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 Post subject: '06 brake line extension
PostPosted: Thu Aug 06, 2009 5:00 pm 
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In order to lift my '06 KJ with the Daystar 2.5" poly-spacer coil lift I had to extend the two back left rear brake line manifolds. I got a 1' piece of 1-1/2" hanger angle and marked, cut and bent it to work.

This is the angle marked to cut and bend
Image

The rear of the axle bracket had to be vertical cut parallel to and against the inside face of the opposite side at both ends
Image

Then the narrower side is bent down to the inside and the adjoining side bent over on top of it
Image

The finished 'box' bracket that mounts to the rear of the left axle where the manifold mounted
Image

The finished products painted
Image

This is the brake line to the rear of the axle from the factory
Image

When bent over the adjoining flange the notch for the manifold tab was plugged by material beneath and had to be filed
Image

The 'box' extension is mounted to the rear of the axle on the wheel well frame
Image

The manifold is then mounted on the bottom of the 'box' bracket
Image

This is the brake line to the front of the axle from the factory
Image

The angle extension is marked and notched at the proper angle to slide around the welded flange, mounted to the frame and the manifold will be mounted to the bottom of it.
Image

This was an easy and fun modification and appears to be good and stout. I hope this is helpful and someone can use it.
John

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'06 4X4 KJ, skid plates, Daystar lift, Wrangler MT/R 245/75/16, Reese hitch, Surco Safari Rack/Hella 500's, Cobra 75 wxst/Wilson 4' Firestick, Optima Red Top, Pilot fog lights, Detours KJ Backbone/Smittybilt XRC8 winch, Spidertrax spacers.

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PostPosted: Fri Aug 07, 2009 6:27 am 
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Good write up! Nice pics.

I'll add the link to the LIFT FAQ. :D

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PostPosted: Fri Aug 07, 2009 8:49 am 
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tonycrd wrote:
I'll add the link to the LIFT FAQ. :D


Thanks. I'd like to get one more picture of the bracket in front of the axle with the brake line attached just so folks can see how that's done. I'll try to post it ASAP.
John

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"Keep the shiny side up and the oily side down"
'06 4X4 KJ, skid plates, Daystar lift, Wrangler MT/R 245/75/16, Reese hitch, Surco Safari Rack/Hella 500's, Cobra 75 wxst/Wilson 4' Firestick, Optima Red Top, Pilot fog lights, Detours KJ Backbone/Smittybilt XRC8 winch, Spidertrax spacers.

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PostPosted: Fri Aug 07, 2009 5:43 pm 
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Very nice write up. We need more stuff like this. Can't ever have to many tech articles.

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 Post subject: Re: '06 brake line extension
PostPosted: Fri Aug 07, 2009 7:58 pm 
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jhblackwell wrote:
In order to lift my '06 KJ with the Daystar 2.5" poly-spacer coil lift I had to extend the two back left rear brake line manifolds. I got a 1' piece of 1-1/2" hanger angle and marked, cut and bent it to work.

This is the angle marked to cut and bend
Image

The rear of the axle bracket had to be vertical cut parallel to and against the inside face of the opposite side at both ends
Image

Then the narrower side is bent down to the inside and the adjoining side bent over on top of it
Image

The finished 'box' bracket that mounts to the rear of the left axle where the manifold mounted
Image

The finished products painted
Image

This is the brake line to the rear of the axle from the factory
Image

When bent over the adjoining flange the notch for the manifold tab was plugged by material beneath and had to be filed
Image

The 'box' extension is mounted to the rear of the axle on the wheel well frame
Image

The manifold is then mounted on the bottom of the 'box' bracket
Image

This is the brake line to the front of the axle from the factory
Image

The angle extension is marked and notched at the proper angle to slide around the welded flange, mounted to the frame and the manifold will be mounted to the bottom of it.
Image

This was an easy and fun modification and appears to be good and stout. I hope this is helpful and someone can use it.
John


This is the finished brake line extension forward of the axle
Image

_________________
"Keep the shiny side up and the oily side down"
'06 4X4 KJ, skid plates, Daystar lift, Wrangler MT/R 245/75/16, Reese hitch, Surco Safari Rack/Hella 500's, Cobra 75 wxst/Wilson 4' Firestick, Optima Red Top, Pilot fog lights, Detours KJ Backbone/Smittybilt XRC8 winch, Spidertrax spacers.

