Anything custom sounds like music to my ears. You mean chopping up a straight 8.25?? Now there I an awesome idea. Seriously.

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2004 KJ 3.7 Limited:
IRO WJ Upper Arm -- WJ Rear LCA's -- Rear Driveshaft Spacer -- JBA Upper A Arms -- 4 inch Lift -- 265/75/16 4" B/S -- WasherBottle Relocate -- Custom High Mount Intake -- Carpet Delete -- Homebrew Winch Bumper -- Warn VR8000 -- Homemade Plow -- Pinch Weld POUNDED -- POR 15 inner fenders --

Update:

My First wj lp30 that I chopped up had really nasty looking gears, so I decided to acquire another lp30 from a 99 wj with the inline six. I divided the number of teeth on the ring gear by that if the pinion and got 3.73. So I scooped it up for 150 bucks.

The new axle is being shop cut in a big bandsaw as we type this. I just couldn't justify spending an extra 1200 for gears and install, when there was a perfectly good d30 at the jy.

Next step for me is to cut out the faceplate. And jig up my empty d30a. This way I get perfect locations for my bolt holes. Being that most of the parts in this kit required custom machining and new seals and axle beatings (not carrier bearings) I may have under estimated the cost.

It costs roughly 180 bucks for the tube inserts, 150~ for the CNBC cut face plate (which I may just hand cut (torch or plasma, haven't decided yet) and the side mount will be some bent up 1/4" plate, drilled and tapped.

Sooooooo... 180 plus 150 or 60, plus 10, plus 150 (axle) plus 100 bucks for the shop to chop it all up.. Gives you a steel diff under kj, with factory gears, installed.

Don't know about you guys, but I'm pretty psyched.

The reason I stopped working on this stuff is because I was prepping for my fourth child. A son, his name will be Henry.

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2004 KJ 3.7 Limited:
IRO WJ Upper Arm -- WJ Rear LCA's -- Rear Driveshaft Spacer -- JBA Upper A Arms -- 4 inch Lift -- 265/75/16 4" B/S -- WasherBottle Relocate -- Custom High Mount Intake -- Carpet Delete -- Homebrew Winch Bumper -- Warn VR8000 -- Homemade Plow -- Pinch Weld POUNDED -- POR 15 inner fenders --

Congratulations!

Congrats again on your son!!!

Sent from my SM-N900P using Tapatalk

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2002 KJ Limited 3.7, 5.25" lift via coilovers, custom HD rear springs, 32.2" tires on moabs (soon 33s) 4.56/JBA diff, OX lockers front/rear, NP241OR, Parker Fab front/rear bumpers, rock rails and roof rack, Viair OBA.

2006 KJ sport 3.7, 4" Ironman lift, 32" tires, Parker Fab front/rear bumpers and rock rails.

Update.

As you can tell, the inserts have rusted, shows exactly how long I have been "sitting" on this project. Been too long. You can also see the intermediate sits nicely where it should.. And for reference, the carrier and spiders in the pic, is wj.. That's right, the kj intermediate fits right into the wj carrier. I will have to remove the carrier to press out the drivers side (what's left of it) axle tube and press in the insert. I will use a half inch bolt and some tuning I have laying around. I will take pics when I get that far. This thing weighs a ton lol!




Tomorrow I hope to cut out the face plate and have things welded up.

I need to make a jig for my D30a, that way I can accurately place the brackets on my lp30.


Ryan

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2004 KJ 3.7 Limited:
IRO WJ Upper Arm -- WJ Rear LCA's -- Rear Driveshaft Spacer -- JBA Upper A Arms -- 4 inch Lift -- 265/75/16 4" B/S -- WasherBottle Relocate -- Custom High Mount Intake -- Carpet Delete -- Homebrew Winch Bumper -- Warn VR8000 -- Homemade Plow -- Pinch Weld POUNDED -- POR 15 inner fenders --

Looking good!!

Sent from my SM-N900P using Tapatalk

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2002 KJ Limited 3.7, 5.25" lift via coilovers, custom HD rear springs, 32.2" tires on moabs (soon 33s) 4.56/JBA diff, OX lockers front/rear, NP241OR, Parker Fab front/rear bumpers, rock rails and roof rack, Viair OBA.

2006 KJ sport 3.7, 4" Ironman lift, 32" tires, Parker Fab front/rear bumpers and rock rails.

Got some more work done today,

Put the diff on a makeshift work table.


Then I removed the carrier. Wasn't that difficult, took two minutes.


Parts on the left back in on the left. Parts on the right, etc


Then using a long drift, knock the seals out.


