Ted's Trick'd out XJ build

[Hilla-GO-Rilla]

I stopped by Ted's garage yesterday and I'm exposing his Top Secret build!
He sold his super jeep and is building up an XJ...He's got some HD axles to go under it, 36" IROCKS, and just finished up some tricked-out Uni-body Stiffeners.

Here is the build up link...
http://www.tedsoffroad.com/teds-xj.htm

Ted update your build page :!:

[TedsOffroad]

Well, thanky there Chris. I am throwing something together to get back on the trails. NOW,, someone buy this 460 ford so I can fund more parts!!!
Here is the ole mail XJ I started with.

http://img409.imageshack.us/img409/6905/31025339tw7.jpg (http://imageshack.us)
Shot with [URL=http://profile.imageshack.us/camerabuy.php?model=PENTAX+Optio+60.&make=PENTAX+Corporation.]

[TedsOffroad]

Allright, I added more pics to my build. iI will put a few pics on here. But I am putting the majority of them on my site. Instead of reposting on here also. But if you have any comments put em here.

[Jeepguy16]

Looks Great
Did you make your own spring perches and Ubolt plates?

[TedsOffroad]

Yeah I did. I can get them made,, If there is enough interest in them. I can get a price.

Here are the Anti wrap spring perches, U bolt plates, and link mounts that I designed and had laser burnt.

http://img181.imageshack.us/img181/473/41405460am6.jpg (http://imageshack.us)

[Gordon]

Ted, that is lookin' great! Fine job and a good plan.

[Jeepguy16]

so the perches add 1 1/2" of lift?

[Gordon]

so the perches add 1 1/2" of lift?

The perches stand taller than stock ones (you can see the gap in the pics), which usually are right at the axle, as well as being longer, front to back, to reduce axle wrap.

[TedsOffroad]

Yeah thats what I figured it would take to make the jeep level. I can design them any height. But I don't think going over 2" would be good. These are also .250" thick. So they will take the abuse.

[Hilla-GO-Rilla]

This is what I'd like done to my XJ...now you've done your prototype!
:thumbright:
http://www.tedsoffroad.com/images/PROJECTS/tedsxj/11.jpg

Get me a quote!

Man!! I've got the fever again!!!! I was doing so good till I saw that white XJ and flashed back to the HillaMobile. I'm starting again on a very very very slow build of my RED XJ...keeping an eye on copy catting on your build.

[Hadfield4WD]

I did 3x3 angle for the reiforceing and welded it up.

http://i85.photobucket.com/albums/k51/hadfield4wd/jeepstuff002.jpg

Also your spring perches attached to your radius arms will flex and being hard welded to the axle tube will cause them to twist. If you are going to weld them to the tubes go all the way over the arm and attach to the other side or flip the ford buckets so they are biased to the middle and let the coils come in on an angle. That's what I did and no problems at all (so far). A coil spring can stand some deflection.

[Jeep07]

I did 3x3 angle for the reiforceing and welded it up.

http://i85.photobucket.com/albums/k51/hadfield4wd/jeepstuff002.jpg

Also your spring perches attached to your radius arms will flex and being hard welded to the axle tube will cause them to twist. If you are going to weld them to the tubes go all the way over the arm and attach to the other side or flip the ford buckets so they are biased to the middle and let the coils come in on an angle. That's what I did and no problems at all (so far). A coil spring can stand some deflection.

Have you wheeled your XJ with the reinforcecment yet or are you still building it?

[Hadfield4WD]

Have you wheeled your XJ with the reinforcecment yet or are you still building it?

Yes and Yes.

Is a 4x4 project ever done.

I still have to modify the skids and put them back on. Build new rockers. Install new radiator. Cut and turn knuckles for proper caster. Rebuild steering box and drill for hydro assist and install the hydro assist. Build traction bar and bracket. Fix exhaust.

Going wheeling memorial day and I'm out of town 3 nights in the next week and a half. I'll build what I can then run what I brung.

[TedsOffroad]

I will probably just flip the spring bucket and leave it at that. A buddy of mine said he tried the same thing I was going for and it worked but would eventually break loose. The 3" angle will work for the braces. I just had access to our CNC press brake at work and thought I'd make some thick ones that matched the frame.

[Hadfield4WD]

I just had access to our CNC press brake at work and thought I'd make some thick ones that matched the frame.

Must be nice. All I have is a 4" angle grinder and a drill press. :grin: I like the braces.

