Finally breaking down and doing a body lift.

[MrSmithsTB]

After about two months of debating, I've decided on a 2" body lift. I chose 2" over 3" simply because I don't want the extra inch. I'll be able to comfortably fit some big ass tires without trying to push it to a point of failure. Puts me out of the running for the current bumper group buy, but as soon as funds permit, I'm going to hopefully work with Mike to get one for the 2" body lift option. I put my feelers out for spare parts, since I know there is always something sitting in somebody's garage. Some people have come through on the more difficult parts, so I'm hoping to have this finished within the next month. Body lift bolts have arrived:


Blocks are en route, and as soon as a certain member has the time, the bumper brackets will be on their way. Only complication is a steering extension, since Zone doesn't sell individual parts like that. I'll be trying to put my own together or adapt from another model. If that fails, I'll have to wait for Mark to have an extra or get something machined locally. I am quite excited for this! I'll update this thread regularly, if only to document my progress in one place.

[irishboy02]

Cool! Im assuming your going to want to have this done before first snowfall? Let me know, id be more than willing to throw some wrench time!

[MrSmithsTB]

Most definitely before the first snow. As soon as the block arrive and I figure out a steering solution, the lift can get put on and I can run without a rear bumper while I wait for brackets. I do have the front bumper bolts and can pick up pipe extensions for the impact bar anywhere.

[madmanvillain]

the steering part is what is holding me back from doing a body lift...because i have the means to do things like a body lift and not have to spend the money on a big name product...i want to piece something together but i dont know what the steering knuckle looks like...if someone has a photo out there would you mind posting it?

[MrSmithsTB]

Look at the installation PDF on zoneoffroad.com. It shows you what we are dealing with. I'm climbing into the engine compartment tomorrow to get some exact measurements regarding diameter, to see if I can make some off-the-shelf hardware work safely.

[bartonmd]

I can still get you in the GB... Be maybe a little extra coin for the new design, but I'd much rather get the punching and bending done at the same time as the others, to break up that cost...

Mike

[MrSmithsTB]

I can still get you in the GB... Be maybe a little extra coin for the new design, but I'd much rather get the punching and bending done at the same time as the others, to break up that cost...

Mike

Once I have everything in, I'll know if I have the Benjamin's available to donate to the cause. Should be in time for the GB if I can.

[MrSmithsTB]

I finally got off my ass and measured. The OD of the steering shaft is 1" at the base. The fitting on the rack that it slips onto is 17mm DD(thanks MarkMC). So, one option for fabricating an extension would be to get an aluminum(or other hard metal rod) 1" OD x 2"(or 3"... there is 1/2" overlap at the bottom) long and drill out to fit the slip joint and then get a 1" ID x 4"(1/2" overlap at the bottom and 1 1/2"" up the shaft) rigid coupling, drilling through both pieces at the appropriate locations to run bolts through and hold it all together. Or just get the aluminum rod as 1" x 3", drill out the bottom and grind down the top(both to 17MM-DD) and drill both ends to push a bolt through. Realistically it is probably a bit more complicated, but in theory it seems very straight forward and simple.

[MrSmithsTB]

Found some 1" OD round rod for a great price. I'm going to be trying to make my own steering extension with it. As long as it works the way I anticipate, should be just as good as the real thing. All that is left are the bumper brackets now...

[HARDTRAILZ]

I have done many body lifts where all you did was use a piece of metal and weld it to each end of the shaft so if you are worried once you fab something...you could weld it.

[MrSmithsTB]

I have done many body lifts where all you did was use a piece of metal and weld it to each end of the shaft so if you are worried once you fab something...you could weld it.

That is an option I'm keeping on the table, as well as adding 2" vertical to the rear frame rails and just moving the mounting holes up, with some other modifications obviously. I though about bolting flat plates to the frame and bolting the bumper to the plates, but I don't know if that will create the risk of losing the bumper if I am towing or extracting.

[johnburgelin]

I'm interested to see how this steering extension turns out as it seems that's the main thing holding me back from making my own kit as well. What type (size/grade) of bolts did you get and what's the total number, it looks like 12, did you order them from mcmaster carr?

[teebes]

I'm interested to see how this steering extension turns out as it seems that's the main thing holding me back from making my own kit as well. What type (size/grade) of bolts did you get and what's the total number, it looks like 12, did you order them from mcmaster carr?

Correct, 12 (6 per side). Grade 8. Not a place to save a few cents on lesser hardware

[Gordinho80]

As per Zone's site, the kit includes grade 10.9 bolts... and lots of other little things...

