Project JimmyRig almost ready to begin. - Page 2

WrenchMonkey · 04-21-2010, 01:46 AM

Quote:

Originally Posted by 94Dodge Truggy

I used a switch to control the air flow and shift fork to engage and disengage the axle up front.

Huh. I thought I was the only one who did that:

Been runnin it for years. Works great for me...

Robert

BIGRAM · 04-21-2010, 07:24 AM

No problems? I can deal with that. Thanks for the input fellas.

WrenchMonkey · 04-21-2010, 01:54 PM

Quote:

Originally Posted by BIGRAM

No problems?

Yeah, but like I said, I thought I was the only one.

Most people seem the hate the disco worse than brussels sprouts.

Robert

sarge · 04-21-2010, 03:11 PM

OK gonna answer a few of the questions , as I have been busy gathering the final parts for the past few days .... first off I need an Astro Van steering box from a 2wd van , anyone got one ?

The rear is a 60

Yes the front is CAD . not worried !;)

I'm going to run a cable from AW direct , just like I had in the wrangler $43.00 and forget it .

I'm welding the rear spiders

The transfer case is going to remain the factory 236GM unit for now. This will at least keep the build a little shorter and cheaper for now . Waiting for a 231C to roll into the yard and thinking of doing a 231/231 Doubler ??????

kingchango · 04-21-2010, 06:25 PM

Quote:

Originally Posted by sarge

231/231 Doubler

interesting

kyrel69 · 04-21-2010, 09:05 PM

Quote:

Originally Posted by sarge

I'm going to run a cable from AW direct , just like I had in the wrangler $43.00 and forget it .

Can you tell me more or let me know when you got this done and I could just come by and take a look at it.
I would like to do this to my truck

BIGRAM · 04-21-2010, 09:40 PM

Quote:

Originally Posted by kyrel69

Can you tell me more or let me know when you got this done and I could just come by and take a look at it.
I would like to do this to my truck

I knew there had to be a cheaper way.

What's the details?

sarge · 04-21-2010, 11:14 PM

http://www.awdirect.com/easy-glide-p...ngle-gear/pto/

Ok the price went up a little bit since I did the wrangler .

unbolt the selector fork assy.( CAD ) on the axle , make sure to unplug vac. and electric lines and put the assy. on the work bench.

Pry open the vac. canister that the vac. line plug into and cut out the bladder and then plug the vac. line ports. put vac. canister back together.

find a good spot on the driver side of the CAD housing and drill a hole through the aluminum housing to the inside making sure you can continue to drill into the CAD fork asstraight as possible and as close to the Forks slide shaft. Make hole just big enough for the threaded end of the PTO cable to go through. Now counter sink the outside hole to the size of the outer cable.

Find a good spot on the inside of the rig to mount the pull handle , make sure you pick a spot that can handle a good tug with out bending or breaking .

Route you cable through the fire wall and down to the CAD unit with the least tight bends as possible.

Put a dab of RTV on the hole in the CAD housing and run the cable through and into the fork, bolt the cable to the fork using lock tight. bolt CAD housing back to axle.

When you get the cable you get a cable clamp and nut and bolt. I welded the bolt to the axle tube so I could clamp the cable on on the back side of the axle tube out of harms way and straight in line with were the cable enters the CAD housing .

This is the readers digest version and with out any pictures , but the info is out there if you search a little. I have not found a good write up using this cable.

I had the cheaper PTO/ Throttle cable however I could not keep the cable from pulling out of the fork after about a day of wheeling. It became a real pain in the arse ...... the extra few buck for the threaded end sealed cable was well worth it and I never had a problem with mine once I switched.

BIGRAM · 04-22-2010, 07:19 AM

That'll be the plan. Thanks for the great writeup.

kyrel69 · 04-22-2010, 09:09 AM

thanks going to have to do that

blazerbrad · 04-22-2010, 09:14 AM

Quote:

Originally Posted by sarge

OK gonna answer a few of the questions , as I have been busy gathering the final parts for the past few days .... first off I need an Astro Van steering box from a 2wd van , anyone got one ?

Is this the style that bolts on the inside or outside of the frame? I have a GM box from a van that bolts to the outside of the frame identical to a fullsize 80's era truck, but has opposite gearing. I know it's from a van but not sure if it's an Astro for fullsize. (I bought this from a junkyard already off the vehicle not realizing it was a van).

scotty85 · 04-22-2010, 09:30 AM

Quote:

Originally Posted by WrenchMonkey

Yeah, but like I said, I thought I was the only one.

