Ironman: Prototyping

[ironmanandy]

I have finally gotten caught up with all of my orders for the first time in 2 years. Its an amazing feeling. I have been working on a ton of prototype Ideas for a while and I decided that I would share the pieces and parts here in the fabrication section because that is exactly all this is.

I finished my P-type double shear track bar bracket tonight. I only wanted 3 parts and only 1 bend. The drawings will go to a laser guy later this week but here is my hand made P-type

http://i494.photobucket.com/albums/rr308/ibuildbigtoys/DCP_3680.jpg

I use a miller 350P pulse Mig welder with a 3 part gas to keep the splatter to a minimum. I only do that stacked dime looking welding for my own personal parts. everything else gets a constant heat stitch type weld.

http://i494.photobucket.com/albums/rr308/ibuildbigtoys/DCP_3681.jpg

The extra set of holes is for a cross bar going to the opposing side of the frame for extra stability.

http://i494.photobucket.com/albums/rr308/ibuildbigtoys/DCP_3682.jpg

I think its important to do as few pieces as possible so I integrated the angle gusset into the lower support. This also allows for longer welds with less stopping and starting. The origin and termination of a weld is the most common fail point. Thankfully miller designed this machine with what they call background voltage, This eliminates cold starts.

[ironmanandy]

I didn't get to spend any more time on this today. but I hope to have more up for ya'll tomorrow night. I ended up spending the evening machining an anti sway setup for a local buggy. Who knew an old YJ sway bar could be turned down and put on a comp buggy :eek:
Its fun to be building new and different stuff again :D

[BlueXJ]

Beautiful welds.

[ironmanandy]

Thanks Dude,
I made the cross bar tonight but no pics yet I;m going to mod the bends a bit more before I show how it works I want extra clearance to work on all lifts.
A-

[ironmanandy]

Here is the final cross member design. I also included the adjuster for the Monster track bar!!!!
http://i494.photobucket.com/albums/rr308/ibuildbigtoys/DCP_3695.jpg
Side View
http://i494.photobucket.com/albums/rr308/ibuildbigtoys/DCP_3694.jpg
Mtn Dew Cap Not Included LOL
http://i494.photobucket.com/albums/rr308/ibuildbigtoys/DCP_3692.jpg
Cross member for Track Bar 1" solid
http://i494.photobucket.com/albums/rr308/ibuildbigtoys/DCP_3693.jpg

I will do two different track bars for taller lifts and lower lifts for clearance purposes. This adjuster for the track bar (Not Shown) if for the lower lift track bar.

[Mudderoy]

I copied this out of the fabrication section so people could post up questions and feedback without having to be moderated.

Wow this is nice! Until Andy told me (I didn't read) I thought this bar was the track bar!!!! It's just the brace! :eek: :rotfl2:

[ironmanandy]

Here is the the bar in place on my 90 2 door

http://i494.photobucket.com/albums/rr308/ibuildbigtoys/DCP_3699.jpg

side view:
http://i494.photobucket.com/albums/rr308/ibuildbigtoys/DCP_3697.jpg

Final product.... word is Rene already claimed this set.
http://i494.photobucket.com/albums/rr308/ibuildbigtoys/DCP_3714.jpg

http://i494.photobucket.com/albums/rr308/ibuildbigtoys/DCP_3713.jpg

I want to sell about 5 sets of these to guys to test out. I need about 250.00 for the kit. I will be selling them for around 300.00 once we know they are perfect.

[ironmanandy]

I have Finished Prototyping my cross member for my long arm system and Thought I would share a few pics with ya'll of the final product before I release them this weekend.

http://i494.photobucket.com/albums/rr308/ibuildbigtoys/DCP_3729-1.jpg
http://i494.photobucket.com/albums/rr308/ibuildbigtoys/DCP_3728.jpg

[4.3LXJ]

Andy, I like how the center unbolts. This is a criteria I utilized when I made my own.:thumbsup:

[alwaysxj]

i had a cross member that i made for my long arms, kind of like this. but man this one is way nicer. great job.

[Mudderoy]

Yeah looks really clean. I like putting products like this on my Jeep. :patriot:

[CT99XJ]

I am digging that crossmember.

[rugidone]

Really like the xmember design! Great Work!

[Mudderoy]

Andy did you give any thought to building more of a boxed design? Connection not only of the bottom of the uni-body but up the sides? I'm sure if would be stronger, but is it necessary or at least a good idea?

[4.3LXJ]

I have seen one or two that did that. Might interfere with rock sliders down the road.

[Mudderoy]

I have seen one or two that did that. Might interfere with rock sliders down the road.

I was talking with Andy earlier, and he said it is bolted and welded to the uni-body. So I understood why it wasn't boxed then. Should be very strong.

[JENSSEN]

Make some engine plates for guys who rip the bosses out of the engine block, the more holes they hit the better :)

[ironmanandy]

lol one thing at a time I gotta get these things out for testing and sell a few before I move on to other parts. LOL
a stock replacement crossmember is next
ANdy

[ironmanandy]

I have been working around with a lot of long arm Ideas. Ignore the threading on this arm because its just a mock up I made the main piece too short but The high ground clearance and tire clearance are the goal for these radius arms.


http://i494.photobucket.com/albums/rr308/ibuildbigtoys/DCP_3736.jpg
http://i494.photobucket.com/albums/rr308/ibuildbigtoys/DCP_3738.jpg
http://i494.photobucket.com/albums/rr308/ibuildbigtoys/DCP_3737.jpg

What yall think?

[4.3LXJ]

As far as clearance goes, I think the tire clearance and ground clearance are great. The only question I would have is where the track bar and top link might meet on full stuff. I am thinking that if you did not market it as a kit compete with bump stops you might have problems with people who buy stuff and then neglect to bump stop properly afterwards. That would be a headache you don't need.

[ironmanandy]

the track bar is nowhere near the path of travel, that's just an illusion in the pic. The track bar is a good 3 inches in front of it.
A

[4.3LXJ]

Doh, you're right. How stupid of me.

[ironmanandy]

Dude, Not stupid at all. That is why I post these things up here so that people can ask questions because I need different points of view and schools of thought. Thanks for mentioning. There is no such thing as a stupid question. only stupid answers

[4.3LXJ]

The really bad part about this is that back in the day, I used to design and build suspensions. And I know XJ suspensions forwards and backwards. I was looking at that thinking, OK now what is some candidate for the Darwin Awards going to do that is really dumb and blame him for. I completely forgot about the positioning.

[drew91xj]

is your crossmember going to be a drop crossmember at all or factory level? ill be upgading my la crossmember eventually and i'm looking for a flat cossmember like factory to gain my belly clearance back.