'04 Harley-Davidson Road King FLHRI Bagger


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 Post subject: Re: '06 brake line extension
PostPosted: Wed Jan 06, 2010 10:24 pm 
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I would like to know if you need those brackets with the ome lift (only springs and struts) 1.5" to 2".

Thanks.

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 Post subject: Re: '06 brake line extension
PostPosted: Wed Jan 06, 2010 11:04 pm 
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Yes. You need it with pretty much any amount of lift on the 06-07 models.

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 Post subject: Re: '06 brake line extension
PostPosted: Thu Jan 07, 2010 7:42 am 
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That's nicely explained and documented. Thanks for taking the time to do it.


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 Post subject: Re: '06 brake line extension
PostPosted: Fri May 14, 2010 3:24 am 
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Is it necessary to lower both brake lines down, or only the one on the rear of the axle?

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 Post subject: Re: '06 brake line extension
PostPosted: Fri May 14, 2010 7:58 am 
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infernicus wrote:
Is it necessary to lower both brake lines down, or only the one on the rear of the axle?

With the Daystar 2.5" lift, only the rear...and that was on the '06 sport gasser. I'm not sure about any other model.

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'06 4X4 KJ, skid plates, Daystar lift, Wrangler MT/R 245/75/16, Reese hitch, Surco Safari Rack/Hella 500's, Cobra 75 wxst/Wilson 4' Firestick, Optima Red Top, Pilot fog lights, Detours KJ Backbone/Smittybilt XRC8 winch, Spidertrax spacers.

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 Post subject: Re: '06 brake line extension
PostPosted: Mon May 17, 2010 3:06 pm 
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Just to clarify a couple points for my slow brain..

1. these are brake lines on the REAR axle only? and there are only TWO lines that you are moving? one drivers one passengers right?

2. you dont have to get longer brake lines to do this? Just fabricate the brackets?

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 Post subject: Re: '06 brake line extension
PostPosted: Mon May 17, 2010 3:40 pm 
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GeekyJeep wrote:
Just to clarify a couple points for my slow brain..

1. these are brake lines on the REAR axle only? and there are only TWO lines that you are moving? one drivers one passengers right?

2. you dont have to get longer brake lines to do this? Just fabricate the brackets?

ANS.:
1) You just lower the brake line on the driver's side rear. There are two "manifolds" that attach to the left frame member, one in front of the axle and one in the rear of the axle. Both of these have to be lowered.

Bracket to rear of axle (note bumpstop)
Image

Bracket to front of axle (note bumpstop)
Image

This is the front before being dropped.
Image

2) No, you don't have to get longer brake lines. The existing lines flex (DO NOT BEND!), or drop enough to accomodate the bracket extension.

Hope this helps.

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"Keep the shiny side up and the oily side down"
'06 4X4 KJ, skid plates, Daystar lift, Wrangler MT/R 245/75/16, Reese hitch, Surco Safari Rack/Hella 500's, Cobra 75 wxst/Wilson 4' Firestick, Optima Red Top, Pilot fog lights, Detours KJ Backbone/Smittybilt XRC8 winch, Spidertrax spacers.

'04 Harley-Davidson Road King FLHRI Bagger


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 Post subject: Re: '06 brake line extension
PostPosted: Mon May 17, 2010 3:48 pm 
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excellent thanks for the info! i jsut couldnt quite grasp what was going on. and im planning my lift now and dont want to get it up in the air and realize i forgot something. or i dontwant to spend $100+ for longer hoses i dont need.

thanks again!

