Build Project Iron III Oxide: A Snowball Effect

Did some flexing and measuring tonight. I think I have a way forward with my limit straps all around. The rear isnt too bad but the front needs it pretty bad haha. These are heavy axles and Id hate to have them hanging on the shocks but the front might max out the TRE before it stops on shock travel.

I ordered some double shear 1/8" tabs and some single shear 1/4" tabs to play with. Looks like I need some 18" straps all around, which makes things easy, but depending on how I put these brackets, it might go down in length.

I was also admiring my driveshafts. Both front and rear are fairly well tucked up above the arms so boulder face sliding should be fine.

I also measured for my brake lines up front so I need to get those ordered tomorrow as well.

After this I think its fluids and start time.

OK, got off the phone with Chris at Hotwire Auto. Turns out with the OD Off switch, the Orange OD Switch wire gets toggled to ground.... but in order for the LED to function, the Green OD Lamp wire IS ground....switched +12V. So the positive side of the momentary button needs to have keyed power and the green completes the circuit when toggled.
Mildly frustrating (no fault to Hotwire Auto, mind you) since I have to do a little more wiring adjustments in the cramped space, but really not terrible :)

Woo, finally got this stupid OD switch mystery solved

So yeah, OD switch wire touches ground to signal OD OFF, and the OD lamp wire is fed +12v from a switched power source.

For future internet sleuthers, the OD Off switch wiring for the Jeep 46RE (and probably others) is:
-OD switch wire = +12v. Ground on other side of switch to momentary contact (not latch)
-OD Lamp wire= ground side for the LED. +12v switched power fed on other side.


As far as other parts go, I ordered:
-Front brake lines
-Limit straps brackets
-Rockjock antirock for the front.
I dont think I will be running a sway bar on the rear. The one on the TJ was always so anemic and it didnt do much of anything so I will run a front. If it comes to it later I can always slap one on the rear but I dont think it will be necessary.

Took a few minutes to make some labels for the switches

Well I built up the courage to put some gas in the tank tonight and guess what. She fired right up!

I only let it run for a few seconds because I didnt have any coolant or tranny fluid in it yet. So that was next. Filled up the tranny, radiator, differentials and the transfer case. Not gonna lie, been anxious about this part and wondering if something deep under a bunch of accessories was going to leak.

So far so good.

Tomorrow I get my brake lines for the front so Ill be able to get some stop with my go.

Ill have to figure out my limit straps after that.

After the weight of driveshafts and fluids, I am DEFINITELY going to need to put a spacer up front. It is crazy how quickly that weight adds up. Im about an inch off of the speedbump stops. Id like more.
I have a 1" spacer set up front and a 5/8" spacer for the rear.

I still need to figure out how to order proper AC lines. I have no idea what Im doing there and man there are a ton of connections to choose from.

Other than that, I think the next stop is the exhaust shop.

Wwwwooooooo it runs! Hell yeah brother! internet high five

I got my brake lines in today so I set off to install them. I tested everything before committing just to make sure I had enough slack at extremes as well as not too much at ride height or compression to where the tire would rub. It looked good so I committed to install them.

Before that, I wanted to tackle the front suspension spacers. I had a pair of JL spacers for the front, since the speedbumps have a bigger diameter than the stock TJ bump stop. I went to install it and found it was JUUUUUUST a hair too small on ID to fit over the speedbump tube. So off to the trusty chicom lathe. I swapped out the jaws and clamped the outside and took the inner diameter out a few thou. Snug fit and it was on.

Spacer installed and the ride height is much better. Plenty of overhead between the bump and bump pad.

Then I installed the brake lines. All good.

I also replaced the drag link boot at then pitman arm. I think some power steering fluid soaked into it at one point in the past 6 years and it degraded. The other side looks fine.

Always expecting a gotcha and I found one haha. Luckily it is relatively not horrible... but will take some work. One of the plug welds on yhe front axle is weeping significant enough to leave a half dollar size puddle on the shop floor over night. So the plan here is to drain that fresh beautiful fluid back into the jug, spray it down, grind out the old factory weld, preheat with a torch and burn in a new weld followed by post heat. I suspect it may have pulled a bit when the truss was welded on and cracked. To be fair the factory weld looks terrible in the spot where it is leaking on the plug so the truss probably pulled it juuuuust enough to make it weep. Oh well... glad it happened to show now and not leave me stranded somewhere. I was tempted to just jb weld it but decided that was not proper

So I got the cover off and hosed it down. I plan to put the cover back on, use a carbide bur ball bit to clean up the old weld them burn it tomorrow.

After all of that is done I should be able to bench bleed the master cylinder and bleed out the brakes. Go, meet stop! :)

Well done
I bet that felt good.

D_JEEPER said:

I also replaced the drag link boot at then pitman arm. I think some power steering fluid soaked into it at one point in the past 6 years and it degraded. The other side looks fine.

Click to expand...

I've noticed that TRE boots don't hold up worth a FAWK anymore. I've pulled new TREs out of the box and the boots are degraded and showing cracks. I think Off Road Design sells a polyurethane boot...

The Freeak said:

I've noticed that TRE boots don't hold up worth a FAWK anymore. I've pulled new TREs out of the box and the boots are degraded and showing cracks. I think Off Road Design sells a polyurethane boot...

Click to expand...

Yeah if this is a reoccurring thing, I'm going all poly. The only thing I can think is the power steering fluid ate it up (apparently that's a thing). Every time I was working on the jeep and noticed the TRE boot was wearing out before I even had a chance to use it, it was like salt on a wound of how long this jeep has been just sitting and rotting away

Oh, I forgot a pic of the weeping plug weld