Most people seem the hate the disco worse than brussels sprouts.

Robert

lol yes they do! not me tho,ive been running my CJ CAD on a vaccum switch for years also with no prollems. well,i did have a prollem... i was takin my dash apart and broke the switch. but that was my fault and i still had no prollem with its operation.

the shift assembly on the axle goes bad alot less often than people believe it does ;)

i do like the PTO cable idea as a fix if my shifter ever does go bad.

sarge · 04-22-2010, 10:30 AM

Quote:

Originally Posted by blazerbrad

Is this the style that bolts on the inside or outside of the frame? I have a GM box from a van that bolts to the outside of the frame identical to a fullsize 80's era truck, but has opposite gearing. I know it's from a van but not sure if it's an Astro for fullsize. (I bought this from a junkyard already off the vehicle not realizing it was a van).

The Astro box bolts to the inside of the frame just like the Jeep and many other smaller SUV's theonly difference is the pitman arm throw is opposite. Since I'm moving the front axle forward this will help line things up. Thanks anyway . I'm sure one will find it's way into the lot before to long.

sarge · 04-28-2010, 06:39 AM

it has begun !!!! pullen the Jimmy in the garage this evening, got it on jack stands and started cutting off anything not needed.

started with the front end ,front bumper off and most of the the other crap either unbolted or plasma cut off.

moved to the back and got it out and waiting for it's new home :

60 in place in the rear......

I ordered a bunch of stuff from DIY4X and Ruffstuffspecialties on Sunday, hoping they arrive tomorrow

94Dodge Truggy · 04-28-2010, 09:23 AM

Lookin good! You extending the wheelbase any?

sarge · 04-28-2010, 10:40 AM

front will be stretched w/ dakota springs and the position of the front cross member ..... hoping to get out there today and fab up the front .

94Dodge Truggy · 04-28-2010, 11:20 AM

I am putting a guess on the rear bumper side plastic mouldings lasting 2 trail rides!

sarge · 04-28-2010, 12:33 PM

wrong , they are going bye bye before

sarge · 04-29-2010, 11:38 PM

My pile of parts keeps getting bigger , thank god for craigslist.

Got the front clean out and got the front cross member tack in .

Got one of my packages in the mail yesterday

mocked up the front and sat it down on all fours

I have two major problems

First problem : I have to run at least 2" spacers or have my rims recentered to clear the knuckles and have enough room for my tie rod and drag link.

Second : my pitman arm is going to hit the Diff , it is only about an inch above it sitting in the garage. Going to have to get an Astro van box before i can even drive it .

Also going to play with the springs alittle , not happy with the front location .

Still have to :

Drive shafts
brakes
exhaust
flat belly
shocks
bumpers
..............

WrenchMonkey · 04-30-2010, 12:29 AM

I personally prefer to run cheaper parts and drink better beer.

But to each his own.

Robert

RuffedUpXJ · 04-30-2010, 09:13 AM

Its the Trentonite coming out of him. I don't think they carry anything besides Nati Light, Hudy, and PBR at the gas stations.

sarge · 04-30-2010, 09:56 AM

Quote:

Originally Posted by WrenchMonkey

I personally prefer to run cheaper parts and drink better beer.

But to each his own.

Robert

Ha ! If you would change your ways you could change your signature to not include BWOKE

But hey ! to each his own

Plus if you drank as much as I do you would drink cheap beer to, Can't beat $14 for a 30 pack for Bud Light with a Natty wrapper.

WrenchMonkey · 04-30-2010, 11:13 AM

A man's got to have his priorities, I guess...

Robert

sarge · 04-30-2010, 08:03 PM

ok back on track , got an Astro van gear box today and ordered a set of Copperhead Fab H1 centers. Figured I would just recenter the rims instead of searching for spacers.
I still haven't got my DIY4X stuff :mad: and the centers will not be here until the end of next week ..... I guess this gives me time to get a bunch of the small things taken care of like brakes and drive shafts and spring mounts.
After sitting in the garage pondering what I needed to do I have decided to add a leaf or two all the way around and give me a little room for tires and may not have to trim as much.

