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Discussion Starter #1
We are starting on this build this week, it's a nice clean TJ with only 48k on it. It's getting our 5.5" Long Arm Suspension Lift Kit, Bilstein shocks, SYE kit and a Tom Woods drive shaft. We will be using the factory transfercase skid plate for now. Here are a few pictures as we progress through the install of our parts:







Tom Woods/ AA SYE kit:





We use these brackets to determine where we need to weld our new control arm brackets:



Getting the frame all cleared out:



Using the location plates:



Getting the new control arm brackets in place:





Alex
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Clayton Off Road
 

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Discussion Starter #2
New control arm brackets tacked into place:



Fully welded:







Cutting off some of the old control arm brackets with the plasma:



Cut through the welds along the top edge with a cutoff wheel:



Use a hammer to take the pieces off:





Then clean it up a little and the rear control arm brackets are totally off:



Add some paint to prevent the East Coast death rust:



Alex
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Clayton Off Road
 

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Discussion Starter #4
Factory axles, 35s for now.

Starting to work on the rear axle bracketry:



Getting it ready for the truss:



Tacked in:



Fully welded in place:



Axle painted, and lower arms bolted in:



Nothing the factory skid plate:



Tight fit next to the LCA brackets:







Getting ready set the pinion angle, 2 degrees down:



Alex
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Clayton Off Road
 

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Discussion Starter #5
To set the pinion angle, we use a bottle jack to make sure we get the pinion exactly where we want it:



Centering the rear axle over the body, we use ratchet straps and pull the body where we want it:



Once the pinion angle and track are set we put the upper arms in. Adjust the upper arms to the exact length so the bolts go in easily:



Rear arms in:



Starting on the front end:







Cleaning up the old trackbar mount and adding our bracket to make it a double shear bracket:



New double shear track bar mount up front:



Trackbar bracket ready for paint:



Alex
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Clayton Off Road
 

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Discussion Starter #6
New front end parts (JKS disconnects, new pitman arm, trackbar and bracket, springs, and control arms) installed:



Clayton Off Road springs and Bilstein shocks installed:



Front radius arms, springs, and shocks installed:



Front and rear suspension complete:



Starting on the exhaust. Cut flange off the cat about a half inch in front of the necked down portion:



Grind off the weld off and knock old pipe out of the flange:



Clean up the ID of the flange:



Cut flange off the muffler right at the end of the muffler pipe:



Clean up the ID of the flange so it goes over the new muffler with a little play:



Alex
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Clayton Off Road
 

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Looking good. Do you have to run the nuts on the inside on the rear uppers? Looks like it would be a hassle getting a t-wrench on them without using a crow foot. I always prefer torqueing on the nut not the bolt. Will the bolts even go through the other way on your truss setup?
 

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Discussion Starter #8
Weld bolt into the flange on the cat facing the muffler:





Cut about an inch off the inlet to the muffler:



Put the flange on to the cat. it's a tight fit so you may need to use a hammer. Try and angle it towards the center of the Jeep. Then install the muffler:



Make sure the muffler is centered between the upper control arm and the transfer case. I like to use a level to get it level with the frame rail:





Tack weld both flanges in place when the muffler is located where you want it:





Unbolt the muffler and weld around the inside of the cat flange:



Outside as well:



Alex
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Discussion Starter #9
Once it is welded up you can bolt it back on:



AA SYE and Tom Woods shaft are installed along with the new muffler:



Cut the tip of tail pipe off the old exhaust where it is a full diameter after the bend. Clean up the end and it needs to be hammered a little to get it round:



Slide the tail pipe in to the muffle and angle it slightly to the outside of the Jeep. Put a couple tack welds on if you are going to have a custom tail pipe bent up to exit in the stock location:









Alex
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Clayton Off Road
 

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Any concerns with the muffler sharing heat with the tcase? I know when I did my JK I put a heat wrap on the evap just to be on the safe side.
 

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Discussion Starter #11
With this one we aren't too worried about it, we have had mufflers this close before.

We finished up our part of the build today and got the TJ ready for it's owner:



Next up is this TJ:



Alex
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Clayton Off Road
 

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Discussion Starter #13
The white one will have a build thread when we get some more photos of it. Yes the black one needs some more parts, the owner can handle all of that when he feels it is necessary!

Alex
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Clayton Off Road
 
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