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Thread: Chassis brace

  1. #1
    Join Date
    Jul 2011
    Location
    Brisbane
    Posts
    142

    Default Chassis brace

    I decided it was time to make something, this happens every now and then, I get the urge to make something even if I don't need it.
    I have a 95 Xj which has the valid "cracked chassis" recall available but as yet it hasn't been required, I only run 30" tyres (may consider 31's at some point but no bigger) and still run stock offset rims and with only a 2" lift this is not really going to stress the front end too much but better to prevent an issue then to try and repair it.....

    So I started with this...



    A donor Xj was stripped of its front section...



    After a brace was welded in place to retain the size and to keep it all rigid to work on....

    So now I can work on it on the bench.

    So with the clip in the workshop I could work out which mounts I could use, the factory bullbar used the large hole nearest the rear of the car, this is ironic considering it was an lloy bar, the ARB steel bar only uses the 3 front bumper bar mountings and the ones on the front crossmember which is quite flimsy....



    So I planned to use the OEM bullbar points as well as the large hole in the middle by machining some steel bar to join the inside and outside plates together, note this is a bolt on mod, no welding to the car will be considered...

    So some plates were cut for inside and outside of each rail....




    The plates were drilled and countersunk for the steel inserts to be welded into...



    It even appears to line up....



    That is always a good start...

    JJ
    Do it once, do it right....

    95 Xj Sport
    2" Old Man Emu / IRO lift
    IRO SYE
    Airflow Snorkel
    Full limited interior

  2. #2
    Join Date
    Jul 2011
    Location
    Brisbane
    Posts
    142

    Default Re: Chassis brace

    So some assembly was then required...







    Which when welded resulted in this...





    Two 12mm nuts were welded into the return on the inside passenger side brace, these line up with the factory holes, this was added to help with the next stage which will be a steering box brace, not really neccessary but what the hell...

    Till next time...

    JJ
    Do it once, do it right....

    95 Xj Sport
    2" Old Man Emu / IRO lift
    IRO SYE
    Airflow Snorkel
    Full limited interior

  3. #3
    Join Date
    Jul 2011
    Location
    Brisbane
    Posts
    142

    Default Re: Chassis brace

    Made and welded the spacers onto the drivers side bracket for the steering box mount and thought that the plates were done, 'til I realized that I forgot the third bumper bar hole which is a 10mm so they need to be drilled then I will be able to clean the plates up ready for painting.

    I found a clamp for the steering box so the next step is to fab up the brace for the box so that should be the next update....
    Do it once, do it right....

    95 Xj Sport
    2" Old Man Emu / IRO lift
    IRO SYE
    Airflow Snorkel
    Full limited interior

  4. #4
    Join Date
    Jul 2011
    Location
    Brisbane
    Posts
    142

    Default Re: Chassis brace

    Managed to get some more done on this, drilled the last of the holes for the bumper mounts (forgot the 10mm bolt!!!)
    The started on the steering box brace, after reading write ups on various sites about how others have done it I decided to run a brace from chassis rail to chassis rail incorporating all the 10mm bolt holes under the rails for the sway bar and the bash plate mounts on both rails, this required a lot of measuring but managed to get all of them to line up, a lot easier when the chassis section is upside down on a bench!!!




    I decided to make the actual brace out of 25x3 angle and then use a clamp attached to this rail to support the box....



    And then a quick zap with the mig....



    Do it once, do it right....

    95 Xj Sport
    2" Old Man Emu / IRO lift
    IRO SYE
    Airflow Snorkel
    Full limited interior

  5. #5
    Join Date
    Jul 2011
    Location
    Brisbane
    Posts
    142

    Default Re: Chassis brace

    Gave me this as a result...



    So then it was a quick strip and clean with the wire wheel ready for painting...




    I will do a trial fit first before doing anything else but if all is ok I will give it a good hit with underbody rust paint and then give my chassis a clean and hit it with the same before final installation....

    JJ
    Do it once, do it right....

    95 Xj Sport
    2" Old Man Emu / IRO lift
    IRO SYE
    Airflow Snorkel
    Full limited interior

  6. #6
    Join Date
    Sep 2009
    Location
    Chico, CA
    Posts
    29,847

    Default Re: Chassis brace

    That qualifies as a beefy set up for sure
    230 hp 4.3L Chevy
    Built 4L60E with manual lockout
    Atlas 4 speed
    Griffin radiator
    On board air
    Warn 9.5ti on custom bumper
    7.5" RE front and bastard pack rear on custom long arms
    30 gal gas tank
    lockers
    And a bunch of other stuff

  7. #7
    Join Date
    Oct 2012
    Location
    Sussex, NJ
    Posts
    68

    Thumbs up Re: Chassis brace

    Nice Job JJ. Good pics and description too. Put another shrimp on the barby! Don't forget the jungle juice to go with it.
    Later..............
    Dave

    Not sure if I can make it over the rock behind me but I'll give it a try.
    "Don't worry about nothin' 'cause nuthin's going to be Alright"

  8. #8
    Join Date
    Oct 2011
    Location
    S.E. Texas
    Posts
    29,260

    Default Re: Chassis brace

    Nice work, mate. That isn't going anywhere, stout for sure.

  9. #9
    Join Date
    Jul 2011
    Location
    Brisbane
    Posts
    142

    Default Re: Chassis brace

    Cheers, I just gotta see if it will bolt straight up to my front end, hopefully using the other front end as a template will mean it should providing neither has any chassis alignment issues....

    Here's hopin'.....
    Do it once, do it right....

    95 Xj Sport
    2" Old Man Emu / IRO lift
    IRO SYE
    Airflow Snorkel
    Full limited interior

  10. #10
    Join Date
    Apr 2011
    Location
    Denton, Texas
    Posts
    5

    Default Re: Chassis brace

    i was going to do this but recently went to full hydro from PSC

  11. #11
    Join Date
    Jul 2011
    Location
    Brisbane
    Posts
    142

    Default Re: Chassis brace

    It is all fitted up now, fitted like a glove...
    Do it once, do it right....

    95 Xj Sport
    2" Old Man Emu / IRO lift
    IRO SYE
    Airflow Snorkel
    Full limited interior

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