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Jefe's SAS

Everyone else has a SAS thread in here, so I figured that instead of being jealous, I'd just start my own :)

I've been planning this for a few months now, and the parts are now starting to collect.

The plan is to buy a TJ D30 front axle to use for sizing and testing purposes, and replace it with a custom HP D44 with a bunch of goodies as the project nears completion.

I will be using Rubicon Express TJ long arms. These are 36" long, and convert the TJ 4 link to a radius arm design. 36" back from the front axle lands the rear mounts right where the torsion bar currently mounts, and the TJ and Ex frame are the same width at that location, so it should make for a great bracket location.

I plan to run 2" remote res. coilovers. I won't decide how much travel they need until I've got the axle temp'd under and see amount of flex, ride height, etc. No point in shoving a 14" travel C/O WAY up into the engine bay if its not going to do me any more good than a 10" or a 12".

I will convert the steering pump and gearbox over to a 1st gen explorer setup. I am hoping that the TJ track bar and steering will work, but will have that custom made if it doesn't.

I'm hoping for about 6" of lift, but may have to settle for more depending on a few things. I'll do a SOA conversion in the rear, along with custom leaves to match front ride height. I will be taking out the 3" BL as one of the first steps.

I plan to start actual work on the project about halfway into April.
 



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Will it make it out off the garage without taking the door with it?
 



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Originally posted by boominXplorer
Will it make it out off the garage without taking the door with it?
If not, my brother will have not 1, but 2 4x4's stuck in his garage (he just put a new lift on his Jeep and its too tall) :D

I'll just have to take the tires down to 3 or 5 lbs and it'll make it out no problem.
 






Build Day 16

Finished welding the crossbrace and got it in, and then checked out the suspension with everything attached:

Drivers side droop:
9-26_2.jpg


This should be droop both sides. Found that my steering is going to bind. Looks like I'll be adding some custom steering links when I get the D44 in. Or I could just go with a drop pitman arm, but then my track bar would need to be lowered also and its already 4" below the frame.
9-26_3.jpg


Pass. side droop: steering binding
9-26_4.jpg


Stuffed both sides:
9-26_5.jpg


droop both sides (without steering):
9-26_7.jpg


Then I welded on the hoops. . . And now its sitting on its own. :bounce: :bounce: :bounce:

9-26_8.jpg


Looks like my guesstimate at spring rates (250/350) was dead on. Its sitting perfectly level.
9-26_9.jpg


Who's taller? Jeep w/ 5.5" lift or Ex with 7" SAS?
9-26_10.jpg


fender well view:
9-26_11.jpg


Left to do:
nitrogen charge shocks
mount shock reservoirs
track bar bracket
plumb brake lines
 






Looking good jefe.

If you lower your steering with a drop pitman you don't have to drop the track bar at the frame, you could raise it at the axle.
 






Jefe, where did you mount the trac bar on the axle? I had mine bolted to the old steering stablizer bracket that is connected to the PS coil seat and it broke right off at Tellico.
 






I don't even know where it went stock. That's why i was asking.
 






Originally posted by JoshC
Jefe, where did you mount the trac bar on the axle? I had mine bolted to the old steering stablizer bracket that is connected to the PS coil seat and it broke right off at Tellico.
Track bar is in the stock location, a couple inches below the steering stabilizer bracket.
 






Looking good Jefe!

One thing your Brother can do to get his J%p out of the garage is take the roof and roll cage out, you have to cut your roof off or remove the garage door for clearance. I say you need to modify the garage to suit the 4X4. Priorities.

The J%$p seems to be taller in the pictures.
 






Excellent:D you guys are quick!
 






Got the brakes plumbed. It looked really nice and clean until I found my least favorite tool; double flare/bubble flare tool :shoot:

9-28_1.jpg
 






HA!! My J**p emerged from it's cocoon last night. Made it under the garage door with less than an inch to spare (Which means I need to wait for the suspension and coils to settle in before I can consider getting the 35's?) Also means I need to look at a removable light bar, I guess.

Jefe's probably only a day or two behind me . . . .can't wait to see it in action!
 






When I put the new lift and 35's on my truck the roof rack scrapes the garage door, but somehow makes it under. Another 1/4 inch and it would not have fit.

Looks good, want to see it in action also.
 


















Good Lord that was fast :eek:

You going to show us some pictures of your control arm mounts?
 






Originally posted by JoshC
Good Lord that was fast :eek:

You going to show us some pictures of your control arm mounts?
Well, lets see, at least 4 hours every week night for the past 3 weeks + 12 hours every saturday = at least 100 hours labor.

Control arm mount pics were posted here a long time ago.
 






Nice.

When is the maiden voyage to Rowher? Is the front locked now or are you waiting for the D44?
 






Originally posted by jobunn
Nice.

When is the maiden voyage to Rowher? Is the front locked now or are you waiting for the D44?
Not even bothering with the D30. I'll be 2wd until my D44 gets in. But that won't stop me from doing Rowher in the next week or so :D
 






Originally posted by Jefe
...Control arm mount pics were posted here a long time ago.

Huh, funny you must have deleted that picture cause it's not in the thread.
 



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Originally posted by JoshC
Huh, funny you must have deleted that picture cause it's not in the thread.
Sure it is. But just for you:
5-31_4.jpg

They have obviously been finished now. . I'll see about getting a current pic up later.
 






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