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 Post subject: Re: BDS Suspension's Project KJ
PostPosted: Thu May 23, 2013 11:45 pm 
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Just found this thread, their are great pictures of all the scary things were afraid of cutting when attempting to modify our KJ's. :mrgreen: Looks like a great build guys :google: . I love the tube work in the Jeep and under the hood :SOMBRERO: . Keep up the good work!! bshooter

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 Post subject: Re: BDS Suspension's Project KJ
PostPosted: Fri May 24, 2013 8:07 am 
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CoopaTroopa wrote:
Can't wait to see this thing all finished up, is it getting doors put back on or staying open? Really actually like chopped top but wonder how it will look when everything is done


Doors will be going back on it in the end, it's easier to fabrication without them in the way. The chopped top is still a rough cut, there's another 2'' or so of trimming before we clean up the edge and have a soft top made (trek top style).


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 Post subject: Re: BDS Suspension's Project KJ
PostPosted: Fri May 24, 2013 1:04 pm 
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Special delivery just came in from our friends at JustDifferentials.com, 5.13 Nitro gears, master overhaul kit, Ox Locker with air actuator for the front along with Nitro 30-spline axle shafts. In the rear we're going with 5.13 Nitro gears, ARB Air Locker and 35-spline Nitro axle shafts. Both lockers will be plumbed into an ARB twin air compressor. All great parts going into our little Liberty CRD. Stay tuned for more...


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 Post subject: Re: BDS Suspension's Project KJ
PostPosted: Fri May 24, 2013 1:14 pm 
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BDS Suspension wrote:
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Special delivery just came in from our friends at JustDifferentials.com, 5.13 Nitro gears, master overhaul kit, Ox Locker with air actuator for the front along with Nitro 30-spline axle shafts. In the rear we're going with 5.13 Nitro gears, ARB Air Locker and 35-spline Nitro axle shafts. Both lockers will be plumbed into an ARB twin air compressor. All great parts going into our little Liberty CRD. Stay tuned for more...


Looking good

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 Post subject: Re: BDS Suspension's Project KJ
PostPosted: Sat May 25, 2013 1:15 pm 
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That is the most badass parts hauler ever.

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 Post subject: Re: BDS Suspension's Project KJ
PostPosted: Sat May 25, 2013 2:58 pm 
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That's really coming along. Looks good. :SOMBRERO:

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 Post subject: Re: BDS Suspension's Project KJ
PostPosted: Wed May 29, 2013 4:13 pm 
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More goodies arrived today for Project KJ. This special delivery comes from our buddies over at Fox Racing who just dropped off a set of 14'' stroke, 2.5'' remote coilovers and 2.0 bumps to be mounted at all 4 corners. We'll have more on these as they get mounted in place over the next couple days as we move closer to getting this chassis rolling again. One month to go until the start of the [url="http://www.4wheeloffroad.com/2013/ultimateadventure/"]2013 Ultimate Adventure[/url], lots more to get done in that time...


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 Post subject: Re: BDS Suspension's Project KJ
PostPosted: Wed May 29, 2013 5:35 pm 
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BDS Suspension wrote:
We don't claim to be engine experts, so we know when to call in a favor. We have some diesel tuning planned for a bit later in the build that will be performed by our buddies over at Offroad Power Products. They'll be going on the UA this year and wanted to check out the progress of our KJ and put their mark on it. It'll be getting a couple of upgrades to bump up the performance w/o sacrificing reliability. We'll have more on the performance upgrades in the next couple weeks as that comes together.


If they make a intake for this diesel, Please have them make it readily available to all of us!!!! i am so sick of the bad designed airbox and intake tube!

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^contact me if interested, maybe selling for the right price to SAS the CRD


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 Post subject: Re: BDS Suspension's Project KJ
PostPosted: Wed May 29, 2013 5:52 pm 
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Oilburner44 wrote:
BDS Suspension wrote:
We don't claim to be engine experts, so we know when to call in a favor. We have some diesel tuning planned for a bit later in the build that will be performed by our buddies over at Offroad Power Products. They'll be going on the UA this year and wanted to check out the progress of our KJ and put their mark on it. It'll be getting a couple of upgrades to bump up the performance w/o sacrificing reliability. We'll have more on the performance upgrades in the next couple weeks as that comes together.