KargoMaster · 05-10-2010, 05:28 PM

A few things...

Everything I get from Kurt has been top notch, and quick... sorry to hear of your frustration... DIY4X is usually a great resource...

Completely agree with recentering... Copperhead would not be my first choice for centers... let us know what you think of them.

On the AAL idea... just remember that video (that I took of you on Big Wally)of the big yellow monster in '03? the more leafs you add (for clearance or whatever) the stiffer your suspension...

10 more days.... any new updates?

04-21-2010, 07:24 AM	#27
BIGRAM Ready to Wheel!!!!!!! Join Date: Jul 2009 Location: Stanton, KY Posts: 263	No problems? I can deal with that. Thanks for the input fellas. __________________ 1994 Dodge Ram 5.9L SWB 3/4 axles, 39.5 IROKS, HYDRO assist

04-22-2010, 07:19 AM	#34
BIGRAM Ready to Wheel!!!!!!! Join Date: Jul 2009 Location: Stanton, KY Posts: 263	That'll be the plan. Thanks for the great writeup. __________________ 1994 Dodge Ram 5.9L SWB 3/4 axles, 39.5 IROKS, HYDRO assist

04-28-2010, 09:23 AM	#40
94Dodge Truggy EX-Vice President Join Date: Jan 2007 Location: Fairfield, Ohio Posts: 3,048	Lookin good! You extending the wheelbase any? __________________

04-28-2010, 11:20 AM	#42
94Dodge Truggy EX-Vice President Join Date: Jan 2007 Location: Fairfield, Ohio Posts: 3,048	I am putting a guess on the rear bumper side plastic mouldings lasting 2 trail rides! __________________

04-29-2010, 11:38 PM	#44
sarge Pure Bacon Join Date: Jan 2007 Location: Trenton, Oh Posts: 1,098	My pile of parts keeps getting bigger , thank god for craigslist. Got the front clean out and got the front cross member tack in . Got one of my packages in the mail yesterday mocked up the front and sat it down on all fours I have two major problems First problem : I have to run at least 2" spacers or have my rims recentered to clear the knuckles and have enough room for my tie rod and drag link. Second : my pitman arm is going to hit the Diff , it is only about an inch above it sitting in the garage. Going to have to get an Astro van box before i can even drive it . Also going to play with the springs alittle , not happy with the front location . Still have to : Drive shafts brakes exhaust flat belly shocks bumpers .............. Last edited by sarge; 04-29-2010 at 11:45 PM.

04-21-2010, 03:11 PM	#29
sarge Pure Bacon Join Date: Jan 2007 Location: Trenton, Oh Posts: 1,098	OK gonna answer a few of the questions , as I have been busy gathering the final parts for the past few days .... first off I need an Astro Van steering box from a 2wd van , anyone got one ? The rear is a 60 Yes the front is CAD . not worried !;) I'm going to run a cable from AW direct , just like I had in the wrangler $43.00 and forget it . I'm welding the rear spiders The transfer case is going to remain the factory 236GM unit for now. This will at least keep the build a little shorter and cheaper for now . Waiting for a 231C to roll into the yard and thinking of doing a 231/231 Doubler ??????

04-21-2010, 11:14 PM	#33
sarge Pure Bacon Join Date: Jan 2007 Location: Trenton, Oh Posts: 1,098	http://www.awdirect.com/easy-glide-p...ngle-gear/pto/ Ok the price went up a little bit since I did the wrangler . unbolt the selector fork assy.( CAD ) on the axle , make sure to unplug vac. and electric lines and put the assy. on the work bench. Pry open the vac. canister that the vac. line plug into and cut out the bladder and then plug the vac. line ports. put vac. canister back together. find a good spot on the driver side of the CAD housing and drill a hole through the aluminum housing to the inside making sure you can continue to drill into the CAD fork asstraight as possible and as close to the Forks slide shaft. Make hole just big enough for the threaded end of the PTO cable to go through. Now counter sink the outside hole to the size of the outer cable. Find a good spot on the inside of the rig to mount the pull handle , make sure you pick a spot that can handle a good tug with out bending or breaking . Route you cable through the fire wall and down to the CAD unit with the least tight bends as possible. Put a dab of RTV on the hole in the CAD housing and run the cable through and into the fork, bolt the cable to the fork using lock tight. bolt CAD housing back to axle. When you get the cable you get a cable clamp and nut and bolt. I welded the bolt to the axle tube so I could clamp the cable on on the back side of the axle tube out of harms way and straight in line with were the cable enters the CAD housing . This is the readers digest version and with out any pictures , but the info is out there if you search a little. I have not found a good write up using this cable. I had the cheaper PTO/ Throttle cable however I could not keep the cable from pulling out of the fork after about a day of wheeling. It became a real pain in the arse ...... the extra few buck for the threaded end sealed cable was well worth it and I never had a problem with mine once I switched.

