BDS Suspension's Project KJ

[BDS Suspension]

It's been a busy week in the BDS R&D Shop as the guys prep Project KJ for the 2013 Ultimate Adventure. The project white board is looming over the guys with a daunting task list and only 10 work days to complete. From body work to engine prep the team is working on all areas of the build. The plasma table was been getting a workout with plenty of parts getting cut out over the last coulpe weeks. A custom aluminum fuel cell was designed in Solidworks and cut out to snuggly fit the contours of our recessed cargo area. We went this route over the conventional cell to allow us to maximize the space available and still allow us room for the dual Optima batteries, air compressors and full size 40'' spare while allowing us to reuse the factory tank's internals to ease plumbing the system. The body work is still on schedule and is being prepped for a fresh coat of paint next week. To help us focus on the KJ body, electrical, and plumbing projects, we decided to pull the axles and drop them off at All Pro Off-Road to help us out with the gear/locker install. You may recall from an earlier update the JK Rubicon Dana 44s we were sleeved, trussed, and gusseted to accept the BDS 4-link suspension linkage, Fox 2.5 remote coilovers, and Fox 2.0 bumps. Internal upgrades for the axles include 5.13 Nitro Gear ring & pinions, air-Ox Locker front with 30-spline Nitro Gear chromoly shafts, and an ARB air locker rear with 35-spline Nitro Gear chromoly shafts. We'll have the axles back next week for final install along with custom driveshafts from our friends at Drivelines Plus to turn this KJ back into a rolling chassis.

In the meantime the work continues on the body and engine. Panels are being prepped for paint and the new radiator and intercooler are getting plumbed into the little I4 Diesel. Parts continues to arrive on the daily and we have big expectations for next week's build progress. A special thanks goes out to our buddies at Offroad Power Products, AFe Power, and Edge Products for go fast goodies to make sure our little 2.8L CRD is up to ***** with turning our 40'' Maxxis Trepadors. We'll have more on those upgrades as parts get installed. Stay tuned for plenty more in the coming days as Project Liberty takes shape.

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[Thelt]

Not to get off topic, but I just saw the van on 40s and that thing is sweet. The KJ build is coming along nicely too.

 

[BDS Suspension]

6 days left to build the KJ before the start of the 2013 Ultimate Adventure... no pressure.

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[Snail Farmer]

I see a few sleepless nights in your near future.

 

[BDS Suspension]

With less than a week till the start of this year’s Ultimate Adventure the shop a bit chaotic right now, not to mention the fact that the vehicle still sits in 1000 pieces strewn across the R&D shop floor. A make-shift paint booth has been set up in the back corner as the the new BDS body/paint guy preps lays down the Anvil Gray paint on the doors and hood right now, followed by the fenders and body tonight/tomorrow. Wiring is getting buttoned up and drivetrain is being prepped to be reinstalled. The axles are pulled aside and the new Nitro shafts are assembled and installed, the PSC ram is being mounted, and heavy duty steering linkage is being fabbed up, and the axles trusses are being finish welded. Radiator/intercoolers have been plumbed into the CRD and a custom intake was fabbed up to run from the factory turbo up into the front cowl. Check out the photos for more on the build and stay tuned as we hit the home stretch to have this KJ prepped to hit the road Friday for the 2013 Ultimate Adventure.

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[Thelt]

This is starting to feel like an episode of Fast and Loud....

 

[tommudd]

This is starting to feel like an episode of Fast and Loud....

Huge difference!
Appears that BDS has a good idea of what to do............
Fast and Loud are ........well lost most of the time

 

[4x4kayak2112]

Huge difference!
Appears that BDS has a good idea of what to do............
Fast and Loud are ........well lost most of the time

Lost all the time!!

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[BDS Suspension]

Busy busy in the shop today, the rigs being worked on from all angles. I'll have photos to post later tonight/tomorrow once it gets out from paint. Here's the rendering for the final look. The color is called Anvil, it a slate gray used on the (2013) 10th Anniversary Rubicons along with black/red graphics. Being that we're running Rubi axles and a Rubi t-case, we thought it was fitting for this project.

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[brokendad]

Nice bit of advertisement on what can be done with lots of money and a full shop. Looks really nice but doesn't do anything for Liberty owner's in the world I live in.

 

[cplchris]

Nice bit of advertisement on what can be done with lots of money and a full shop. Looks really nice but doesn't do anything for Liberty owner's in the world I live in.

thats not even remotely true, this will eventually drive aftermarket companies to make more stuff for liberties. Not to mention it isn't very polite to come into a build thread and try to throw in a dig at a company for doing something like this.

 

[BDS Suspension]

We're in the home stretch for Project KJ with plenty more that needs to go on for final fitment. After a frustrating 48 hours resolving a no start issue that held up progress the team is scrambling to get this KJ Ultimate Adventure ready. Since our last update, axles have been assembled the rest of the way, bumpers have been fabbed up, the no-start issues have been resolved, body has ben prepped for paint and skid plates have been started. After another long day yesterday the Jeep went into the makeshift paint booth to be shot a color called Anvil. It's a slate gray color that Jeep used for 2013 on the 10th Anniversary Rubicons along with red/black accents. WIth paint drying on the top side, the Jeep has been wheeled out into the shop to start being reassembled. It's a mad rush to the finish (or start) of Ultimate Adventure 2013 and it's all hands on deck. We'll be posting photos periodically on our Facebook Page <https://www.facebook.com/BDSSuspensions> so stay tuned to watch it come together.

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[BDS Suspension]

We're getting it finished up for the 2013 Ultimate Adventure. Keep an eye on the BDS Facebook Page for updates from the trip at https://www.facebook.com/BDSSuspensions

 

[wheeee32]

I´m liking the color on it.:smokin:

 

[4x4kayak2112]

We're getting it finished up for the 2013 Ultimate Adventure. Keep an eye on the BDS Facebook Page for updates from the trip at https://www.facebook.com/BDSSuspensions

Can you please post here....some of us don't have facebook

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[tommudd]

Carter is busy finishing it up and getting ready to be a long ways down the road by noon tomorrow to sign in for the 2013 UA
So since I was there most of the day today he asked if i would post up some pictures here
so ............OH they are backwards but oh well Got to hear it fire up and run around the parking lot before I left for the day Still lots to finish but with the great crew they ahve I'm sure they'll get it done

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[tommudd]

The Skyslider

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[tommudd]

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Before we got the back seat back in

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[BDS Suspension]

Need Help!!! BDS KJ

Hey everyone, we're in route to the start of this years UA, but have a bit of a dilemma we were hoping you guys could help us get resolved. Drivetrain combo is CRD/45RFE/NP-241OR/JK Dana44s

We're having an issue with the ****** going into limp mode and believe its due to a wheel speed sensor issue. We robbed some off the front of another JK and wired them back into the harness but still going into limp. Heard the KJ OEM sensor used is based off the rear diff but haven't confirmed or had a chance to looking it. May try hooking one of the front sensors into the rear harness.

One thing we're still trying to work out is a wire coming out of the ABS module. With all the rerouting its a but cramped in there but there is a pink w/white stripe wire that comes out of the ABS module, need to know where it goes to.

Please help!

 

[Leeann]

In the book, there's a pink/tan wire out of the ABS module that goes to fuse 38, 10a, in the junction block and then to the shifter assembly (says fuse ignition switch output - run). it's the only pink wire I find on the diagrams.