If they make a intake for this diesel, Please have them make it readily available to all of us!!!! i am so sick of the bad designed airbox and intake tube!


That's one we're looking at now and making plans for when the front end work is a little farther along. With the amount of modification that's been done to the front whatever we come up with will definitely be custom. We're thinking it may incorporate a snorkel just in case Rick Pewe decides to find some deep mud or water crossings on this year's UA.


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 Post subject: Re: BDS Suspension's Project KJ
PostPosted: Wed May 29, 2013 5:53 pm 
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This week the guys are fabbing up the rear of the KJ. After discussing the options on how to fit the rear suspension, roll cage, spare tire, fuel cell, dual batteries, air compressor, and more into the rear of this Liberty, the decision was made to remove the OE trunk floor and build a new subfloor that will act as a skid plate and give us additional storage space. With all the comments we've been hearing along the build about not much Liberty left, this week isn't going to help our case :) . That being said the guys are making progress and while the visual of the rear layout may not make total sense yet, it should as they fab work comes together. The plan is to build a fuel cell to mount at the bottom of the subfloor. It will be taller on the driver's side to incorporate additional fuel storage and allow us to reinstall the OE fuel sending unit and OE filler door location. Dual batteries will be mounted driver’s side forward of the fuel cell, air compressor mounted on the passenger side. Spare tire will be mounted at slant and additional space will be allotted for tool storage and spare parts.

With our Fox remote coil-overs and bump stops in the shop now, the guys will be finishing up the suspension, mounting C/Os and setting up the bumps to work with our low center of gravity suspension. We’ll have plenty more on the install and setup as the suspension comes together.

Lastly this week, we just received a cool retractable canvas soft top to install on what’s left of our Liberty’s roof. This 36×40 retractable sunroof came from slidingragtops.com will be taking up the remaining real estate on top of our Jeep. Call it JK envy, this retractable top is a cool way to get the topless feeling out on the trail and some wind in our hair on the highway, so to speak. It'll also help as we finish building and finish welding up the roll cage.

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 Post subject: Re: BDS Suspension's Project KJ
PostPosted: Wed May 29, 2013 7:27 pm 
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Looking better all the time
One of the guys here in Ohio had one of the sliding rag tops
looked real good :wink:

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03 OVERLAND EDITION /Kilby-Skidrow-Mopar-4XGuard skids/ 2.5 inch TOTAL CONTROL JBA coilovers -JBA Arms/MOABS-31 FALKEN WILDPEAK AT3W / 4.10's etc, 04 Kilimanjaro Edition loaded, plus 05 KJ limited


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 Post subject: Re: BDS Suspension's Project KJ
PostPosted: Wed May 29, 2013 9:18 pm 
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Don't remember reading it or maybe I just skipped over it, but is the cab getting sealed off? Kinda like the chopped top cherokees or is it going to stay open?

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 Post subject: Re: BDS Suspension's Project KJ
PostPosted: Wed May 29, 2013 9:26 pm 
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CoopaTroopa wrote:
Don't remember reading it or maybe I just skipped over it, but is the cab getting sealed off? Kinda like the chopped top cherokees or is it going to stay open?


Just a rough cut for now. Cab will get sealed off with a "trek top" style canvas top


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 Post subject: Re: BDS Suspension's Project KJ
PostPosted: Wed May 29, 2013 9:40 pm 
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With this project at hand, is BDS considering simplifying this suspension for a kit for the future? Theres only a few kits available and competition is key to success. Jeep gave us a the great KJ body to work with, unfortunately we have to scratch our heads for a better suspension.. :banghead: :2cents: Good Job guys. bshooter

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 Post subject: Re: BDS Suspension's Project KJ
PostPosted: Fri Jun 07, 2013 9:32 am 
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bshooter wrote:
With this project at hand, is BDS considering simplifying this suspension for a kit for the future? Theres only a few kits available and competition is key to success. Jeep gave us a the great KJ body to work with, unfortunately we have to scratch our heads for a better suspension.. :banghead: :2cents: Good Job guys. bshooter


We went into this project this this being a one-off build and one something different than your everyday JK/TJ/XJ. I can't speak for R&D on this one, but my thought from the marketing side of things is with the amount of fabrication that would be involved to mount steering and suspension it's to far outside our typical bolt-on suspension mentality to offer a production version of the kit.


