BDS Suspension's Project KJ

[martin_metal_88]

so you are telling us that not only you can do whatever you want to almost any car you want plus you are paid to do so! That's like being paid to have sex, with more rubber XD

 

[4x4kayak2112]

That's like being paid to have sex, with more rubber XD

That my friend is illegal in the U.S. unless you video tape it. Then its a-okay.


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[BDS Suspension]

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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...

 

[martin_metal_88]

tuned for more? Is there any place left on the libby to add anything else? ahah!

 

[BDS Suspension]

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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 2013 Ultimate Adventure, lots more to get done in that time...

 

[BDS Suspension]

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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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[4x4kayak2112]

I love the retractable roof!

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[BDS Suspension]

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.

 

[BDS Suspension]

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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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[BDS Suspension]

Here's some update photos from last night... more info to come.

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Paper templates before we cap off the body cut

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Electric fan, radiator and intercool arrived. Now to figure out fitting them all in behind the grill along with our Warn 9.0 Rc winch and Rigid LED Lighting.

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JK 241 Rocktrac bolted right up, no body mod necessary, no indexing needed.

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Pac Racing C/O springs arrive 12x3x250 and 14x3x350 for front. 12x3x200 and 14x3x300 for the rear

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[BDS Suspension]

It’s been a couple days since we updated you on Project KJ, our ’05 Liberty CRD for the 2013 Ultimate Adventure (UA) hosted by 4Wheel & Off-Road Magazine. This week the guys running full steam to getting this Jeep prepped, with tons of fab work still needing to take place and off the shelf parts arriving daily. This week the suspension and steering work continued, t-case was installed, radiator and intercooler arrived and mocked into location, and body work began to cap off the rear window chop. Only 12 days remain until this Jeep needs to hit the road for the secret start point of UA and the guys are starting to feel the pressure.

To get a lower 4Lo range, we went with a NP-241 Rocktrac case out of a JK Rubicon. This will give us 4.0:1 low range and help improve its crawling capabilities. The case bolted right up to our 545RFE ******, no indexing or body mods needed. Driveshafts are being sourced from Drivelines Lines Plus and should be hear the first part of next week. Pac Racing dropped off the springs to fit our Fox 2.5 coilovers. We went with 12x3x250 and 14x3x350 up front for the weight of the diesel, winch and tubework and stuck with a 12x3x200 and 14x3x300 coil for the rear. Shocks are being assembled to reinstall on soon.

The new radiator, cooler, and electric fan are being mocked up and plumbed. Our Warn 9.0 Rc will mount below (recessed into the front bumper) along with a pair of Rigid dually lights. Air intake, winch controller, C/O reservoir mounts, and PSC steering pump/resevoir still need to be installed. Nothing like trying to cram 10lbs of $#!T into a 5lb bag. Time is not on our side at this point, stay tuned for more updates are this Jeep comes together.

 

[Cardhu]

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WTF happened to the trans cooler?

 

[BDS Suspension]

WTF happened to the trans cooler?

I noticed that when I was down there too, not sure if it was lie that before or happened when it was out of the vehicle. I believe it is getting replaced (not sure though, the guy to ask wasn't down when I stopped by).

 

[Honduras]

I SWEARDAGOD IF YOU PAINT THAT JEEP PINK... :hunter:

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[BDS Suspension]

I SWEARDAGOD IF YOU PAINT THAT JEEP PINK... :hunter:

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HAHA, pink is not planned, but why not throw out the option... it's easy enough in photoshop. For those that didn't see the rainbow of color options, check out Project KJ: What color would you pick? - BDS

 

[ThunderbirdJunkie]

HAHA, pink is not planned, but why not throw out the option... it's easy enough in photoshop. For those that didn't see the rainbow of color options, check out Project KJ: What color would you pick? - BDS

The bright green!!

Sent from ThunderbirdJunkie's mind via satellites

 

[Snail Farmer]

X2 I say the bright green!

 

[BDS Suspension]

Lots of progress yesterday, the rear window chop is getting capped off as well as the tailgate. Pac Racing coils are installed on the Fox 2.5 remote coilovers and will be going back into the Liberty soon. Our fabbed motor mounts are being modified to allow the 4-link to fully compress. The roof has been cut to accept the sliding rag top. While up there, the remaining "ribbed" roof panels were cut off and a patch panel was installed. Body/Fender modifications continue as we mock up the fenders to accept our 40'' Maxxis tires on 17'' B.A.D. beadlocks at full stuff. Stay tuned fore more as we prep for the 2013 Ultimate Adventure that begins 6/29/13.

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[first&lastKJ]

Safety glasses?
Keep the pics. coming, can't wait to see this thing in action.
Hope you post some video.

 

[martin_metal_88]

The Dark red, The bright green, or the dark blue