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Norcal69's Common Sense Build.

Discussion in 'Builds and Fabricators Forum' started by Norcal69, Sep 11, 2014.

  1. Dec 20, 2021
    bigjohn

    bigjohn Member

    Kelso Wa
    Joined:
    Mar 18, 2010
    Messages:
    916
    I don’t know if I mentioned it but after my rubicon trip my poly spring bushings were absolutely shot. Especially in the front. It drove like a different jeep, and not in a good way. That trail Is brutal on springs and particularly bushings. That was my conclusion.
     
  2. Dec 20, 2021
    zinertia2

    zinertia2 "and which part are you keeping?" 2022 Sponsor 2021 Sponsor 2020 Sponsor

    Greencastle , IN
    Joined:
    Feb 15, 2018
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    158
    I machined a flat spot on top of my shims - removing as little material as possible. Seems to work fine - but my shims are pretty low degrees (about 3)
    Dennis
     
  3. Dec 21, 2021
    nickmil

    nickmil In mothballs.

    Happy Valley, OR
    Joined:
    Sep 23, 2002
    Messages:
    12,119
    if the head is on the angled plane of the shim and the shank of the bolt is on on the plane of the spring then that definitely could be the cause. Good shims, like those member McRuff makes, have a recess machined in the shim so the bolt is not put in stress when torqued.
     
  4. Dec 21, 2021
    Norcal69

    Norcal69 Out of the box thinker 2022 Sponsor 2021 Sponsor 2020 Sponsor

    Northern California
    Joined:
    Sep 6, 2014
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    2,843

    The Rubicon trail is really hard on springs. Spring under jeeps regularly hit the springs on rocks and slide on them all while being flexed to the maximum.
    3 Rubicon trips, 20K or so miles and a multitude of other offroad adventures it was pretty used up.
    The shims I use are from warrior products. They have a flat machined in them so that the center pin is pulled straight.
    [​IMG]
     
    Lilbuff63 likes this.
  5. Dec 22, 2021
    wheelie

    wheelie beeg dummy 2021 Sponsor

    York, PA
    Joined:
    Mar 6, 2004
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    4,191
    I’m not a huge fan of poly bushings.
     
    ITLKSEZ likes this.
  6. Jun 18, 2022
    Norcal69

    Norcal69 Out of the box thinker 2022 Sponsor 2021 Sponsor 2020 Sponsor

    Northern California
    Joined:
    Sep 6, 2014
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    2,843
    The safety clip on my stock warn winch hook somehow fell off, I took that as a sign it was time to upgrade my winch hook.
    I found this Factor 55 Flat Link E on ebay, missing box and instructions price score!

    [​IMG]

    Coupled it with a soft shackle to make winch connection as fast as a standard hook.

    [​IMG]

    Stows flush with the front bumper.

    [​IMG]


    [​IMG]
     
    jeepstar, Lilbuff63, Muzikp and 5 others like this.
  7. Jun 18, 2022
    bigjohn

    bigjohn Member

    Kelso Wa
    Joined:
    Mar 18, 2010
    Messages:
    916
    Is that The Brennan’s garage soft shackle? I’ve been thinking about ordering a free for Anna and my Jeeps.
     
  8. Jun 18, 2022
    Norcal69

    Norcal69 Out of the box thinker 2022 Sponsor 2021 Sponsor 2020 Sponsor

    Northern California
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    Sep 6, 2014
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    2,843
    I bought several a while back on Etsy. I don’t remember the sellers name.
     
    bigjohn likes this.
  9. Jun 27, 2022
    Norcal69

    Norcal69 Out of the box thinker 2022 Sponsor 2021 Sponsor 2020 Sponsor

    Northern California
    Joined:
    Sep 6, 2014
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    More pre Rubicon upgrades!
    The frame flex/body flex that a jeep endures on the Rubicon cannot be duplicated off of the trail. The last 3 trips really put some damage in on my floorboards and hat channels as well as crushing my poly body mounts. The body mounts had crushed to the point that the transmission was rubbing the floorboard and causing very annoying vibrations.
    The body was sagging pretty good over this crack. I jacked the tub up before welding the reinforcement.

    [​IMG]

    I started off and gave all of the body mount hat channels a reinforcement with 1/8" angle. 3" minimum on each side of the damage.
    Here is one of the repairs completed.

    [​IMG]

    After all of the body mount locations were reinforced it was time for some new body bushings. I found these 2"x2" square 15/16" thick bushings at summit. The gave 1/4" of body lift over the previous bushings. That 1/4" coupled with the 1/8" plating of all the body mounts gave plenty of transmission tunnel clearance.

    [​IMG]

    With new found clearance it was time to work on the next step. My roll cage ties into the dash/front pillar and the floorboard on each side. It seems that most of the flex in these early chassis is right behind the front leaf springs, even with the bell housing area. I ordered some bushings, housings and weld tabs from Ruff Stuff. I feel guilty ordering the tabs, but they are so clean and only $3.95 each. Here is the drivers side front setup. The round tube is 1.5" .095 DOM that was harvested from an old race car bumper.

    [​IMG]

    Proof that I can lay a decent bead when I focus.....

    [​IMG]

    Welded to the floorboard sandwich plate.

    [​IMG]

    Here you can see the cage to frame tie in installed. If you imagine the hidden tube running angled from the dash down to the floorboard you will see that it lines up almost perfect with the cage to frame tie in. The shadow on the body almost shows the line up perfectly.

