle and then had a friend do the same thing I was doing and the pinion never points up past where it should. I know I still need a traction bar for when the leaves break in, but this doesn't seem to be the current problem.

Derek - No, they're kustom packs. It's an XJ main leaf and second leaf with two chevy leaves under that (one has the little spring keeper on the front) and the bottom leaf is the bottom XJ leaf. It ended up close to the right height and it should break in well. These probably won't last long since the three of us collectively have 4 sets of YJ springs, two sets of Waggy springs, another set of XJ leaves, some oddballl j-yard leaves to take apart and a whole bunch of useless Samurai leaves. I'm pretty sure we can figure out a good combination someday.:D

BigRedFord04
11-07-2003, 03:24 PM
i've got two sets of rear ford leaves. one is a `78 and one is a `95. if you want 'em for any reason, if for nothing else than to add to the collection, they're CHEAP.

bburris
11-07-2003, 10:29 PM
Are they 2.5" wide? That's mostley what we've been 'collecting'.

BigRedFord04
11-08-2003, 03:29 PM
i dont know about kate's but mine are 3" wide

bburris
11-08-2003, 04:12 PM
I'm pretty sure hers are too. I think the preferred F150 leaves are the 2WD ones.

Shaggy
11-09-2003, 02:15 AM
there is also another set laying close to austin's and kate's off my 80 bronco... they are the same as the 95 but have an add-a-leaf

stx4wheeler
11-09-2003, 02:26 AM
i think i might have some 2.5 inch rear springs off of my 78 ford parts truck in Mcallen, if my dad hasnt taken the truck to the bone yard, but i wouldn't be able to take them off till thanksgiving

bburris
11-09-2003, 02:38 AM
I don't think we need any more. Paul's wife already complains about the various "useless" **** that's laying around the shop. Thanks for all the offers though... :cheers:

bburris
11-17-2003, 04:21 AM
I figured I'd update with recent pics. We used Paul's engine hoist to "ramp" it a few days ago while the 33s were still on. I picked up a set of 36" SXs this weekend, so this is my Jeep's last night with 33s. I guess I'm going to see how long the D30 will hold up...
http://www.texasoffroad.net/albums/lonestar/Dana30HP/MVC_125S.sized.jpg

http://www.texasoffroad.net/albums/lonestar/Dana30HP/MVC_126S.sized.jpg

http://www.texasoffroad.net/albums/lonestar/Dana30HP/MVC_129S.sized.jpg

http://www.texasoffroad.net/albums/lonestar/Dana30HP/MVC_128S.sized.jpg

Chadnutz
11-17-2003, 07:45 AM
A forklift is much easier. :flipoff2:

TXsizeK5
11-17-2003, 12:25 PM
Yup, cause we all have one of those laying around. :flipoff2:



Brett, did you get 36x12.50? Where from, how much?