Project XJ

[Jeff]

So I made some quick moves and got most of my suspension prepped this weekend. I only had a few hours to spare so I was proud. I will likely re-post these same pics (remove them from this post) to build a more complete buildup. Basically the two projects underway are convert the JK shocks and build the "Bastard Packs"

JK shock mod:
Here are the stock JK shocks I got from my buddy Zach. They are from his wife's 2008 Wrangler X with the S-package (better springs and shocks, but not quite Rubicon status) They have 3000 miles on them.


Part one is simple, remove the dust covers. Why would I do that? Well, dust covers and boots trap more stuff then they keep out. This is evidenced by the fact that my OEM covers (metal) are all rusted apart while the rest of the shocks are ok. They hold in the road salts and mud. So f' um.



Easy enough! Screwdriver and they are gone. Next up is the only real mod you need to do to make them work. The rears will bolt right in. however the fronts require the installation of a bracket n the bottom of the shock where there is currently a bushing. So I must push out the metal bushing from the rubber and once I remove it from my old OEM shocks later, install the bracket. To give you an idea...


Left is obviously how they look now, I need to install a bar as shown on the right on the rear shock. Here are some pics of the pressing the bushing out.







So with that the shock project is done for now! See the poll, I think I want to paint them up while I have them out...lame I know but it does look neat. VOTE!

Anyway, next is the initial prep of the rear leaf packs. This, much like the shocks cannot really be completed until I have the oem stuff out, as I am using the top spring from the old XJ leaf pack. But prep is important and saves time later, much like cooking.

These springs are stock rear leafs from a 1989 S-10 pickup 2wd, 8ft bed. They have almost 11in of arch from the floor to the bottom of the overload leaf.



I am using the top leaf from the XJ pack so I will not need the eyes on each end of the spring. First step is to remove them with a cut-off wheel.





Next is to remove the spring clamps. I'm not sure if I am going to be re-using these or not so I just cut the bolt out of them for now.




The final step in disassembling the pack is to place it in a C-clamp of a vise and remove the center pin bolt. These are old so the answer is cutoff wheel.





Now the only thing holding the springs together is the vise...let it loose slowly...





The result of all that cutting and grinding!


Now all I need to do is clean up the leafs. I have a friend with a sandblaster, he is gonna make um purdy for me then its time for paint.

Both springs tore down. I then cleaned them with degreaser and a wire brush. I will do a better job posting the complete spring buildup once I get some parts and some more pics. Holla back!