Building a new and improved Jalopy frame

I'm sick of how weak and how much the stock 2A frame twists in the Jalopy (I think it flexes more than the springs jeep toss). And now after the *cough* tow bar incident , I figured I should build a new frame this spring/summer. So far, I'm liking the way it is turning out. Oh and since I have free rein on this frame, I'm gonna put coil springs in all four corners off like a Jeep ZJ. :twisted: Another trip to the junkyard!

Right now, it is all tacked together. Next, I'll cap all the ends and put diamonds on the joints for strength.

 

I would use a TJ long before a ZJ. Only because of spring rate. TJs are lighter and thus have a lighter spring rate so you will have springs that might compress some under the light weight of an Early Jeep. Remember we are generally 2/3 to 1/2 the weight of a modern Jeep.

 

I was originally going to use TJ front coil springs all the way around, but the guys over on the wrangler forum said that ZJ springs would be better. Coil springs are like a new technology to me. R) I'm not sure what is best to use.

 

The reason they like them is they give a 1" lift to a TJ because of the higher spring rate. I would go TJ personally. I bet you can ask around on the local forum and find a couple of guys with stock spring sitting around and get them for nothing.

 

Oh, ok. Makes more sense now. There was a set on CL for $50 a while back when I was first thinking of this. I'll keep looking...

 

Geez, I've always wanted to do what you're doing. Looks good so far. What size box tubing are you using?

 

It's 2"x3"x1/8" rectangular tubing. For the two frame rails, I used a little under 12' per side.

 

How about these coils?

http://westernmass.craigslist.org/pts/2318496567.html

 

Whats the worst that happens? You spent $50.

 

Light rig, custom frame where you can position the coils anywhere you want-I would want wimpy spring rates, especially if this is not a dd and most use is going to be off-road. Looking nice, Nate!

 

Thanks duffer. I'm not sure if I want to put it on the road (to get to my friend's trails easier). All it really needs are brake lights, turn signals and a new ws glass. I do want it to flex really easily and something that soaks the bumps up real well too. Some of my trails have wash board and if you aren't thinking and are in 2nd going 15 mph or so, it will about vibrate you apart.

 

Did anybody know this? By adding diamonds to the joints like I will be, it increases the strength of the joint by 3 times or so. That's what my welding teacher told me.

 

I thought about doing this with 1" x 3" tubing.

 

I brought my frame into the welding shop at school today and capped all the ends and welded the diamonds onto the joints. Then I also called up Endangered Species Jeep in Holyoke MA. They have a stock set of used TJ Rubicon springs in like-new condition. I'll be picking those up tomorrow.

 

I picked up my coil springs today and mocked them up under the frame. :twisted: I took some measurements, the center of the Jalopy frame sits 18" off the ground right now. The new frame will sit 26" off the ground when it is on the axles and 31s. Thats an 8" lift! I might pick up another couple of inches when I put the spring mounts and bushings on too.

I referenced the Jalopy to my stock 3A. The 3A sits at 17" with 29s. So that means it has stock height springs in it, but they are not the stock springs. They are 5 leaf 1/4" thick...

 

I made some more progress today. Since I have no channels to run the wiring inside the frame to protect it, I bent up a piece of 1/2" EMT for it. After I run the wiring, I am going to silicone up the ends to keep the mud and crap out. I think I'll run another bigger one on the other side for the battery and winch cables since one battery will be located in the back and the other might go under the dash...



Then, I was going to work on making up some bumpers, but then I remembered I need a power steering box mount. I'll have to notch the crossmember a little for the steering shaft.



I welded on a piece of tubing with the ends cut a 45° and capped that too.



And to mount it, I'm going to plasma cut some holes and weld some 7/16" pipe to run the bolts through and keep it water tight. The outboard side will be flush with the frame, but the inboard will stick out a little to compensate for the saggy box contour.

 

I finished up my power steering box mount and crossmember notch.

I started out by marking out the four mount holes and plasma cutting the holes in.



Then I cut my four pieces of pipe to length and I didn't have any 7/16" bolts long enough, so I cut the heads off some to use as alignment pins to tack the pipe in place.



And finish welded those up.



Then I had to notch my crossmember. This one really hurt.



And welded in a chunk of 4" pipe and voila! A nice power steering mount.



Next, I'll build some bumpers and I'll have to figure out a nice way to mount the warn 8274. Then after that, I'll have to tear the Jalopy apart... I'll miss not being able to drive it for a while.

 

I made a rear bumper today, nothing too special.



And I started on the front one too. I only tacked it on so I can take it off to make winch mounts. I also put the frame up on all four springs. It's really bouncy. This thing is going to be rugged but have a nice ride to it. :twisted: 8)



I think I will have to build a guard for the power steering box. It hangs kinda low...

 

I finished up making the bumper and marked out the holes for my winch (should I start calling a wench?) mounts.



I did the same thing as I did for the ps box mount. I cut holes in with the plasma cutter and welded some pipe in. I cut in a place for the cable and welded some flat stock in to keep it water tight.



I welded the bumper on and that makes the actual frame DONE! Now the fun stuff begins like suspension and body and motor mounts...