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Well I Went & Did It.. Rocky Road Conversion On The Way.

Discussion in 'Intermediate CJ-5/6/7/8' started by zila, Sep 21, 2017.

  1. Oct 14, 2017
    tarry99

    tarry99 Member

    Northern California
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    Yes , in fact if I have to drill a 1/2" or larger hole using a hand drill in some tough steel or at a compromised position or angle.........I'll always start out drilling a 3/8" hole.........and then grab the Car or bridge reamers and finish off the hole size.............much easier on your wrists and knuckles.
     
  2. Oct 14, 2017
    zila

    zila I throw poop

    Rock Springs,...
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    Last edited: Oct 14, 2017
  3. Oct 14, 2017
    timgr

    timgr We stand on the shoulders of giants. 2022 Sponsor

    Medford Mass USA
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  4. Oct 14, 2017
    zila

    zila I throw poop

    Rock Springs,...
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    Thanks Tim I have never used one. and only heard of em on here.. I'll probly order the ebay one today. Snowed last night so gettin the heap to the car wash with no top has me on the fence. Maybe later..

    Edit: Ordered the reamer.. So I will have no excuses come Tuesday night
     
  5. Oct 14, 2017
    tarry99

    tarry99 Member

    Northern California
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    Yep what Tim mentioned above..........watch E-bay ......sometimes there is some good deals on new old stock.
     
  6. Oct 14, 2017
    zila

    zila I throw poop

    Rock Springs,...
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    Reamer on the way and heap washed.. Step one done sorta.. Still can't find where I put that box of ambition. Might be in the nap room
     
    jpflat2a likes this.
  7. Oct 14, 2017
    wheelie

    wheelie beeg dummy 2024 Sponsor 2023 Sponsor

    York, PA
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    If you find any extra, I'll gladly pay the shipping to my address. :rolleyes:
     
  8. Oct 17, 2017
    Norcal69

    Norcal69 Out of the box thinker 2024 Sponsor 2023 Sponsor 2022 Sponsor

    Northern California
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    We are all waiting.........
     
  9. Oct 17, 2017
    zila

    zila I throw poop

    Rock Springs,...
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    Still waiting on the reamer. But I am thinkin I can get started soon..

    Edit: Here's a list of tips and stuff I learned along the way. Updated 4/30/2018

    First, number the pages on the instructions..

    2. Make sure you use the right bracket in the appropriate location.

    3. Run a drill bit through all the holes in the RR stuff to remove the powder coat.

    4. Have an assortment of grinder wheels on hand and a portable grinder.

    5. An angle drill is very helpful. No I didn't have one and paid for it..

    6 Sharp drill bits and a 1/2" car reamer will help. But you cannot always get the reamer in place to use.

    7. According to RR and OME the arrow goes toward the stationary spring hangar.

    8 Each old hanger is different. Be prepared to grind on the old hangar.

    9. Before inserting the metal sleeve in the spring bushing on the statonary end check to see if it will go in the bracket. I had to clearance 3 of mine ..

    10. None of the existing brackets on my heap were the same. Each one presented a different problem.

    11. When I inserted the frame sleeves in the front box section, I put the bolts in from the inside so the sleeve wouldn't fall into the frame. Also check the length as I had to grind 3 of the four sleeves off to get them flush.

    12. Wear earplugs while grinding or a welders cap. I had a spark go in my ear, even with a face shield. Yes it effin hurt.

    13. Do a parts inventory of the RR parts. They don't send a list but you can figure it out. One of my U-bolts didn't have enough thread on it.. and I also ended up purchasing a few washers and bolts.

    14. Look carefully at the u-bolt plates. One has a wider set of holes to accomodate a larger u-bolt under the front punkin. FWIW, I had a proper size u-bolt made at Six States for $8. UPDATE: And speaking of Ubolt plates make sure to clean the powder coat off of the mating surface where the shock bolts on. AND use blue Lock Tite on the bolt!! I also ran a tap into the lower shock bolt hole to clean the Powder coat out.. So far after less than 100 miles, all the lower bolts have come loose..

    Edit: They came loose again! I lost a front bolt. Checked the rest and all were a bit loose. Sooo I drilled the bolt head and U-bolt skid and installed safety wire.. All the way around. If I have one more episode I will drill into the U-bolt skid bolt hole from the top, Tap it and install an allen head set screw with locTite..


    15 The instruction will get you there but are in need of an update. Also there is a photo of the front shackle bracket in the middle of the stationary instructions.

    16. Make sure you place your jack stands where they will not interfere with the work you are doing. And raise em up so you can have room to work.

    17. Don't be afraid to call RR. I always got a good answer and a person on the phone.

    18 It helps to place a large rag under the area you are drilling to catch chips.. I got a chip in my *** of all places even doing this. I vacuumed the shop but those pesky chips keep showing up.

    19. insert the rear shackle bolt to the spring from the inside out. It's pretty obvious they will hit the fuel tank if not.