[TedsOffroad]

Thanks for the heads up on the front spring idea. I just flipped the buckets and let the springs be on an angle. I had allready moved the front forward about an inch, so the aren't the straightest in the world. But for what I'm going to use it for it won't matter.

I am going to get a quote on 2 foot sections of the frame braces. These can be cut to fit. If enough interest is shown. These would be laser cut and formed, with the holes allready in them.

http://img181.imageshack.us/img181/954/34xj7.jpg (http://imageshack.us)

[Hadfield4WD]

Here are my radius arms. This is one of the many mockups. This is without final paint and before I cut the old mounts off. Here is also the new crossmember. I pushed everything up so my belly is at 24" however the mounts hang down a couple inches. I may make changes to that.

http://i85.photobucket.com/albums/k51/hadfield4wd/FrontaxleSteering006.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/FrontaxleSteering007.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/radiusarm1.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/radiusarm2.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/radiusarm3.jpg

1.75 solid stock drilled and tapped for 2.5" JJ

[TedsOffroad]

Here is my page on my site. This is what I have completed so far.
http://www.tedsoffroad.com/teds-xj.htm

This is how I my radius arms turned out.

I slotted the Link "1.5"x .250" D.O.M."and welded it to the radius arm
http://img443.imageshack.us/img443/3720/28gd4.jpg (http://imageshack.us)

Then I boxed It in.
http://img224.imageshack.us/img224/3384/29oj6.jpg (http://imageshack.us)

[SamuraiGuyTN]

Looking good.

But I do have a question about the Trac bar. Isn't the angle on it to much. I was always under the impression they had to be at an almost nuetral point to work properly. Other wise your axle moves laterally during suspension travel. For example... driving over a speed bump, the axle would move to the right as the axle went up. possibly causing some binding in the steering.


I guess What I would do would be to lengthen the upper mount and lower mount. may have to shorten the bar so nothing hits the frame. ANd it should be shorter over all from being at a neutral point.

[Gordon]

Dang, that's sweet. Gotta stop by and check it out.

[TedsOffroad]

The idea for a track bar and drag link is to be perfectly horizontal. That will give you the best ride and suspension travel. My highsteer on the one ton YJ was almost flat. I haven't seen a cherokee with over 5 inches of lift with a track bar and drag link that was level. I have seen alot of them on more of an angle than mine. It's not the best but for what I am going to do with it it won't matter.

[Hadfield4WD]

HOrizontal is best but clearances affect the position alot. The key is to get the Drag link and trac bar parallel the will eliminate the bumpsteer.

Here is mine on mock up

http://i85.photobucket.com/albums/k51/hadfield4wd/FrontaxleSteering002.jpg

Here it is complete. And just so you know it's sitting with the tires turned the axle is centered. As you can see the trac bar is hidden my the drag link and parallel.

http://i85.photobucket.com/albums/k51/hadfield4wd/finalassembly011.jpg

Ted looks like we'll have twins.

[SamuraiGuyTN]

ok cool. I just remember that I tried something like that on my samurai for stability on the road. It was also at around the same angle, when I Drove up on an RTI ramp right after, it ripped off.

[Hadfield4WD]

What are you using for front springs? I have RK 4.5" in the front nets about 4 after 2 years of hard wheeling on them plus 2.5 mounting the spring on the radius arm make about 5.6 - 6.5. The rear I had bad axle wrap in my RK spring so I have a custom pack from and S10 and some of the leaves from the 4.5 RK pack. I actually have a lot of wieght int he back so they agged a little. I'll be adding 1.5" blocks when the traction bar is made and I have 2.5 shackels. Should end up level. Flexes real good. I used only the long leaves and Deaver spring liner in between the leaves as well.

[TedsOffroad]

Yeah so far they do look like twins.. I'm doing a quick build to get something together to get back on the trails with and abuse the crap out of. So I am not taking as much time with it as i did the Silver YJ. If the Samurai is running leaves in the front that may be why the track bar ripped off. The coil spring setup will travel in a radius with the track bar as the suspension flexs. The leaves are trying to flex straight up and down. They will twist some because of the give in the shackels and bushings. This would actually be pushing and pulling on the track bar the more the leaves flex. Depending on how much twist you had before adding the track bar. It may have put to much stress on it and ripped it off. Don't know if that made much sense or not.
Here is my front track bar set up

http://img365.imageshack.us/img365/1332/48ng0.jpg (http://imageshack.us)

[TedsOffroad]

A few more pics up on my site of my build. Check it out.
http://www.tedsoffroad.com/teds-xj.htm

[Dino1967]

looks great ted

[SamuraiGuyTN]

Thats the coolest looking upper shock mount I have seen in a while. Yeah i have leaves.

