Custom XJ long arms...

So yeah, I'm building my own custom long arms for my '96 XJ.

Anyone have any ideas/suggestions/tips/tricks??

Any input is appreciated

Backpack

depending on the lift you want...

I'd make a 3 link instead of a 5 link, but you'll need to let it twist some still. look at all the TJ kits out there.

apart from the long arms, it would probably be easiest to use a "kit" for springs and other little things.

If your going to change axles at the same time, coil over shocks would be the simplest route

Yeah....its already lifted on rubicon express zj 5.5" coils and fox 12" 2.0's.  I have the lengthened panhard bar and all that jazz...

I am staying with the stock dana 30 though.

im designing a 3 link with 7/8" f.k. heims on the frame end, 1 1/2" - .250 DOM for the arms.  3/4" heims for the upper axle mount and bushings on the bottom (mostly to absorb vibration and decrease noise).

The biggest problem im having is designing the mounts on the body.  Im pretty sure that im going to sandwich the mounts i make between the stock crossmember and the frame but the stock crossmember supports the trans and t=case.  Will this 3/16" drop ( i plan on using 3/16" plate) affect them at all??   I dont really think it will but i was hoping someone could give me some input on that.  I know thats how the full traction kit works (April '04 on project JR) which is why im assuming the drop of the crossmember wont have any affect.

Backpack

Also, if any of y'all are ever in San Dimas, Ca.  let me know...ill buy you a beer

I'm working on 2 hours of sleep so this may not make since but why not just yank the itty bitty crossmember and build your own bigger better crossmember/skidplate and fab your mounts for arms into it.  

Point well taken...Just make a new crossmember that can handle all the abuse you think you can put towards it. also what process are you useing to weld this all together? the strenght of the welds relies heavily on the process you weld it with. Being a welder, i might be the only one to really think about that asspect of it...Just another factor to consider i guess ya could say...  

I think i might do the new crossmember idea...it would make it alot stronger and basically simpler for only adding a little bit of weight.  The thing with that is ill have to mount my trans and my exhaust to the new cross member.  While i dont expect that to be much of a problem...it is gonna be more work.  The only problem is i dont think my welder will penetrate well enough into the 3/16 or 1/4" plate i plan on using.  i only have a little lincoln 110.

Thats a good point too, and i have thought about the welding considering my entire front suspension and axle will be relying on those welds. 

anyone in so-cal have a 220??

Backpack

ass far as the tranny mount goes just mount it on the tranny coat the area around the holes where the bolts go to mount it to the cossmember/skidplate with a easily seen paint and you'll know exactly where to drill the holds with doing a bunch of pain the ass measureing  

Yea with that lincoln, your really running a big risk with weld strength. Thats more of a hobby welder. Good for exhust and some ornamental stuff. Thats why i dont have me a welder yet, i cant afford the high price of a multi process welder. If you have a buddy that knows how to weld and has a good welder, i would say talk to them, or just look into maybe buying the parts that you need. Also, you can maybe turn up the heat beyond its rated capacity, as long as you cut the duty cycle in half. so if its got a say 60% duty cycle, at 125amps you can run it up to say 300amps at 30% duty cycle, and thats like the 60% duty cycle. The duty cycle of your welder is based on 10 min. So 60% is 6 min arc on, 4 min arc off. Just some knowledge to take into consideration. and Yes i do know what i am talking about as i am going to school for welding here in Seattle Washington.  Not that im trying to talk you out of welding up your own parts, its always good to hear about another thats fabricating some own parts for them selfs. Just i would hate to have you do all that work, and then the first or second time out 4x4ing, have all your welds fall apart and then have you wreck your Jeep.  

so i decided not to build a whole new Xmember.  im just going to cut off the ends of my stock one and weld flanges on the ends that bolt sideways into the new long arm brackets.  also, i decided to weld some C-channel along the frame for 5 or 6 feet to stiffen it and i plan on welding the long arm mounts directly to the C-channel. 

this way i dont have to worry about locating my trans and exhaust correctly on a completely new crossmember.  it saves on weight, materials (money that i dont really have), work and it simplifies the long arm mounts quite a bit...while all the while stiffening the frame.   

so many benefits...ill post pictures but itll definately be a few months down the road because im still in the planning stages of it. 

also....i found out a friend of mine is a welder by trade so he said hed weld it for me, but personally i'd like to use a 220.  does anyone know where i could gain access to a 220 welder for a couple bucks or some beer?  please let me know. 

Backpack

well if your buddy is a welder by trade, he might have a welder and maybe for some beer you can talk him into giving you a lesson or two, let him know you would like to do it your self and see what he says. Never hurts to ask. Good luck to it all.