Its been a minute since I started the Atlas, higher tuck and 35s project. But I have some progress to report. Although the case has been test fit with the new Genright crossmember and mocked up with
@Alex01 ’s UCF 1” drop skid for a while, I finally got the shifters and console buttoned up and having been working on numerous details underneath and today I got the exhaust mods done.
I’ll start with the shifters. With the Atlas clocked at 7 degrees down, 1.25” body lift and 1” drop (internal) skid I was able to bring the 2 speed TJ mechanical shifters through the stock hole without cutting any sheet metal (though I did clearance the tunnel from underneath).
View attachment 511903
View attachment 511902
I plugged the 4 holes for the stock shifter linkage with 7/16” plastic hole plugs from Lowes.
Next, I needed to deal with the shift boot. Advance Adapters supplies a 2 stick boot which could cover the stock tunnel hole almost perfectly but the 2 boots are side by side and the sticks are arranged front and back. I called AA about this they said its a universal boot and shared various MacGyver methods they had seen their customers use. For example, inverting the boot since the bends in the sticks do make them side by side below the sheet metal or cutting a 2nd hole in a single boot. I had actually considered both of these but ultimately decided on something else. Using a piece of inner tube, I made an inner boot with a slit which I attached with silicone and five M5 machine screws through the stock holes.
View attachment 511907
View attachment 511904
Then using the 5th hole on the drivers side and a 6th which I drilled and put an M5 rivnut in, I put on the AA universal boot sideways as an outer boot.
View attachment 511905
I didn’t seal between the 2 with silicone. I’d rather any small amount of water that gets past the inner (which I predict will be minimal) leak out and evaporate instead of be trapped and get nasty. I can seal later, if I’m wrong about that. This seemed to give the best stick freedom from binding of any of the methods. Now to get the console back together. With my heated seats, ARB air pump behind the passenger seat and sound system equipment under the driver seat (I’ll post details on that later) there is a lot a wiring under the console. In the pic below, you can also see where the tub had to be pushed up/left to clearance the new the transfer case (red arrow). Less obvious is the clearancing for the shift linkage (blue arrow) except where a pole jack slipped and put a sharp dent and a tiny perforation in the sheet metal
I patched that with silicone underneath and gorilla tape inside.
View attachment 511924
But it all came back together well.
View attachment 511908
I bought aluminum shift knobs from AA (it came with black plastic knobs) to match my AX-15 shifter. Nevermind how it all works, the cool factor of the twin sticks could almost be worth the money and effort by itself
View attachment 511909
The next time consuming thing: Today the exhaust got done. Not surprisingly, A higher tuck (2.5” to 1” drop) and the change from stock transmission mount to a Genright crossmember required exhaust changes. My exhaust is a custom stainless 2.5” set up done locally that I had already had revised after some earlier changes. I decided this time I would attempt it myself. I recently built a stainless system for my tow rig. Much of that just slid together but I did need to do a little cutting and welding. Since I now have the 309 wire and trimix gas for MIG welding stainless and since my TJ system took such a beating on the Rubicon last fall, I thought it was a great opportunity to try this revision myself.
I won’t bore anyone with too many details, but it was an all day project. Basically, I had to move the catalytic converter forward 7” to clear the Genright crossmember, the normal exhaust hangar which attaches to the stock transmission mount plate had to be refabricated and a bunch small tweaks to make it all work were necessary. Here it is at the tacked together stage.
View attachment 511932
Here are the pieces after final welding, ready for reinstall. The exhaust is stainless but the crossmember is carbon steel so I had to switch wire and gas on my welder several times today so I could use the right process for tacking and the final welds for the different parts (PITA). You can also get a nice look at some of the self clearancing which occurred on the Rubicon.
View attachment 511933
The finished product. The welds certainly aren’t pretty especially compared to the very nice adjacent TIG welds. MIG welding stainless is challenging. You have to move more quickly. I turned off the lights in my shop and put a light inside the tubes at the welds check for leaks. I found and patched 3 or 4 pin holes. Overall, I’m satisfied. Its better than my last attempt
View attachment 511940
I had to weld a new hangar on the tail pipe due to the change in height of the system here.
View attachment 511937
And for better perspective front to back:
View attachment 511945
View attachment 511944
Here is the a pic of the completed transfer case install. Fluid is in (I like the sight tube). 4WD switch and speedo are hooked up with new 32T gear to compensate for the jump from 33s to 35s. New Tom Woods driveshafts are in. I also want to use this shot to point out some of the many simple but useful things I’ve learned from
@mrblaine.
1. Using rubber coated straps to elevate and bundle the fuel, brake and electric lines on the frame rail. Tidy and protected.
2. Using counter sunk bolts in place of the standard head bolts on the lower left side of the Atlas to increase clearance on the low side.
3. Instead of welding the stock exhaust hanger from the transmission mount directly to the Genright crossmember, it is welded to a plate which is attached by bolts to a tab welded onto the crossmember. The exhaust can be removed without supporting the drivetrain and dropping the crossmember.
View attachment 511938
This is the UCF DIY 1” drop skid in 3/8” 6061 aluminum. It differs from the standard ultra high clearance skid in that it lacks the transmission support and central holes.
View attachment 511941
Here’s a look at the clearance between the Atlas and the UCF DIY 1” drop skid. Plenty, but it would be significantly closer without the recessed bolt modification. Thanks Blaine.
View attachment 511939