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 Post subject: Re: BDS Suspension's Project KJ
PostPosted: Fri Jun 07, 2013 9:34 am 
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Here's a shot from earlier this week on the front end of the KJ.
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We'll be heading down to BDS R&D this afternoon to shoot another video update on Project KJ and get some photos of the progress. Plenty of parts have started to arrive in the last week, heavy duty ball joints from Alloy USA, the remaining axle parts from Nitro Gear, NP-241 Rocktrac t-case and miscellaneous parts to move the project closer to completion. Pac Racing Springs, a local spring manufacturer out of Michigan came by the shop to take some measurements and discuss spring rates. We should see a set of coils arriving soon to install on our Fox 2.5 remote coilovers. Once those arrive we'll get our C/Os installed and be one step closer to rolling. Front suspension is coming together and the rear suspension is getting buttoned up as well. Plenty more to come this afternoon, stay tuned for more.


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 Post subject: Re: BDS Suspension's Project KJ
PostPosted: Fri Jun 07, 2013 9:45 am 
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Well when it comes time to roll that beast out the door let me know :wink:
I'll volunteer to run up to have comparison shots done of mine with a typical 4 inch lift and then yours to show folks the difference ! I'm just down across the border :ROTFL: can come up anytime! :JEEPIN: :JEEPIN:

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03 OVERLAND EDITION /Kilby-Skidrow-Mopar-4XGuard skids/ 2.5 inch TOTAL CONTROL JBA coilovers -JBA Arms/MOABS-31 FALKEN WILDPEAK AT3W / 4.10's etc, 04 Kilimanjaro Edition loaded, plus 05 KJ limited


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 Post subject: Re: BDS Suspension's Project KJ
PostPosted: Fri Jun 07, 2013 11:00 am 
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I think by the time it gets done it should be called the BDS Libuggerty! (Half Liberty half buggy).


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 Post subject: Re: BDS Suspension's Project KJ
PostPosted: Fri Jun 07, 2013 11:30 am 
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You guys are welcome to check out the stop by our Coldwater, MI shop and check out the project progress. Just give us a heads up ahead of time.


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 Post subject: Re: BDS Suspension's Project KJ
PostPosted: Mon Jun 10, 2013 10:24 am 
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There was plenty of commotion around the BDS R&D Shop when I stopped by Friday late afternoon. Seems the approaching deadline to have the KJ prepped in time for the 2013 Ultimate Adventure has brought the team together as they work to complete suspension, drivetrain, cage, body mods, fuel cell and more. I mentioned in the last post parts have been arriving on the daily are are prepped for install. There’s still a number of areas that require fabrication and finish welding. Suspension linkage is nearly completed and uses a 4-link front and triangulated 4-link rear. 14” stroke Fox 2.5 remote coilovers arrived and are awaiting a set of Pac Racing springs to be installed (will have more on the coil specs when they arrive). Fox 2.0 bump stops will be installed soon to help keep our soon to arrive 40” Nitto Trail Grapplers off of the fenders. Up front our PSC JK steering box has been mounted to a reinforced front “framerail” and accepts the OE steering shaft linkage. The “framerail” is being notched to allow the track bar clearance at full compression.

Parts awaiting to be installed are heavy duty ball joints and axle seals from Alloy USA, our Nitro 5.13 Gears, Nitro 30-spline front shafts and Air-Ox Locker front, ARB Air Locker rear and Nitro 35-spline shafts, JK NP-241 Rocktrac T-Case with 4.0:1 low range, and an ARB air compressor. A shiny new Warn 9.0 Rc winch is sitting on deck ready to get recess mounted into a front bumper that we will be built in the coming week(s) to protect the front end and the new radiator, intercooler, and electric fan we have to go in. Driveline’s Plus is building a custom set of driveshafts for us as we move towards having this Jeep Liberty CRD mobile again. The fuel cell is being built in CA and just for fun we opened up the sunroof hole to accept the larger 36×40” Sliding Ragtop. Plenty more to come on this project, stay tuned for updates and more.

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