Mildly Out of Hand 02 Sahara Build

I’ve definitely reached the limit of the jeep in this setup so I’m going to be redoing the suspension pretty drastically. Looking to do a 5 inch rear stretch with 12 inch 2.0 coilovers all around with a mid arm. I’m bad at updating the forum so I’ll keep everyone posted if I remember. I’ve been collecting parts for months now.
 
Installed my genright tank Saturday to get a head start on my stretch/ 4 link. Unfortunately I didn’t realize that the tank covers up the stock shock mounts, which normally wouldn’t be a big deal but I need to drive my jeep to koh later this week.

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This left me no choice but to make some temporary shock mounts to run for basically the next couple weeks. They hang low but tuck up behind the tire and they cycle well. Should buy me some time before the coilovers go in.
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I’m super happy with the genright tank I have plenty of room for the stretch and didn’t have to sacrifice any capacity. @DylanM345 can continue to abuse my old savvy skid that’s served me well over the last few years.
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Also threw in my cable t case shifter which has been laying around.
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And here’s a sneak peak of what’s to come.

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It went down this weekend jeep wise. Worked on the Jeep from 8 AM to Midnight on Saturday and 8 AM to 3 AM Sunday to get my Jeep off the lift and rolling. I ended up using a savvy truss, TMR link brackets for the frame side on the top setting (this puts them 1/2 an inch lower or so then savvy). I will measure the exact stretch I ended up with but was shooting for around 5-6 inches. I used Poly Performance towers for my shocks and the shocks are 2.0 12s. Travel bias is 50/50 but the tire slightly rubs the spring under articulation. The internet was right when they said coilovers on stock width axles are tough. I looked through photos of @L J s Jeep and have concluded that Blaine really is a wizard making those shocks work with 3.75 inches of backspacing and full 12 inches of travel. Still need to finish a few things, but figured I'd throw down some photos. My Jeep is staying semi lower with around 19ish inches to the frame rail. This posed some challenges that resulted in notching the floors and welding in some 3 inch exhaust pipe. I also had to notch the factory crossmember. I must have cycled the axle a hundred times. For anyone doing a project like this I wouldn't recommend the 1 weekend strategy, but with a lift a few buddies and lots of beer it turned out pretty good.
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Next up is take it all apart to paint, exhaust work, bumps, and limit straps. Then I will use the savvy kit for a front three link. I think I'm going to keep it coil sprung in the front until I am ready to stretch the front on wider axles too.

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PS don't judge my welds too harshly still new at that. I did get pretty good with a grinder and air chisel. Cutting off all those brackets was a serious PITA
 
Also wanted to say thanks @Alex01 , @Sj's TJ , @starkey480 , @L J. The photos measurements and answered questions saved me some time and were a huge help. I'm excited to get back to wheeling in this thing. Here's some bonus photos of the little TJ on chocolate thunder Friday night the last weekend of hammers.

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And a random photo of some snow in the Central Coast of CA!
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It went down this weekend jeep wise. Worked on the Jeep from 8 AM to Midnight on Saturday and 8 AM to 3 AM Sunday to get my Jeep off the lift and rolling. I ended up using a savvy truss, TMR link brackets for the frame side on the top setting (this puts them 1/2 an inch lower or so then savvy). I will measure the exact stretch I ended up with but was shooting for around 5-6 inches. I used Poly Performance towers for my shocks and the shocks are 2.0 12s. Travel bias is 50/50 but the tire slightly rubs the spring under articulation. The internet was right when they said coilovers on stock width axles are tough. I looked through photos of @L J s Jeep and have concluded that Blaine really is a wizard making those shocks work with 3.75 inches of backspacing and full 12 inches of travel. Still need to finish a few things, but figured I'd throw down some photos. My Jeep is staying semi lower with around 19ish inches to the frame rail. This posed some challenges that resulted in notching the floors and welding in some 3 inch exhaust pipe. I also had to notch the factory crossmember. I must have cycled the axle a hundred times. For anyone doing a project like this I wouldn't recommend the 1 weekend strategy, but with a lift a few buddies and lots of beer it turned out pretty good.
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Next up is take it all apart to paint, exhaust work, bumps, and limit straps. Then I will use the savvy kit for a front three link. I think I'm going to keep it coil sprung in the front until I am ready to stretch the front on wider axles too.

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PS don't judge my welds too harshly still new at that. I did get pretty good with a grinder and air chisel. Cutting off all those brackets was a serious PITA
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May be time to edit the threads title.
 
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You’re probably right. Let me know what ya think

Much better. I don't know too many mild builds with coil overs and a stretch. Are you pushing the front forward at all? I assume coils are going to that corner next.
 
I wouldn’t go that far she’s still rockin a 231 and the ol dirty thirty.

In that case, what's in between a M and W? You're definitely on your way to W. The 30 you can get away with. Where's your atlas?
 
Much better. I don't know too many mild builds with coil overs and a stretch. Are you pushing the front forward at all? I assume coils are going to that corner next.

I think I’m going to hold off on the coilovers until I get wider axles one day and do a front stretch at the same time. I’ll probably do some 2.0 smoothies with a resi with the regular mid arm setup.
 
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99% of my rear suspension work is done. Got my bumps frenched into the frame, finished all my welding and painting, adjusted ca's, cycled a million times, made some bump pads, and trimmed the body. All that's left is messing with spring rates, mounting my resis permanently, cleaning up my fender cut, new smaller muffler, and adding rear fenders. I also plan to extend the sliders, and add corners, a sway bar, and mess with shock valving one day .
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I ended up with around 98 inches of wheelbase and 6 up 6 down, however the tire rubs the coil spring under articulation, which was expected with such narrow axles. The setup will be perfect with waggy axles, jk axles, or maybe sixties who knows.

This was certainly a cool learning experience and the Jeep drives great! I can't wait to wheel it and get cracking on the front half of the Jeep.

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Edit* here is how it sits, ride height will need to be tweaked to get rid of the rake and stuff. For now it'll live in mullet mode with the mid arm rear short arm front.
 
I was in a pretty serious accident about a month ago that left my hand and wrist unusable for the next year or so. With all the recovery and surgeries the jeep has been sort of put on hold now that I haven’t really been able to work on it, go to work, and I still want to graduate college in June. However I did have some buddies lend me a hand and I got my new corners and sliders mocked up.
Before:
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before trimming rear arch.
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After trimming
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I’m still torn on whether or not to do a rear fender flair. Let me know what you guys think.
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This will all be done in black when it’s done.

Last little update was that I also snagged some air bumps for the rear for a super good deal

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