05 Flame Red TJ Build

[NashvilleTJ]

That’s some clean fab work. What did you use to cut out the blanks?

 

[someguysjeep]

i could be a little anal about the way i installed the new body mounts, maybe it was right maybe not.

i did 1 at a time so i didn't have to support the tub really, i left the others torqued and lopped off 1 mount. then torqued the new rubber and mount into place b4 welding. not finger tight...... torqued. then tack it in good, i loosed enough mounts to move the rubber up enough for no contact b4 welding, not so much for it's gonna melt, more the cooking temp could dry and harden it. then torqued um all back and moved to the next and repeat.

 

[someguysjeep]

That’s some clean fab work. What did you use to cut out the blanks?

ahh. no better than factory, but does it have to be?

a hand band saw and a grinder. used my mag drill for the big hole and a punch press at work for the small 1's.
it's not perfect, it could have run over the frame so the weld wrapped around the top of the frame. i figured the back wall of mine helps resit a tear off by adding another leg that would have to fail as well.

 

[JMT]

got a small shop press? get them boys a sheet of steel and a hole saw and let um get at it.

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this was the cut away Savvy bracket i hung the UA from inside the frame. just added a few small gussets. i also poked through jjvw's and toximus' threads for info on this.

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You overestimate my current skillset. Great fab work, nice inner C modification

 

[someguysjeep]

You overestimate my current skillset. Great fab work, nice inner C modification

i may have some left overs around if your interested i'll look for um.

 

[JMT]

The free length of the rear Currie 4” coil is very near 18”.

 

[JMT]

My Jeep is BAD ASS! Love this thing. So fun!

 

[Wildman]

My Jeep is BAD ASS! Love this thing. So fun!

OK dude spill the beans.... Where did you go or what did you do??

 

[JMT]

OK dude spill the beans.... Where did you go or what did you do??

Can a guy not just enjoy his Jeep?! Damn!

 

[JMT]

Ok, I did do something. Installed the T-Flex Hand Throttle. I added the small thimble caps to the sheath, a part well known to cyclists, but not part of the kit. Add on both ends for a clean install. Using this thing everywhere I go now! Cool and useful mod! I’ll try on trails tomorrow. Used it a bit in a housing development this evening.

 

[JMT]

that setup in the last pic, it didn’t work, so I went to the hardware store and made it right. More pics tomorrow. I’ll have to adjust a few things to make it perfect. I started to head off to the ORV park and when I shifted into 1st the lever hit the dash. Shitty instructions. I fixed the lever, but I can make it better.

 

[Mike_H]

that setup in the last pic, it didn’t work, so I went to the hardware store and made it right. More pics tomorrow. I’ll have to adjust a few things to make it perfect. I started to head off to the ORV park and when I shifted into 1st the lever hit the dash. Shitty instructions. I fixed the lever, but I can make it better.

I think I have most of the stuff required to make a hand throttle, if you wouldn't mind posting those instructions.

 

[NashvilleTJ]

Nice clean install there, JMT.

 

[JMT]

I think I have most of the stuff required to make a hand throttle, if you wouldn't mind posting those instructions.

Sure. Here’s a pic of the final setup. The c clip they give you is junk, I saw the washer idea in a pic from @Alex01 somewhere.

 

[JeffG]

Today I took the afternoon to do a fix I’ve been thinking through for a month or more. I learned a lot, and this is a novel solution that could be a write-up for people with the 05-06 manual with MML and BL. The problem I encountered with this setup is that the transmission and TCase are so low relative to the tub that the shifter attachment falls right down into the lower rubber shifter boot and rips it to shreds.
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The problem is compounded by the angle change that leans the shifter knob that comes out of the transmission back. Then all the heat starts moving into your cab, which is not fun. What I learned is why the real answer is a TT, but if you don’t have $1600 at the time, here’s a way to fix it so you can stop your feet from feeling like they are in flames :flamethrower2:. If you live in a very cold area, you might not want to do this fix, just enjoy the extra heat!