04-22-2010, 09:09 AM	#35
kyrel69 Join Date: Jan 2007 Location: Middletown, Ohio Posts: 372	thanks going to have to do that

04-28-2010, 06:39 AM	#39
sarge Pure Bacon Join Date: Jan 2007 Location: Trenton, Oh Posts: 1,098	it has begun !!!! pullen the Jimmy in the garage this evening, got it on jack stands and started cutting off anything not needed. started with the front end ,front bumper off and most of the the other crap either unbolted or plasma cut off. moved to the back and got it out and waiting for it's new home : 60 in place in the rear...... I ordered a bunch of stuff from DIY4X and Ruffstuffspecialties on Sunday, hoping they arrive tomorrow

04-28-2010, 10:40 AM	#41
sarge Pure Bacon Join Date: Jan 2007 Location: Trenton, Oh Posts: 1,098	front will be stretched w/ dakota springs and the position of the front cross member ..... hoping to get out there today and fab up the front .

04-28-2010, 12:33 PM	#43
sarge Pure Bacon Join Date: Jan 2007 Location: Trenton, Oh Posts: 1,098	wrong , they are going bye bye before

04-30-2010, 12:29 AM	#45
WrenchMonkey Mechanical Animal - CORE Member - - Moderator - Join Date: Feb 2008 Location: Beechmont Posts: 1,883	I personally prefer to run cheaper parts and drink better beer. But to each his own. Robert __________________ DIRTY DEEDS, DONE DIRT CHEAP Whatever doesn't kill you makes you stranger

04-30-2010, 09:13 AM	#46
RuffedUpXJ On XJ 2 Now Join Date: Feb 2007 Location: Fairfield Twp. Posts: 314	Its the Trentonite coming out of him. I don't think they carry anything besides Nati Light, Hudy, and PBR at the gas stations. __________________ 88 XJ - 5" lift - 35" BFG's - Bumpers - Rock Rails - Homebrewed OBA - Roof Rack - Tube Doors - Trimmed - Dented 87 XJ - D44 - Disco D30 - 235's - 231TC - Stock for now

04-30-2010, 11:13 AM	#48
WrenchMonkey Mechanical Animal - CORE Member - - Moderator - Join Date: Feb 2008 Location: Beechmont Posts: 1,883	A man's got to have his priorities, I guess... Robert __________________ DIRTY DEEDS, DONE DIRT CHEAP Whatever doesn't kill you makes you stranger

04-30-2010, 08:03 PM	#49
sarge Pure Bacon Join Date: Jan 2007 Location: Trenton, Oh Posts: 1,098	ok back on track , got an Astro van gear box today and ordered a set of Copperhead Fab H1 centers. Figured I would just recenter the rims instead of searching for spacers. I still haven't got my DIY4X stuff :mad: and the centers will not be here until the end of next week ..... I guess this gives me time to get a bunch of the small things taken care of like brakes and drive shafts and spring mounts. After sitting in the garage pondering what I needed to do I have decided to add a leaf or two all the way around and give me a little room for tires and may not have to trim as much.

05-10-2010, 05:28 PM	#50
KargoMaster Cleaning off the rust... Join Date: Jan 2007 Location: Cincinnati, OH Posts: 1,009	A few things... Everything I get from Kurt has been top notch, and quick... sorry to hear of your frustration... DIY4X is usually a great resource... Completely agree with recentering... Copperhead would not be my first choice for centers... let us know what you think of them. On the AAL idea... just remember that video (that I took of you on Big Wally)of the big yellow monster in '03? the more leafs you add (for clearance or whatever) the stiffer your suspension... 10 more days.... any new updates? __________________ brad 5.0L \| 435 \| 203 \| 300 \| 4.10 \| 39.5 Buildup BACK underway...