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 Post subject: Re: '06 brake line extension
PostPosted: Wed Jun 23, 2010 1:57 pm 
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What was the size and threading of the bolts you needed to purchase?
im trying to have all teh equipment i need pre purchased.

thanks.

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 Post subject: Re: '06 brake line extension
PostPosted: Wed Jun 23, 2010 4:25 pm 
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GeekyJeep wrote:
What was the size and threading of the bolts you needed to purchase?
im trying to have all teh equipment i need pre purchased.

thanks.


I don't remember. But when I get home tonight I'll check it with my bolt guage and let you know. I suspect a No. 8 bolt big (or small) enough to go through the existing hole in the bracket should work. There's not a whole lot of pressure on the bracket..
John.

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"Keep the shiny side up and the oily side down"
'06 4X4 KJ, skid plates, Daystar lift, Wrangler MT/R 245/75/16, Reese hitch, Surco Safari Rack/Hella 500's, Cobra 75 wxst/Wilson 4' Firestick, Optima Red Top, Pilot fog lights, Detours KJ Backbone/Smittybilt XRC8 winch, Spidertrax spacers.

'04 Harley-Davidson Road King FLHRI Bagger


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 Post subject: Re: '06 brake line extension
PostPosted: Tue Feb 22, 2011 1:49 pm 
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Can you tell me what area in home depot you find that metal piece to fashion the bracket? I looked all over home depot this past weekend and couldn't find it anywhere. I didn't know what to ask for but I figured I have some time yet since I haven't ordered my parts yet. Also, if you happen to know what size bolts and stuff you used that would be great info as well. Just want to get everything together before I start the lift project. Thanks.

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 Post subject: Re: '06 brake line extension
PostPosted: Tue Feb 22, 2011 5:58 pm 
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bigjimslade wrote:
Can you tell me what area in home depot you find that metal piece to fashion the bracket? I looked all over home depot this past weekend and couldn't find it anywhere. Thanks.


Hopefully the link below will open. That's similar to what I used. Somewhere near the fasteners (nails and screws) and hardware section they should have "metal stock" with different lengths of all kinds of plates, angles, threaded rod, etc. Just ask for their "metal stock". The bolts will be the same size as what's used stock. I honestly can't remember what I used. Whatever fits thru the holes in the angle iron should work. Hope this helps.
John

http://www.homedepot.com/Tools-Hardware ... ogId=10053

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"Keep the shiny side up and the oily side down"
'06 4X4 KJ, skid plates, Daystar lift, Wrangler MT/R 245/75/16, Reese hitch, Surco Safari Rack/Hella 500's, Cobra 75 wxst/Wilson 4' Firestick, Optima Red Top, Pilot fog lights, Detours KJ Backbone/Smittybilt XRC8 winch, Spidertrax spacers.

'04 Harley-Davidson Road King FLHRI Bagger


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 Post subject: Re: '06 brake line extension
PostPosted: Thu Dec 20, 2012 5:46 pm 
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hello just wondering would anyone happen to know why i cannot see the PHOTOS?


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 Post subject: Re: '06 brake line extension
PostPosted: Thu Dec 20, 2012 6:08 pm 
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patriotNo6 wrote:
hello just wondering would anyone happen to know why i cannot see the PHOTOS?

WELCOME!!
Usually it has to do with your web browser, I believe Internet Explorer has issues. Try Chrome or FireFox.
8)

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SOLD2007 6 Speed - Projector Retrofit -Custom LED Tail Lights - Lights on Cowl & 130w 8" ProComps - Full Skids-RockLizard Super Skink Sliders-Front Hitch
Frankenlifted-Al's A-Arms-Goodyear Duractracs 31x10.5R15x7 Cragar D Window 4"bs-Cobra 75WXST - 4' Firestick
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 Post subject: Re: '06 brake line extension
PostPosted: Fri Dec 21, 2012 3:14 pm 
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...or your proxy server at work, which is typically what i experience, as it blocks photobucket.

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