12 2" x 3" Lift Block
1 Bolt Pack
1 Bolt Pack
1 Bolt Pack
1 Steering Extension
1 Front Bumper Brkt (drv)
1 Front Bumper Brkt (pass)
2 2" Front Bumper Spacer
1 Radiator Brkt (drv)
1 Radiator Brkt (pass)
2 Bushing
1 Rear Bumper Brkt (drv)
1 Rear Bumper Brkt (pass)
1 1/2" Bolt Fish Wire
2 5/8"-11 nut tabs
4 1/2"-13 x 1-1/4" bolt tabs
1 0.750 x 0.095 x 2.000 Spacer
1 Spare Tire Winch Bracket
1 Loctite

I wouldn't mind a body lift... but its just not in the cards right now...

[teebes]

As per Zone's site, the kit includes grade 10.9 bolts... and lots of other little things...

12 2" x 3" Lift Block
1 Bolt Pack
1 Bolt Pack
1 Bolt Pack
1 Steering Extension
1 Front Bumper Brkt (drv)
1 Front Bumper Brkt (pass)
2 2" Front Bumper Spacer
1 Radiator Brkt (drv)
1 Radiator Brkt (pass)
2 Bushing
1 Rear Bumper Brkt (drv)
1 Rear Bumper Brkt (pass)
1 1/2" Bolt Fish Wire
2 5/8"-11 nut tabs
4 1/2"-13 x 1-1/4" bolt tabs
1 0.750 x 0.095 x 2.000 Spacer
1 Spare Tire Winch Bracket
1 Loctite

I wouldn't mind a body lift... but its just not in the cards right now...

Ahh, but there is a difference between 'Grade' (SAE) and 'Class' (ISO). The bolts in the kit would be 'Class 10.9'. Class 10.9 are equivalent to Grade 8 bolts as far as Yield/tensile strength. This is useful info found on Pirate, a good read for all: http://www.pirate4x4.com/tech/billavist ... signed.pdf (scroll down to the fancy chart)


+1 on the other stuff.. Like the radiator mount brackets...

[Regulator1175]

Here is some info from my do it yourself body lift.

I purchased the 3" blocks from Zone. They should be easy for anyone to find.

The bolts for the body came from Fastenal, listed below. Item 1 is for the front two body mounts, you need two. Item 2 is for the remaining body mounts, you need 10. Item 3 is for the front bumper, you need two.

As far as brackets go, the front bumper brackets were just 3" pieces of pipe with washers on either end.

For the radiator support I used a couple pieces of the sheet metal cut from the front bumper and bent it to fit as a form of strapping for the radiator.

The rear bumper brackets were donated. (Thanks Kyle.) As far as bolts, I used grade 8 nuts and bolts from Lowe's. They seem to be on of two pieces in the set-up that need major custom work.

As far as the steering extension, I got that part from Mark. I would imagine he may be willing to sell just that piece, but it will take someone to contact him to find out.

Fastenal bolts:

1) Part number 35112 M12-1.75 x 240mm 10.9 DIN 931 Part Thrd Plain Hex Cap Screw
2) Part number 0122040 M12-1.75 x 190mm 10.9 DIN 931 Part Thrd Plain Hex Cap Screw
3) Part number 95234 1/2-13 x 10.5 Grade 5 Yellow Zinc Hex Cap Screw

Good luck

[MrSmithsTB]

Mark is willing to sell the extension separately. The only drawback with that is waiting for his source to make them and ship them to him, and then hoping he as extra after filling his kit orders. This is a nice fall back for me, since I will have to modify it to fit a 2" lift anyway. For anyone homebrewin a 3" kit, this would be ideal. I'm looking for alternative solutions right now. One is to take some round rod and try to "machine" it just as the pro versions are. Another idea is to weld some pipe onto the shaft end that will slip over the rack & pinion end to secure. I third option that could possibly work(and keep in mind this is a crude, yet rigid, alternative) would be to cut two equal lengths of 1/4" steel, drill the ends, and bolt them in place on both the shaft and r&p ends, shimming with steel washers where necessary. The third option may be the easiest, but I am wary about it reliability. Nothing would be worse than to lose steering in a city or highway driving situation.

One thing I made sure to not scrimp on was the quality of bolts. I got a complete set from an OS member that upgraded to 3". I have all of the body bolts, the front bumper bolts and extension pipes/washers. I have the hardware to make radiator brackets. Blocks are going to be here Thursday. Once I figure out a steering extension solution I can get the parts installed. Concerning the rear bumper, I will either be using a set of Zone brackets or I will be "slightly" modifying the frame rails and cross member with a cutoff and some angled steel.

[KE7WOX]

Just out of curiosity, can you order from Fastenal without having a Tax ID / company?

[HARDTRAILZ]

I am using my steering extention from the 2 inch with the 3 inch...i believe they are the same.

[Regulator1175]

Just out of curiosity, can you order from Fastenal without having a Tax ID / company?

Yes, I was able to walk into my local store and order them without providing anything but my name.

I am using my steering extention from the 2 inch with the 3 inch...i believe they are the same.

Yes, I have understood they are the same size.