[BroncoMike]

Nice work Ted!

I like the radius arms! Keep us (or me) informed how well they do!!

[TedsOffroad]

Wheew almost have it ready to drive. I would have got to move it this weekend. But my drop pitman arm and inner seals for my 44 didn't come in. We all know how ordering parts goes. I still have to finnish the cage and throw a little green on it. but that wont take long. I'm thinking mid june it should be ready for a run or two. Depends on what breaks on the first run. I have a couple new pics up on my site of the bumpers and fenders trimmed.

[TedsOffroad]

Got my cage in, seats in and sprayed some linner in the floor. I took it out on a test run up a local spot to see if everything was working properly. Everything went pretty good, except for the old calipers locking up. That was no big deal. I went to the parts store and got new ones. All thats left to do is fill in the rear inner wheel wells where i trimmed it and then shoot some green on it. http://www.tedsoffroad.com/teds-xj.htm


Cage Completed
http://img401.imageshack.us/img401/4568/51te2.jpg (http://imageshack.us)

[TiredIronGRB]

Very, very nice...the radius arms are sweet :wink:

[TNjeeper97]

That thing is looking good (and capable, too). Can't wait to see more!

[Gordon]

Way :smokin: , Ted. Time for a quick ride up Bumpus, eh?

[Hilla-GO-Rilla]

:confused3:

Your Torturing Me!

I'm coming over to look at it tonight....

[TedsOffroad]

come on down Chris. It's almost ready for a test run up bumpass. I have a few little things to do. May get them done this weekend. But a few buds are talking about going to Harlan. I may go and be a passenger for that trip. Then get it ready

[TedsOffroad]

I got some paint shot on my XJ. It was suppose to be OD green but they mixed it wrong and I didn't know till I had it taped up and ready. So I shot it with what they mixed. I may see if the paint store will mix me some more. Or I may just leave it alone. I took it to stoney creek with some buds the day after I painted it and tried all the hard spots. So far its doing pretty good. I did break down and buy a trailor so now I don't have to worry about driving back home after a day of bashing. I have a painted pic on the project page, and some pics on the trail pics page. Hopefully I'll have a little video up also in a day or two.

[TedsOffroad]

I finally have this thing ready for a few more runs. I had to put a motor in it. The block had a crack near the rear seal. I have more pics on my projects page and trail rides page. www.tedsoffroad.com

Before
http://img409.imageshack.us/img409/6905/31025339tw7.jpg (http://imageshack.us)
Shot with

After
[URL=http://imageshack.us]http://img262.imageshack.us/img262/2710/65vw0.jpg (http://profile.imageshack.us/camerabuy.php?model=PENTAX+Optio+60.&make=PENTAX+Corporation.)
Shot with

Testing
[URL=http://imageshack.us]http://img409.imageshack.us/img409/8125/42wj1.jpg (http://profile.imageshack.us/camerabuy.php?model=PENTAX+Optio+60.&make=PENTAX+Corporation.)
Shot with [URL=http://profile.imageshack.us/camerabuy.php?model=PENTAX+Optio+60.&make=PENTAX+Corporation.]

[redplastic2p3t]

Man that sucks about the motor..on a side note. Im thinking about going to back to tellico july 6th, you and Kelly should come on up with the rest of us...Im not sure on who is gonna be there though (probably just me and patrick so far)

[TedsOffroad]

A Tellico trip sounds fun. How long are you thinking of staying down there?? Since I got my trailer I may be able to do it. I have to get a brake box on the truck first.

[redplastic2p3t]

till the 8th.. i think..

[TedsOffroad]

Sounds good, that will test this ole ride out. I don't know if I can stay till the 8th but if I have to I will head back early. The motor I put in it only holds about 20 lbs . I'm going to change the sending unit and see if it may be bad. But other than that I guess it's ready.

[Gordon]

Glad you got the motor swapped out, Ted. Was busy all this week so never got down there. May have a dirty oil pickup screen in the pan, if the pressure switch doesn't do it. Any knocks or clatters? Does the pressure increase with RPM?

