Project Coppertop Axle Swap

[RuffedUpXJ]

What's your TB length and your draglink length? I ran the same setup for a week and ran into some bump steer and when the Jeep would roll I ran into some issues where the roll would cause the some understeer and felt unstable. I ran mine to the top of the tie rod to have the exact length TB and draglink. Just a thought incase you run into this issue. And crank the **** out of those bolts on the knuckles.

Looks good. Nice and wide.

[blazerbrad]

Looks good. Just one comment, on that stacked rod end steering do you think it will hold up okay? Just seems like a lot of leverage on that single bolt?

[Coppertop]

Originally Posted by WrenchMonkey

Badass, man. When do you wanna do mine?

Thanks,get the parts coming.We're make it a summer project.I like the idea of a flat fender flare in the NAXJA thread.The TJ flare outer lip is catching on the tire.Moving up is no longer a option.

Originally Posted by RuffedUpXJ

What's your TB length and your draglink length?

Draglink 39 inches from center eye to eye.Trackbar 27 inches.At this point,I'm gonna give it a try,because the only way I see making them closer to the same length is making a complete new trac bar bracket and moving it forward on the frame.

Originally Posted by blazerbrad

Looks good. Just one comment, on that stacked rod end steering do you think it will hold up okay? Just seems like a lot of leverage on that single bolt?

Thanks,Great comment,I'm thinking the same thing..I've talked to a few guys running this set-up with no issues.Rusty's offroad sells a similar set-up that uses 5/8 bolts(I'm using 3/4 bolts).Time will tell..

I'm carrying spare bolts just in case.

Nick

[RuffedUpXJ]

When you move it forward and place it front of the spring I got mine to 33 inches and made the draglink that length as well/ Helped on road manners a lot.

[Coppertop]

Good Deal,Hope to give it a test drive this weekend.

Nick

[Coppertop]

The time is flyin' by ,I'm still working on the rigg.....:( Got the new brake system installed and gave it a test drive round the neighborhood last week.The brakes are way better,but I'm still not happy .So ,I ordered a adjustable porportion valve.While waiting on parts,I gutted the interior and finished the roll cage and reinforced the area under my roof mounted tire carrier.Then came the floor rust repair (still working on this).Hope to give it a highway road test very soon.
The rear seat has been removed for good.It's a two door two seater...

Nick

[gothodgie]

Originally Posted by Coppertop

The time is flyin' by ,I'm still working on the rigg.....:( Got the new brake system installed and gave it a test drive round the neighborhood last week.The brakes are way better,but I'm still not happy .So ,I ordered a adjustable porportion valve.While waiting on parts,I gutted the interior and finished the roll cage and reinforced the area under my roof mounted tire carrier.Then came the floor rust repair (still working on this).Hope to give it a highway road test very soon.
The rear seat has been removed for good.It's a two door two seater...

Nick

can't wait to see it...

[Coppertop]

I'm not able to reuse my OEM sway bar (to narrow), everything is in the way of mounting the brackets to the axle.Been looking around for ideas.Allthough ,the more I think about it.....With the wider stance ,it should be more stable.So, maybe I won't need one.

Nick

[Coppertop]

Got the rigg out of the garage yesterday for the first test drive.Hit 70mph on the Hwy with no issues.Then drove down East Miami River Road,I'm impressed with how it was handling the sharp turns ,almost like a sports car . I doubled the posted speed on most of the turns. I'm still on the fence about not running a sway bar.Overall ,I'm pleased ...Next,I'm going to finish installing the rest of the skids,rock rails,spare tire ,and all the gear I carry.Then run the same test.


Nick

[itbrokeagain]

How did your brakes turn out? What did you end up doing?

[Coppertop]

Originally Posted by itbrokeagain

How did your brakes turn out? What did you end up doing?

The brake system (a brief summary) 98 xj brake booster and pedal assy,99 dodge 2500 master cylinder,all wheel disc brakes,and Wilwood adjustable proportioning valve.
After installing the proportioning valve the brakes are good.

Nick

[itbrokeagain]

That sounds easy enough.

Why the Xj booster? I thought the upgrade was a Wj booster.
I assume you kept the stock metal lines.
Are the calipers on the rear 3/4 or 1/2 ton? I assume they are Chevy right?
How much fab work did the 2500 master take to mount up? Did you have to do anything to the pushrod?

Sorry for all the questions but I am trying to figure out what I am going to do.

[Coppertop]

Originally Posted by itbrokeagain

That sounds easy enough.

