Front End Extension (dail up beware)

[Itsmejoe231]

I tried to resize all the pics so it would not be so lond to d/l for dail-up.
There are more pics in my gallery.

I had a bolt on kit for my front suspension and really didnt like all the brackets that went with it so I wanted to get rid of all that and at the same time extend the front like I did the rear a while back. This is a never ending project. If you do one thing you have to do something else to make the whole project work. I used 2x4x3/16 box tubing and butt welded it to the frame rails, plated the outside all the way around, and attached the spring hangers to the new frame rail. I reused my bumper with some mods.

While extending the wheelbase the steering would not work well moving it that far so the steering box had to be moved. So I had to drill new holes, install sleeves and weld it up. This included having to extend the steering shaft. I had a spare steering shaft so that was not to bad.

Now that it was all together, the drive line was too short. So here is a link to what I did to remedy that.
http://www.zukikrawlers.com/showthread.php?t=167

Now the shocks will not work so I had to cut off the ones I had and move them forward.

When I got all that together I went on a test drive through the big ditch in front of the house and the wheels rubbed the finders so it was time for the sawzall. I didnt want a chop job so I trimmed what I could get away with and maybe use bumpstops if I need to. I plated the fenders in. this is like welding on a beer can. I had my machine on the lowest setting with the feed rate to its lowest setting too.

Here are some pictures:
http://www.zukikrawlers.com/albums/album11/DSC01248.jpg
http://www.zukikrawlers.com/albums/album11/DSC01249.jpg

http://www.zukikrawlers.com/albums/album11/DSC01250.jpg

http://www.zukikrawlers.com/albums/album11/DSC01259.jpg


http://www.zukikrawlers.com/albums/Fender-Trim/DSC01364.sized.jpg

http://www.zukikrawlers.com/albums/Fender-Trim/DSC01369.jpg

http://www.zukikrawlers.com/albums/Fender-Trim/DSC01371.jpg

http://www.zukikrawlers.com/albums/Fender-Trim/DSC01373.jpg

http://www.zukikrawlers.com/albums/album11/DSC01372.jpg

[holeshot]

Looks good, Joe.
I know what you are talking about when you try to weld Zuki fenders. It sucks.
I like the look of your shackles. You build or buy them?

[Itsmejoe231]

Thanks, I built them too.

[TX_ZUKI]

Looks great Joe! Can;t wait to see it in Gilmer!
toast

PS I have the same brakeline holders!

[Itsmejoe231]

Thanks, I still have to finish the passenger door before Gilmer lol

[TX_ZUKI]

ah you don't need doors, I haven't had any for 2 years. Thanks, I still have to finish the passenger door before Gilmer lol

[Itsmejoe231]

yea, I just dont want to show up with on door done. I will be there regardless.

[txzuk1988]

what thickness is the metal you used for the fender repair.

Nice work on the fabbing:bling: ....the evolution never ends, does it.jamminzz

[Itsmejoe231]

Thanks, I am not sure what gauge it is. It was like 1/16 thick, just a little thicker than the fender. I got a piece of it at Home Depot.

[Billjohn]

You cleaned that up alot better than I did. I used a BFH on the front corners of mine, and then trimmed the fender flairs.
http://www.izook.com/reviews/swfrntbmpr/images/shrockworks033.jpg

[Itsmejoe231]

Thanks Bill, I am still waiting to see how functional all this is on the trail. I left my options open for going shackle reversal if i want to later. And if the tire still rub I will get out the BFH.:mrgreen:

[Itsmejoe231]

I do know a panhard bar is in the making soon. I did notice that my axle will move side to side by just turning my wheels in the garage.

[Billjohn]

I went the other way... I moved the axle forward (again) and it hit the fender -bad- while flexing it up in the driveway (more on how to do that later). I then bashed it enough to give about an inch clearance at full stuff. I didn't plan, I reacted.

[Billjohn]

I do know a panhard bar is in the making soon. I did notice that my axle will move side to side by just turning my wheels in the garage.

Our Grey Ghost project truck did that so badly that we couldn't turn very well on the trail... so a panhard was required!

[Itsmejoe231]

I think the difference is that I used the sammy shackle hanger in front when I should have built something wider for the yj. I might still do that before the next run. I put washers between there but it still did not tighted it up like I would like.

[Billjohn]

I think the difference is that I used the sammy shackle hanger in front when I should have built something wider for the yj. I might still do that before the next run. I put washers between there but it still did not tighted it up like I would like.

You will be happier with a panhard, and it will also keep both sides from dropping out at once when you get verticle. The geometry of a panhard will only allow one side or the other drop, not both sides at once. It's an additional benefit.:mrgreen:

[Itsmejoe231]

I never looked at it that way, but I see what you are saying. Cool Panhard bar it is.:mrgreen:

[Itsmejoe231]

And it needs to be as close to parellel as possible to the drag link, right?

[Billjohn]

And it needs to be as close to parellel as possible to the drag link, right?

Exactly.