Gonzo becoming great - EVENTUAL convertable build

[Billygoat]

Like the title says EVENTUAL convertible, thinking ETA of 2012.
I do hope to do my quick release hinges and a few sets of doors this year.

Some recap:

Here is Gonzo, an 83 Cherokee Laredo with "minor" paint fade, so dubbed because the colors reminded me of the muppet, and fitting because it is going to become a little of a W.T.F.? is that truck, like the muppet...



A few things I have already done:
TFI and GM module upgrade



Round headlights with relays


A couple holder console and CB


And the most recent addition is a custom cluster, I started this for Thumper, but decided I like the burled walnut stock cluster I picked up a lot more for Thumper, so I redid this face with diamond plate.


Those 4 black round things are blacked out indicators, top 2 turn, left side brake, right side 4x4. I will add a voltmeter, power port and switch panel someplace made out of the same ABS plastic diamond plate, just not sure where yet.

Next up is suspension work.

[kaklask]

I really really like the guage cluster that is awesome!

[Gambler68]

Originally Posted by kaklask

I really really like the guage cluster that is awesome!

Ditto.

[jeepjseries]

Looking good.

[EBCIII]

That cluster is Killer! Beale.

[Billygoat]

The front end is getting a shackle reversal.

First I took off the bumper and unbolted the springs


The "blue saw" (nickname at work for torch) made quick work of removing the front spring hangers


Combination of propane torch, sawzall and cold chisel got the 28 year old bushings out


For anyone that has not done a spring lift yet, or got lucky, here is some info, the center pin IS NOT centered, here is a shot with the springs standing on opposite ends. Pins circled


So when I put them back in I will flip them this will slide the axle forward and giving it room to move rearward in the wheel well as the spring compresses, vs forward as it did with the shackles in the front.

Starting on the front spring mount lowering supports if I can keep my hands from sticking to them, lows below zero this week and an unheated shop.

[SnowShoe]

Originally Posted by EBCIII

That cluster is Killer! Beale.

X2

[Brizio]

Nice job so far!

[Billygoat]

Originally Posted by SnowShoe

X2

Thanks guys, I shoot a couple more pics of it for ya!
Took a lot of time with a dremel tool and exacto knife to cut in the heat controls.

[jaber]

Originally Posted by Billygoat

Thanks guys, I shoot a couple more pics of it for ya!
Took a lot of time with a dremel tool and exacto knife to cut in the heat controls.

It was worth it.
VERY nice work...

[Billygoat]

As promised a couple more, sorry my camera does not take close up detail pics very well, but as I have said before it was free.

[Billygoat]

Back on the Shackle flip

This bad boy is going to be the base support for the front hangers



I know it is heaver than the factory frame, but I am also going to tweak the snow plow I built for my CJ8 a few years ago to fit on the Cherokee, so this will double as support for that too.

I got the hangers squared up and tacked on, the was a little shy of what I needed so I use some large end caps to get then length, the 1 will cut cut flush, I just didn't have any steel cutting blades left for the sawzall, and hack sawing 1 was enough.



Close up of 1 hanger welded off, don't worry that it hangs over the back side, the gusset plates will support it.

[Leapfrog]

Can't wait to see it finished.

[Billygoat]

I actually got smart and figured now would be a good time to swap my stock very leaky steering box {bottom} for a salvage yard (hopefully) not leaky J20 box {top}




Glad I did because I had to clearance my support frame.




Here is where it sits now, I have the support heavy tacked to the main frame - only 1/16" difference eye to eye between the sides.
I will finish burning it off and get the gussets cut and welded in next.

[Billygoat]

Good weekend, front is DONE!

Front of the tube got a single gusset on each side under the beam of the "C"
And I put some filler rod in and stiched the tube to the front crossmember.




The back of the tube got double gussets lined up with the legs of the spring holder, driver side got the same gussets, but they got cut short and but into the steering box bracket. You can see I also put a tie plate on the face to tie the gusset/tube/frame together even more.




OOOPS! Warm weather must have softened the dirt floor in my shed and when I was torquing the u-bolts down over she went
At least I notice it staring to move and was able to roll out, my trouble light was not so lucky - that is what I call an acceptable loss.
When I got it back up I did put blocking under the stands, and added a chain to the rafters.




With everything all tightened up (no shocks) I fully extended and then compressed the springs, shocks checked out, maybe a little short for full extension, but not an issue for me since this truck won't see much worse than field roads, all the 3" lift shocks crossed to stock for a 97 grand Cherokee stock rear, so I just got some Monroe gas magnums front and micromatics rear from O'reileys for under $25 each.
You can see in the pic even with the springs flipped to push the axle forward the bump stops still line up well with the axles and there is no interference with the tie rods. I did decide to space the bump stops down 1 inch, the springs had a decent negative arch in this pic.
Note I don't recommend that anyone copy my method of compressing springs, probably not the safest thing in the world, so you are own your own if you get hurt.



Not much room in the shed, but a couple shots trying to show the front end stance now. I think I picked up 2-3/4" but that was the one measurement I didn't take before I started, so I am going off where the rear sits.





I was going to go with 31x10.50 tires, but now am leaning toward 30x9.50 tires to save a few bucks and not overload the stock gears as much.
Thinking about these
http://www.discounttiredirect.com/direct/findTireDetail.do?pc=18292&counter=1&ar=950&rd=15& sw=false&cs=30

**EDIT**
Forgot to mention, the main reason for flexing the suspension was to check the front shaft out, and the stock is short, I have the cross ref that was listed in another thread, so the plan is to find a stock one that is longer and get it shortened.
With my 229 I need to have one in balance.

[3rdelement]

how did that j20 steering box install go? direct bolt on?

[Billygoat]

Originally Posted by 3rdelement

how did that j20 steering box install go? direct bolt on?

100%, the only thing you have to watch is the years ALL FSJ switched from flare to o-ring fittings on the hoses in 78(?), you can adapt, or have hoses made if you mismatch, but if you stay in the same fitting series it is just turning wrenches.

[sappy76]

I about 90% sure I'm going to do a shackle reversal on my Chief this summer. I'll be very interested in your thoughts on the ride after you get it on the road. I have a SkyJacker Softride 4" lift on mine now and I'm wondering if there are any hidden issues with these springs. Also, where did you learn to do this? Did you have some past experience that told you to add the cross brace on the front mount? (I saw an article in this month's issue of JP where they did a shackle reversal on a commando. They did not add the cross brace.) How did you mount the shackles to the rear?

Thanks for the picts and the writeup, it helps me a lot.

[Billygoat]

Originally Posted by sappy76

I about 90% sure I'm going to do a shackle reversal on my Chief this summer. I'll be very interested in your thoughts on the ride after you get it on the road. I have a SkyJacker Softride 4" lift on mine now and I'm wondering if there are any hidden issues with these springs.

I have heard you can run into issues with the shackle wanting to swing forward and lock with lift spring.

Originally Posted by sappy76

Also, where did you learn to do this? Did you have some past experience that told you to add the cross brace on the front mount? (I saw an article in this month's issue of JP where they did a shackle reversal on a commando. They did not add the cross brace.)

I got the cross brace idea from a CJ reversal kit, it was bolt in and looked lame, but I liked the support, and I did it the same when I made the one for my CJ. Also it works will with my snow plow mount, adapting the plow I built for the CJ to the Cherokee. Might be overkill, but I like overkill when changing the suspension from stock.

Originally Posted by sappy76

How did you mount the shackles to the rear?

Bolt right into the existing spring hangers, they are the same on both ends of the front springs.

[Tad]

Looking real good there!