Why the Xj booster? I thought the upgrade was a Wj booster.
I assume you kept the stock metal lines.
Are the calipers on the rear 3/4 or 1/2 ton? I assume they are Chevy right?
How much fab work did the 2500 master take to mount up? Did you have to do anything to the pushrod?

Sorry for all the questions but I am trying to figure out what I am going to do.

No problem Tony, glad to help. The dodge truck MC will not bolt to the WJ booster(bolt pattern not even close and hole to small)So,I had to go back to the XJ (98) brake booster and pedal assy. It bolts right up no mods needed.The push rod was replaced with a 1/4x2 fine thread grade 8 bolt with the corners rounded on the head.All brakes lines are standard 3/16 flare.I had to change out the ends on the MC side.The new Wilwood adj proportioning valve came with flare nuts to change out all existing lines.The rear are chevy calipers.I bought the kit from Shawn on Pirate.Nice kit everything you need to do the job.
The links that helped me figure it out.
http://www.naxja.org/forum/showthrea...upgrade+thread
http://www.pirate4x4.com/forum/showthread.php?t=746609


Hope this helps..

Nick

[Coppertop]

Loaded up the heep with everything I carry..Ran the same route(I-275and East Miami River Road).At one point reached 75mph..Handled really well ,with the only issue being body roll.
I'm convinced.....I need a sway bar.I'm wondering if a sway bar from a full size truck will work??

Back to the garage.

Nick

[gothodgie]

Cool... I am sure you are happy to have it on the road again...

How wide do you nead ? i have 2 fj60 sway bars... they are in my pile of parts, you are more than welcome to try one if you like... sway bars are for wimps.

[Coppertop]

Sweet,a yota sway bar will be a nice touch... The stock xj bar measures 37inches wide.If one of your's is at least 43-44 inches wide it may work.The wider one is needed to clear the coil springs.

I'm on vacation this week.Just let me know the best time to pick it up.Yes,it's getting close..Can't wait to hit the trail.

Nick

[gothodgie]

the fj60 sway bars are only 36"s wide... sure looked wider than that laying on the ground... good luck...

[Coppertop]

Thanks for checking....The search continues.

Nick

[Coppertop]

Been busy in the garage this week...Time for a update,with pics..
The Viair #1007 onboard air fit nicely behind the pass seat.It will supply air for the front ARB Locker and air the 36 tires.I built a removable metal frame to allow for a storage container above .You can barely hear it run.:)




The roll cage got some yella padding.

Also, installed a rear brake line lock(next to the T/C lever and ran the brake line inside to the rear.

Rear fenders needed a trim.




I'm finishing the fenders today with some sheet metal to close up the bottom and black bedliner paint.

Build sheet coming soon..
Nick

[Coppertop]

The rear fender trimming is done and the rear shackle relocation brackets are on.I like ........





Back to the garage.
Nick

[RuffedUpXJ]

Move the shackle further towards the front on the relocation bracket, it will help achieve some angle which will allow more flex. I would say move up 2 holes if not three and put the leaf in the last hole on the shackle to maintain the height.

[Coppertop]

I'll give it a try...I can't wait to hit the trail this weekend.

Thanks
Nick

[WrenchMonkey]

Yeah, I've heard the same thing, that you want about 45* in the shackle.

Does look great man!

See ya

[Coppertop]

Thanks...Yeah ,my plan was to have the rear shackles dialed in by now.Then finish welding them and paint.Then,late sunday noticed the rear rotors had oil on them from the wheel seals leaking.I replaced them and drove it to work 60 mile hwy round trip yesterday.Checked again, still oil sprayed on the rotors.This time the seals are dry.I'm puzzled...

Thinking,maybe there was oil build up in the rotor cooling fins.:confused:

Nick

[Coppertop]

Overall,I'm pleased with the new set up.I'll start with the good.Love the Rough Country long arms,nice ride on the hwy and great trail flex.No bump steer and no vibs .Love the front slectable ARB and the lock out hubs.Very happy with the 513 gears.

The issues:
Lost MPG:( Averaged 13 mpg before the swap.Now it's at 11.5 mpg.
The rear springs are flattening out and flexing upward like there weak.:confused: This caused the pinion angle to be way off.At times the two yokes were contacting.I'm calling Rough Country first thing tuesday.
The rear wheel seals are still seeping.
The front tires are hitting the rear part of the fender when flexed out.

Happy to be out of the garage and on the trail.Even know it was just for a day.




Back to the garage.
Nick