    [​IMG]

    More proof that I can lay a sexy bead when necessary.

    [​IMG]

    Here we have both cage frame tie in pieces painted. They are surprisingly symmetrical.

    [​IMG]

    Drivers side installed. Please ignore the line lock lines, they are one of the few remaining transgressions still lingering from the previous owner.

    [​IMG]

    [​IMG]

    Here is the passenger side.

    [​IMG]

    I have the necessary pieces to do something similar on the rear, I'm not sure how comfortable I am doing that much welding near the gas tank without removing it. With 2 weeks to Rubicon it may have to wait until this winter.
     
    Danefraz, tymbom, timsresort and 13 others like this.
  10. Jun 27, 2022
    txtoller

    txtoller Member 2022 Sponsor 2021 Sponsor 2020 Sponsor

    Weatherford, TX
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    May 28, 2014
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    I like that!
     
  11. Jun 27, 2022
    scott milliner

    scott milliner Master Fabricator

    Seattle Wa.
    Joined:
    Dec 17, 2002
    Messages:
    2,278
    This was my fix.
    [​IMG]

    [​IMG]

    [​IMG]
     
  12. Jun 27, 2022
    Muzikp

    Muzikp Active Member 2020 Sponsor

    Sacramento Ca.
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    Sep 27, 2016
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    So is the body sandwiched between these two plates that tie it all together? I wanted to do something similar on mine but the general consensus around here was that the body would crack over time and I should use the roll cage connectors thru a hole in the body instead. :shrug: I like what you did, I may revisit the idea.
     
  13. Jun 27, 2022
    Norcal69

    Norcal69 Out of the box thinker 2022 Sponsor 2021 Sponsor 2020 Sponsor

    Northern California
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    2,843
    If the two plates are the same size the body will crack over time. My inner plates are 1” bigger on the inside than the outside.
     
    Muzikp likes this.
  14. Jun 27, 2022
    wheelie

    wheelie beeg dummy 2021 Sponsor

    York, PA
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    Mar 6, 2004
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    I find that cage tie in work rather innovative. I like it.
     
    Norcal69 likes this.
  15. Jun 27, 2022
    timsresort

    timsresort Member 2022 Sponsor 2021 Sponsor

    South Lake Tahoe CA
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    Jan 22, 2014
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    I like it too, and we are looking at something like this after my brother's recent rollover. The cage on his Commando was tied to the frame, and it held. (the rest of it did not fare too great).
     
    Norcal69 likes this.
  16. Jun 27, 2022
    Lilbuff63

    Lilbuff63 Member 2022 Sponsor 2021 Sponsor

    Sonoma County Ca
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    Nice work, looking good!
     
    Norcal69 likes this.
  17. Jun 28, 2022
    Norcal69

    Norcal69 Out of the box thinker 2022 Sponsor 2021 Sponsor 2020 Sponsor

    Northern California
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    Tim,
    I'm not familiar with the Commando dash arrangement so this might not be possible.
    You might consider tying into the dash pillar as well as the floor. It really stiffens the body up!
    I did this same setup on my jeep as well as Steve's. Shortly after he rolled his jeep going about 55 mph and the cage held up really well.

    [​IMG]
     
    Last edited: Jun 28, 2022
  18. Jun 29, 2022
    Norcal69

    Norcal69 Out of the box thinker 2022 Sponsor 2021 Sponsor 2020 Sponsor

    Northern California
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    I took the Jeep out for a mix of driving after work yesterday. With the cage tied to the frame there is much more road feel than before. My suspension is very soft and soaks up bumps well but the bumps are a little sharper feeling now. Steering is crisper and input is much more pronounced while the Jeep overall is noticeably more stable. I ran 10 miles or so on the freeway at 70-75 (flow of traffic) and while the road feel was increased the drive was one hand on the wheel relaxed. Really sporty feeling for a street legal farm implement.
    from the beginning I knew that the body and frame flex were soaked up steering input and engine torque, but was surprised at how much they were flexing together. Over the winter I plan to tie the rear of the cage into the frame as well. I should have done this years ago!
     
    Danefraz, Muzikp, 47v6 and 6 others like this.
  19. Jun 29, 2022
    Tom_Hartz

    Tom_Hartz Member 2022 Sponsor 2021 Sponsor 2020 Sponsor

    North Carolina
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    Apr 9, 2014
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    450
    Now you have me thinking.
     
    Norcal69 likes this.
  20. Jun 29, 2022
    Jeepsterjim

    Jeepsterjim Member

    Lincoln, CA
    Joined:
    Apr 25, 2019
    Messages:
    331
    Question:
    To try and remove stress load on the shim and center pin and the "pins head" why not drill a hole through the shim the same diameter as a taller pins head. I've seen this done by different spring shops. They would drill out the shim center hole to the dia. of the center bolts pin head dia. for the reasons mentioned above. Personally, I'm not sure it makes a difference.

    Example: Shim center hole is drilled out to 1/2 inch dia. OR?
    then if the shim needs 1/4" of a pin head to make it protrude thru the top of the shim and another 3/8" to stick up above the shim so that the diff will secure itself well, you would need 3/8" dia bolt, 4" long threaded shank, with a 1/2" dia pin head, 5/8" tall. DANG hope that makes sense, LOL. I've used this set up with no problem. The biggest reason center bolt bend or shear off is the U bolts are lose.....done that. Went to 9/16 dia U-bolts, stronger plates, and a higher torque rating. Plus maintenance.
     
    Last edited: Jun 30, 2022
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