I made a puller out of some stuff I hade laying around, and pulled the axle stub from the housing.




I did get the inserts installed, pics to follow later tonight. However I asked the shop to cut the axle tube to a certain length and they missed by a 1/4" (too short) and the cut the diff housing a 1/4" too wide.. But luckily, my plug design was more versatile than I had originally though and I was able to offset the inserts to compensate. "Whew"
Big time save.. More pics to follow later

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2004 KJ 3.7 Limited:
IRO WJ Upper Arm -- WJ Rear LCA's -- Rear Driveshaft Spacer -- JBA Upper A Arms -- 4 inch Lift -- 265/75/16 4" B/S -- WasherBottle Relocate -- Custom High Mount Intake -- Carpet Delete -- Homebrew Winch Bumper -- Warn VR8000 -- Homemade Plow -- Pinch Weld POUNDED -- POR 15 inner fenders --

Forgive my welding. There were 7 stop and starts. My prescription glasses are awol, so I did the best I could. You can see the different recesses for the bearing and the seal.

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2004 KJ 3.7 Limited:
IRO WJ Upper Arm -- WJ Rear LCA's -- Rear Driveshaft Spacer -- JBA Upper A Arms -- 4 inch Lift -- 265/75/16 4" B/S -- WasherBottle Relocate -- Custom High Mount Intake -- Carpet Delete -- Homebrew Winch Bumper -- Warn VR8000 -- Homemade Plow -- Pinch Weld POUNDED -- POR 15 inner fenders --

Looks like its coming along

Sent from my SM-N900P using Tapatalk

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2002 KJ Limited 3.7, 5.25" lift via coilovers, custom HD rear springs, 32.2" tires on moabs (soon 33s) 4.56/JBA diff, OX lockers front/rear, NP241OR, Parker Fab front/rear bumpers, rock rails and roof rack, Viair OBA.

2006 KJ sport 3.7, 4" Ironman lift, 32" tires, Parker Fab front/rear bumpers and rock rails.

The welds on this side were purely to make it oil tight. I mean yes, they are stout (for not being able to see right lol).

The welds in the tube end, will also serve the same purpose. However the two tabs will give it strength, even though the tube ends aren't of structural concern as much as the faceplate and the rear bushing mount will be.. I will probably end up using preheat for those parts.

More to follow later.

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2004 KJ 3.7 Limited:
IRO WJ Upper Arm -- WJ Rear LCA's -- Rear Driveshaft Spacer -- JBA Upper A Arms -- 4 inch Lift -- 265/75/16 4" B/S -- WasherBottle Relocate -- Custom High Mount Intake -- Carpet Delete -- Homebrew Winch Bumper -- Warn VR8000 -- Homemade Plow -- Pinch Weld POUNDED -- POR 15 inner fenders --

Well looks like this project is dead in the water. Until I buy a plasma.. Budget is 1100 cad. Any ideas? Anybody in the Ontario area wanna lend me theirs?

My oxy rig can't even touch 1/2" plate, I just keep getting a facefull of slag lol...

I was looking at a forcecut40.

Again, I'm all ears

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2004 KJ 3.7 Limited:
IRO WJ Upper Arm -- WJ Rear LCA's -- Rear Driveshaft Spacer -- JBA Upper A Arms -- 4 inch Lift -- 265/75/16 4" B/S -- WasherBottle Relocate -- Custom High Mount Intake -- Carpet Delete -- Homebrew Winch Bumper -- Warn VR8000 -- Homemade Plow -- Pinch Weld POUNDED -- POR 15 inner fenders --

I have a versacut60. Cuts thru my 5/8" table easily once I learned it quirks. Granted its not a hyperterm, but it does the job very well.

Sent from my SM-N900P using Tapatalk

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2002 KJ Limited 3.7, 5.25" lift via coilovers, custom HD rear springs, 32.2" tires on moabs (soon 33s) 4.56/JBA diff, OX lockers front/rear, NP241OR, Parker Fab front/rear bumpers, rock rails and roof rack, Viair OBA.

2006 KJ sport 3.7, 4" Ironman lift, 32" tires, Parker Fab front/rear bumpers and rock rails.

Ive witnessed 4x4kayak cutter. Sumbitch is no joke

Literally, just finished using a Hypertherm PowerMax1000 G3... *tim Allen grunt* .... Cut the 1/2" literally as fast I could drag the torch.. I got a few squiggles in there on account of arc flash, didn't have shade 5 glasses, and I couldn't pass up the chance to cut the face plate.. Buttttt...

Woot woot!! The face plate is cut!!!