The 05-06 console is unique. It is not nearly as easy to finagle as earlier model Jeeps. What I needed to accomplish was two things. First, extend the shifter about 1.5”. That will almost get the attachment out of the lower shifter boot. Second, move the center console area back 1”. This is the maximum distance you can move it, since the rear of the console runs into the tub in front of the back seat and your TCase lever and Parking Brake will hit the console too.

1. Remove your shifter bezel by snapping it outward at each of the four corners
2. Unscrew your shifter from the Tranny portion (star pattern bolt about 3/4” long)
3. remove the shifter
4. Remove the 10mm and 8mm bolts holding the lower shifter boot to the tub. Keep it for practicing your template later on. Here’s what it should look like at this point.
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5. You’ll see the black clips at the mounting locations. There’s no need to remove them.
6. Modify your old lower shifter boot by cutting 1 1/8” off the rear corrugated section and the side that hits the TCase mount. Here a pic of the old and new side by side so you can see where I cut (I used tin snips).
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7. Mount the old one in the hole and trim more as needed till you have it 1” back.
8. Mark new holes 1” above your other holes (except the top hole which you can no longer use) and drill them.
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9. Check for figment and trim if necessary.
10. Re-install with 10 and 8mm bolts.
11, stick the transmission portion of the shifter up through the hole. I put some Vaseline there just so it would have a lubricant and wouldn’t damage the rubber, but probably not necessary.

Now we are 1” back!
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12. Extend your shifter knob. The bolt size is M8x1.25. And you’ll need it 2-2.5” long, with a spacer and I needed a few washers to take up the slack. Here’s the stock one beside the new extended one.
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Install that puppy and you should be relatively ready to go. It’s not a perfect solution, the shifter is still too far back, but that’s due to the angle.

In Neutral
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In 2nd
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Back together. Everything worked!
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Now no more heat in the cab! This solution allows me to just move everything back forward when I do the TT. I didn’t have to drill the tub, except the new mount in the cup holder. I just used a self tapping screw.

I hope this helps someone out there!

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Hello. Are you still monitoring this post I have a question.

 

[JMT]

Hello. Are you still monitoring this post I have a question.

I can try. I removed that mod about 1 year ago, so I have a general idea what I did. It worked fine for the time I had it.

 

[JMT]

I love this rig. Everything is dialed in perfect. It just works beautifully. The anti-rock has really stabilized things, especially with the 4:1 Tera Low, and the Hand Throttle. I have so much control. I absolutely love it. Even with that 82:1 ratio, and the jeep so slow, I can still, when aired down make crazy steep hill climbs in loose dirt. It just crawls. I’m so pleased and this was my goal before Moab. I do have to admit though, it’s a bit slow getting around

 

[NashvilleTJ]

That’s great news, JMT. How are you liking the Razr‘s so far?

 

[Apparition]

I love this rig. Everything is dialed in perfect. It just works beautifully. The anti-rock has really stabilized things, especially with the 4:1 Tera Low, and the Hand Throttle. I have so much control. I absolutely love it. Even with that 82:1 ratio, and the jeep so slow, I can still, when aired down make crazy steep hill climbs in loose dirt. It just crawls. I’m so pleased and this was my goal before Moab. I do have to admit though, it’s a bit slow getting around

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So you don’t miss disconnects?

 

[JMT]

That’s great news, JMT. How are you liking the Razr‘s so far?

Absolutely no complaints. They hook up great in mud, loose soil, snow, the rocks I’ve been over (all dry). But they are practically brand new. Time will tell more. My goals were to have a tire that performed better on snow and wet rocks than the STT Pro’s. Bottom line is I’m being very picky. This is an experiment arising from OCD.

Discount did put clamp on weights on the inside when I told them not to, so I’m going back soon to get that crap fixed.