    20. If anyone has any questions either PM me or post here.

    21. TAKE YOUR WATCH OFF .!! My Seiko now has weld marks on it..
     
    Last edited: Oct 15, 2018
  10. Oct 17, 2017
    zila

    zila I throw poop

    Rock Springs,...
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    Reamer was supposed to be here today. Nooope.. But I did actually start between knife making .

    Pile o parts

    Springs

    Actual start
     
  11. Oct 18, 2017
    Stephen Gillett

    Stephen Gillett New Member

    Connecticut
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    Aug 31, 2017
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    remind me which version of the kit you bought? what's your desired end lift amount?
     
  12. Oct 18, 2017
    zila

    zila I throw poop

    Rock Springs,...
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    I bought the RR YJ/CJ spring conversion kit. Supposedly 3-1/2 " lift which is about what I have now. I bought the heavy duty springs.
     
  13. Oct 18, 2017
    scott milliner

    scott milliner Master Fabricator

    Seattle Wa.
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    Dec 17, 2002
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    Heavy duty is still really soft springs. You are really going to like them.
     
  14. Oct 19, 2017
    Stephen Gillett

    Stephen Gillett New Member

    Connecticut
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    Aug 31, 2017
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    Yeah, I'm headed for the HD set I think. Running a 12k winch at present, want to make sure i stay level.
     
  15. Oct 19, 2017
    zila

    zila I throw poop

    Rock Springs,...
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    Progress today: Got the U-blots and spring plates off. Rear axle on jack stands. Springs ready to unbolt. No pix as this is pretty standard stuff.. Reamer arrived, and I purchased a can of tool makers layout fluid. Tomorrow rear springs come off and front mount install begins.
     
  16. Oct 19, 2017
    4wealn

    4wealn Member

    Ontario, Canada
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    Nov 15, 2013
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    137
    Sweet, keep the updates and pics coming.
     
  17. Oct 20, 2017
    zila

    zila I throw poop

    Rock Springs,...
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    So far today. Between other things I hadn't planned on. Spring on pass side removed. Rear shackle hung [use 7/16" bolt and nut supplied]. Front hanger ready. Cleaned with a cats paw and tool makers blue applied.



     
  18. Oct 20, 2017
    zila

    zila I throw poop

    Rock Springs,...
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    First problem encountered. I carefully measured up from the bottom of the bracket 1-1/8" as per the instructions. Marked and cut off both sides. Layed out the new hole at 1-5/8" from bottom of old bracket before cutting. First problem is the body mount is interfering with the bracket location. Gonna grind it for clearance, See photo and white mark. Second issue is the part I cut off is a bit too much. I will probly weld a sleeve in there to support the crossbolt. On the rest of the brackets I'll mark the perimeter of the hole first by placing the bracket on before cutting and drilling. Also I used my dial caliper to measure. But find that a tri square works better for this. One more thing I needed to file a bit of the powder coating off to get the bracket over the old hangar..

    Bracket clamped in place.
    Edit: Turns out to be the front bracket not the rear. DOH!!

    Square and center punch
     
    Last edited: Nov 16, 2017
    tarry99 likes this.
  19. Oct 21, 2017
    zila

    zila I throw poop

    Rock Springs,...
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    Update.. First and foremost. MAKE SURE YOU HAVE THE CORRECT BRACKET !! I screwed up and grabbed a bracket for the front. They are very similar.. Thought about it last nite in bed and this A.M. I compared brackets.. So I start over. Word: I ended up grinding on the original bracket to get the new one to fit. There are shoulders inside the new bracket that need clearanced. It is a tight fit. And they are covered in powder coating. I filed the coating off the mating surfaces, but still needed to grind the old bracket. C clamped it on and checked it out. one of the side frame bolt holes is sitting partially on a hole in the frame.. May just weld that hole up and grind it flat again.

    When I do the other brackets I am going to slide them on before doing any cutting and drilling. I believe the portion of the bracket that is cut off may be too much. So I am going to check first. It looks like if I cut right at the top of the old bolt hole it will be about right. We'll see on the next one.
     
  20. Oct 21, 2017
    zila

    zila I throw poop

    Rock Springs,...
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    Got the correct Passenger side bracket mounted.. Finally. Installed the bushings and metal spacers in one rear spring. Problem #3 or whatever.. The sleeve is 3" as the instructions call out, BUT, the opening is 2-7/8". Didn't notice and finally took the driver side bracket and some bushings and a sleeve and looked it over. The loose bushings slide right in. The metal spacer tube, nope. Ground he spacer down but still no soap. The bushings are stopping at 3" for some reason.. I compressed the whole mess in my vice for the night. Maybe tomorrow it'll come together.

    NOTE: The bushings for the spring are two different sizes.. It's pretty obvious. Test fit the metal bushing before installing it in the spring and trim to fit.

    Notorious 3" sleeve

    Bracket in place.


    From bottom

    Spring mess chillin for the night
     
    Last edited: Oct 22, 2017
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