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2004 KJ 3.7 Limited:
IRO WJ Upper Arm -- WJ Rear LCA's -- Rear Driveshaft Spacer -- JBA Upper A Arms -- 4 inch Lift -- 265/75/16 4" B/S -- WasherBottle Relocate -- Custom High Mount Intake -- Carpet Delete -- Homebrew Winch Bumper -- Warn VR8000 -- Homemade Plow -- Pinch Weld POUNDED -- POR 15 inner fenders --

What are you using? Oxy/acetylene, oxy/propane? With either you should be able to cut 1/2" plate easily. Just have to have your pressures set right, a decent cutting torch

You can also use a circular saw with a metal cutting blade. Milwaukee makes an 8" and a 6 1/2". I'm sure every other manufacturer out there makes something. I might have a 7 1/4" steel cutting blade I would sell.

I've cut up to 3/4" plate with relative ease.

Sawzall with coarse tooth quality blades. There's been times where that is what we had to use.

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2006 Jeep Liberty CRD 142,000 miles New engine 2-2014, Green Eco tune, FS2500 bypass filter Weeks elbow, European Torque converter, brakes front UCA's wheel bearing and front hubs. Front hitch OEM lift pump
98 K2500 Suburban 6.5td
96 K1500 " 6.5td
95 2 door Tahoe 6.5td
94 K3500 cc srw 5 speed 6.5td
91 International Model 6 speed spicer 4700

I've only got the little oxy/acet tanks. Doesn't get me very far..

We got the hypertherm at work.. Holy crap that thing is AWESOME!!!

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2004 KJ 3.7 Limited:
IRO WJ Upper Arm -- WJ Rear LCA's -- Rear Driveshaft Spacer -- JBA Upper A Arms -- 4 inch Lift -- 265/75/16 4" B/S -- WasherBottle Relocate -- Custom High Mount Intake -- Carpet Delete -- Homebrew Winch Bumper -- Warn VR8000 -- Homemade Plow -- Pinch Weld POUNDED -- POR 15 inner fenders --

This particular piece (pics to follow in a few days) is curvy. Very curvy. Had to cut it freehand. I think I did okay, for having arc eye lol:. It is the faceplate for the diff.

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2004 KJ 3.7 Limited:
IRO WJ Upper Arm -- WJ Rear LCA's -- Rear Driveshaft Spacer -- JBA Upper A Arms -- 4 inch Lift -- 265/75/16 4" B/S -- WasherBottle Relocate -- Custom High Mount Intake -- Carpet Delete -- Homebrew Winch Bumper -- Warn VR8000 -- Homemade Plow -- Pinch Weld POUNDED -- POR 15 inner fenders --

Yep, she's rolling along.

Sorry for the rough edges, again this was a trial, so CNC isn't an option.

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2004 KJ 3.7 Limited:
IRO WJ Upper Arm -- WJ Rear LCA's -- Rear Driveshaft Spacer -- JBA Upper A Arms -- 4 inch Lift -- 265/75/16 4" B/S -- WasherBottle Relocate -- Custom High Mount Intake -- Carpet Delete -- Homebrew Winch Bumper -- Warn VR8000 -- Homemade Plow -- Pinch Weld POUNDED -- POR 15 inner fenders --

Today's progress ended at getting all the holes drilled prefect.

In three days times I hope to have at a minimum, the jig complete, and have the faceplate welded to the diff.

Beginning of December I hope to start road trials, and beginning of next year I will have hopes to sell some kits. Prices are still fluid, but I imagine for a complete ready to go unit with 3.73 gears installed, it will be well below the 750 dollar mark.

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2004 KJ 3.7 Limited:
IRO WJ Upper Arm -- WJ Rear LCA's -- Rear Driveshaft Spacer -- JBA Upper A Arms -- 4 inch Lift -- 265/75/16 4" B/S -- WasherBottle Relocate -- Custom High Mount Intake -- Carpet Delete -- Homebrew Winch Bumper -- Warn VR8000 -- Homemade Plow -- Pinch Weld POUNDED -- POR 15 inner fenders --

Sounds awesome!!!


Sent from my SM-N900P using Tapatalk

_________________
2002 KJ Limited 3.7, 5.25" lift via coilovers, custom HD rear springs, 32.2" tires on moabs (soon 33s) 4.56/JBA diff, OX lockers front/rear, NP241OR, Parker Fab front/rear bumpers, rock rails and roof rack, Viair OBA.

2006 KJ sport 3.7, 4" Ironman lift, 32" tires, Parker Fab front/rear bumpers and rock rails.