[TedsOffroad]

It's okay that you didn't get to make it down. The swap went easier than I thought. I was going to put a new oil pump in it before I put it in, but thought I'd just see how it would run. The oil pressure on my old motor held 40 lbs all day. But like you said the screen could be blocked a little. The pressure will gain with RPM's but not like I would like it to. It "lopes" a little bit until it warms up. Thats probably from blocking off the EGR tube. The tube on my intake had a tear on the seam. So i just blocked it to see if it would run. It does good enough right now to hit the trails. So I'm not to worried.

[Gordon]

Mine does that same loping at first start and for a minute or so. I just don't worry about it. Has never caused any problems. I run at about 60# to 70# at full gallop and mid range at idle, but I run 15W40 with a qt of Lucas stabilizer. IIRC mine's got about 80K on the motor.

[TedsOffroad]

Took the ole XJ to Tellico over the weekend. Went up slick rock and school bus, came down the helicopter pad short cut and Guard rail. Everything done great, the track bar bracket tried to work loose. I am going to beef that up a little. The only other thing I have to do is add some limiting straps to the front and it'll be ready to bash some more.

http://img187.imageshack.us/img187/7628/46ci2.jpg (http://imageshack.us)

http://img187.imageshack.us/img187/4048/48ou7.jpg (http://imageshack.us)

http://img373.imageshack.us/img373/5357/49nq1.jpg (http://imageshack.us)

[TiredIronGRB]

That sure made a nice rig.

[Gordon]

Man, that's sweet!

[Hadfield4WD]

Looks good. I love Tellico.

[TedsOffroad]

Well I took the xj out for some more test runs, I made a couple make shift straps "out of chain" before I ordered the Nylon ones. But the chain seamed to work, and didn't make much noise so I may just leave it. Here are a couple more pics. Other than a winch and maybe some tube doors later on I'm calling this build finnished.

http://img524.imageshack.us/img524/8795/picture097qe7.jpg (http://imageshack.us)

http://img524.imageshack.us/img524/8271/picture107tb3.jpg (http://imageshack.us)

[Want2Wheel]

I like the last picture.

[Dino1967]

very nice ted
been meaning to come out myself but always stuff coming up
ill give ya a call when i do get time to come out

[TedsOffroad]

Well after about 7 months of hard wheeling everything is working great.
The body has just a few more dents in it than before. The cross member drags some, so I am building a flat belly pan for it. And the main problem I have had are the stock 44 front axles shafts don't like the rocks I have been hitting. So after having no luck with the stock ones I am going to get some Alloy USA Chrome-Moly shafts. I don't know any one running them, but their warranty is the best I have found. 10yrs no questions asked. You break it they give you a new one. I found a place on line that has them complete for $475.

http://img64.imageshack.us/img64/4195/66pc5.jpg (http://imageshack.us)

http://img64.imageshack.us/img64/4644/67aq0.jpg (http://imageshack.us)

http://img64.imageshack.us/img64/6641/68pj1.jpg (http://imageshack.us)
I am going to add a trans guard and angle the T'case guard more.

http://img112.imageshack.us/img112/7456/69ow7.jpg (http://imageshack.us)

[TiredIronGRB]

That looks marketable 8)

[Hadfield4WD]

I have been beating on Alloy Usa Shafts all year. No problems. I have the Yukon Super Joints in them. They come with stock spicer that just won't cut it for me. I like the flat belly. I did mine similar, and my brackets hang down like yours. I would change mine to be flush with the brackets so I have a flat belly with nothing to hang up. I would give up clearance for this. That would be the only thing I would change on mine.

[Bluegill]

Very sharp, Ted! :smokin:

[TedsOffroad]

I built a transmission guard that bolts to the crossmember. I haven't had any problems with the link mounts hanging up on anything. I designed them on a angle to help slideover rocks. The brackets and links have plenty of rock rash on them and are holding up great. Al I have to d now is do some exhaust work and wait on the axles to get here.

http://img208.imageshack.us/img208/1116/70rr1.jpg (http://imageshack.us)

[Hadfield4WD]

Like that trans guard.

[TedsOffroad]

Mounted the high lift. It should be out of the way. I welded 1/2 inch bolts to the cage, made some wing nuts, and got one of those isolators to keep the handle from shaking around.

http://img134.imageshack.us/img134/5653/dsc01797ui0.jpg (http://imageshack.us)

[sparkn89]

sweet xj

[96 coutry cherokee]

Even thow you said you didnt like the color.I do it makes kinda a military aspect and when ppl think that its kinda means that they are able to go where ever they want :) looks great!!! maybe mine will grow up to be like yours :kewl: