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 Post subject: BDS Suspension's Project KJ
PostPosted: Wed Mar 20, 2013 5:36 pm 
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How's it going, Carter here from BDS Suspension. I wanted to reach out to this group with a new project rig we're working on. We specialize in building American made suspension lifts and accessories for popular trucks and Jeeps backed with the industry's only no fine print warranty. We are the official suspension for the 2013 Ultimate Adventure hosted by Petersen's 4Wheel & Off-Road Magazine and with that comes the need for a trail rig to take on the trip. We've build plenty of TJs, JKs, and XJs over the years and thought it was time to show the KJ some love. For all the flack the KJ gets we want to build one to be a comfortable dual purpose rig, capable of highway cruising and extreme 4wheeling. We currently offer a 2'' lift kit for the KJ, but this project will require something a bit more custom than a simple bolt on kit.

The problem we've seen with most KJs is due to the small fenders, you need to go sky high to clear a 35''+ tire. Our plan is to build a low slung KJ on 37''+ tires with minimal lift. We picked up an '05 Liberty CRD and plan to overhaul it over the next 2-3 months as time allows in the R&D shop. There's a lot up in the air at this point, but the guys started on the tear down to see the bones of this rig. Basic plans include a SAS, multi-link suspension with Fox coilovers, stubby bumper with recessed winch, full cage, plenty of body mods, engine tuning, and 37''+ tires on beadlock wheels. We'll be posting photos, videos, and writeups throughout the build primarily on the BDS Blog http://bds-suspension.com/blog/?cat=393 as well as posting on the BDS Facebook page https://www.facebook.com/BDSSuspensions, YouTube page http://www.youtube.com/user/bdssuspension, and on a couple forums. Stay tuned for more in the coming weeks as this project starts to take shape.

Here's a video we shot introducing the project,
http://www.youtube.com/watch?v=sXvuQJ2etGw

And photos from the tear down as we start to figure out the cage, front axle, suspension, and body mods,
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 Post subject: Re: BDS Suspension's Project KJ
PostPosted: Thu Mar 21, 2013 8:40 am 
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NICE!!

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 Post subject: Re: BDS Suspension's Project KJ
PostPosted: Thu Mar 21, 2013 3:47 pm 
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The latest update just got posted at http://bds-suspension.com/blog/?p=4553
See the latest video update on YouTube at:
http://youtu.be/avRxrUOLtyA


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 Post subject: Re: BDS Suspension's Project KJ
PostPosted: Fri Mar 22, 2013 12:38 am 
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Saw this on Jeepkj.com, so I am watching it on here!

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 Post subject: Re: BDS Suspension's Project KJ
PostPosted: Fri Mar 22, 2013 8:28 am 
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This is very exciting to watch, and long overdue :BANANA:

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 Post subject: Re: BDS Suspension's Project KJ
PostPosted: Fri Mar 22, 2013 9:26 am 
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Interested to see what y'all do with this. A couple thoughts:
- the mock-up drawing has the rear portion of the roof removed with a jk-esque bar coming down to the tailgate. This might look cool, but you loose a LOT of the utility of the vehicle by doing that. Also, unless you're going to do an exo-cage, that severely damages the strength of the body in a crash situation.

- Doing a solid axle AND not lifting it much will be interesting to see. In addition to the fender clearance, the clearance around the frame where the IFS subframe mounts may become a clearance issues, not to mention the oil pan of the CRD being lower than that of the gasser. VM Motori may have some alternate oil pan configurations that could help out there.

Dan

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 Post subject: Re: BDS Suspension's Project KJ
PostPosted: Sat Mar 23, 2013 12:42 am 
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Thanks for the input, we'll see what happens with the back of the cab, still discussing a few options to maximize the cab strength. While an exo is an option, one of our goals is to keep the build as clean as possible and most of us in the shop aren't fans of the exocage for this project.

Here's a link to the most recent video going over the progress, shot earlier this week,
http://youtu.be/avRxrUOLtyA

Axles made it to the shop, plan is to build up a set of JK Rubi axles into something that will hold up to the abuse we'll put them through. Sleeve kit, truss, knuckles, shafts, etc. more on that in the coming days as we start stripping them down.

We also plan to trim the front inner fenders next week so we can roll the axles under it and mock up the stance and see clearance between the axles & oil pan on our CRD.

Stay tuned for more...


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 Post subject: Re: BDS Suspension's Project KJ
PostPosted: Sat Mar 23, 2013 1:03 am 
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FYI here is what it looks like behind the sheet metal at the rear of the front fender wells (for when you cut it open to make room for the tires)

Driver's side

Image

Passenger

Image

and the link of the guy who cut them....

http://www.lostjeeps.com/forum/phpBB3/viewtopic.php?f=6&t=61556

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RRO: Adventure Rack/Rails ** MOPAR: Skids/Renny Flares & 255/75r17 (32.1) BFG M/T on JK wheels ** ARB: Bumper/IPF lights/790/948/shocks ** GDE: TCM/Hot Tune ** ROCKLIZARD: Super Sliders/Komodo Bumper

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 Post subject: Re: BDS Suspension's Project KJ
PostPosted: Sat Mar 23, 2013 8:23 am 
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arengant wrote:
FYI here is what it looks like behind the sheet metal at the rear of the front fender wells (for when you cut it open to make room for the tires)

Driver's side

Image

Passenger

Image

and the link of the guy who cut them....

http://www.lostjeeps.com/forum/phpBB3/viewtopic.php?f=6&t=61556


Hack job

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 Post subject: Re: BDS Suspension's Project KJ
PostPosted: Sat Mar 23, 2013 2:03 pm 
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tommudd wrote:
Hack job


I have only seen his and KJWildmans

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05 CRD Sport Dark Kahki

RRO: Adventure Rack/Rails ** MOPAR: Skids/Renny Flares & 255/75r17 (32.1) BFG M/T on JK wheels ** ARB: Bumper/IPF lights/790/948/shocks ** GDE: TCM/Hot Tune ** ROCKLIZARD: Super Sliders/Komodo Bumper

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 Post subject: Re: BDS Suspension's Project KJ
PostPosted: Sat Mar 23, 2013 4:56 pm 
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Suuuweet!!! Nice to see a major company building one up for some hardcore use :JEEPIN: Deff following this thread.

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 Post subject: Re: BDS Suspension's Project KJ
PostPosted: Thu Mar 28, 2013 8:38 pm 
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No updates this week? :ALONE:

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 Post subject: Re: BDS Suspension's Project KJ
PostPosted: Fri Mar 29, 2013 10:13 am 
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Right? I've been super impatiently checking their blog too!

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 Post subject: Re: BDS Suspension's Project KJ
PostPosted: Tue Apr 02, 2013 9:05 am 
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I was a bit delayed on posting the build progress from last week while I was out in Moab for EJS, but BDS R&D had some time to continue progress on Project KJ. We were able to chat with a number of companies out in Moab and pitch our idea to them to see if they are interested in helping out. We'll have more on those parts as parts arrive.

To make room for the massive tires we plan to run on this Liberty, we needed to make some room in the fenderwells. R&D took a plasma torch and sawzall to the inner fender up front removing nearly all of it. Front there the unibody was plated and the end result looks similar to a frame rail for us to start mounting suspension brackets. We'll be building a new inner fender in the coming weeks and plan to tie in a coil-over mount and engine support to retain the rigidity this Jeep's unibody had from the factory.

ImageImageImage

For axles on this project we decided to build up a set of JK Rubicon Dana 44 axles. While there are plenty of axles on the market, (i.e. Currie 9, Dynatracs ProRock 60s, Ruff Stuff fabricated housings, Spydertrax Spyder 9s, etc.) we wanted to utilize and axle that is attainable to the masses and show it can be built up to survive off-road abuse. The JK axles have a track width of 65'' (over the stock 62'') to help us gain room to mount the coil-overs, steering assembly and allow the larger tires to have a full sweep from left to right. To fine tune the overall track width for the stance we want we'll find a wheel with our ideal backspacing. At this point we've stripped the brackets off our JK axles and have them in place to begin mocking up tire size, wheelbase, and height. We're using a set of 40x13.50 Maxxis Trepadors on 17x9 (5'' BS) steel wheels we had laying around the shop for mockup. In keeping this Jeep as low as possible, potentially running 3-4” of lift with plenty of droop from a linked suspension we will begin mocking up suspension geometry using a set of 14'' Fox remote Reservoir Coil-Overs that we have in the shop. The decision is still out whether a set of 12'' C/O or 14'' C/O will be better suited for this build and the performance we're hoping to attain, stay tuned for more in the coming days as the guys continue to prep this KJ. Check out the blog for all the info on this build at http://bds-suspension.com/blog/?cat=393
ImageImageImage


Last edited by BDS Suspension on Wed Apr 03, 2013 12:37 pm, edited 1 time in total.

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 Post subject: Re: BDS Suspension's Project KJ
PostPosted: Tue Apr 02, 2013 10:17 am 
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I think there'll will be a few folks very surprised if you can stuff the rubicon axles and all the links and steering in there with only 3"-4" of lift, but if you can, that'd be a real boon for the "not a monster truck" goal of the project.
:POPCORN:

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 Post subject: Re: BDS Suspension's Project KJ
PostPosted: Tue Apr 02, 2013 3:48 pm 
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BDS Suspension wrote:
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In keeping this Jeep as low as possible, potentially running 3-4” of lift with plenty of droop from a linked suspension we will begin mocking up suspension geometry using a set of 14'' Fox remote Reservoir Coil-Overs that we have in the shop.


I like the big tire/low lift idea. People always give me crap about running a small lift (2") with 265/75R16 tires. But, I think keeping your weight down low helps you out offroad.

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 Post subject: Re: BDS Suspension's Project KJ
PostPosted: Wed Apr 03, 2013 12:41 pm 
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Our biggest concern right now is the steering. We've got some ideas and are seeing what stock unit or aftermarket complete units will fit our parameters and still give us the option for hydro assist... Suspension linkage is getting mocked up today/tomorrow. I'll have more in the coming days as that gets worked out


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 Post subject: Re: BDS Suspension's Project KJ
PostPosted: Wed Apr 03, 2013 12:47 pm 
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Pretty sweet so far. I hope you don't actually cut the back like the drawing up top. That looks really bad in my opinion. Love following this post to see how this is going though.

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 Post subject: Re: BDS Suspension's Project KJ
PostPosted: Wed Apr 03, 2013 9:02 pm 
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BDS Suspension wrote:
Our biggest concern right now is the steering. We've got some ideas and are seeing what stock unit or aftermarket complete units will fit our parameters and still give us the option for hydro assist... Suspension linkage is getting mocked up today/tomorrow. I'll have more in the coming days as that gets worked out



One guy did this:

"-Steering: 1990 Ford Bronco II steering box; custom pitman-arm; stock drag-link and tie-rod from the scavenged ZJ; Napa hydraulic hoses; boxed and trussed steering box mount"

http://www.lostjeeps.com/forum/phpBB3/viewtopic.php?f=73&t=64692

Image

Or...

"Astro Van rwd steering box, and PSC steering linkage. "

Image

http://www.lostjeeps.com/forum/phpBB3/viewtopic.php?f=73&t=56114

And some more talk about Jeepbummin trying to use the JK box here:

http://www.lostjeeps.com/forum/phpBB3/viewtopic.php?f=73&t=62602

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 Post subject: Re: BDS Suspension's Project KJ
PostPosted: Sat Apr 06, 2013 6:05 pm 
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This project is awesome, can't wait to see the next bit of progress! :rockon:


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