BDS Project KJ

BDS Project KJ Progress, Rear Fabrication

This week the guys are fabbing up the rear of the KJ. After discussing the options to mount 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.  We’ve seen some comments on the message boards about not much Liberty left, and this week’s update won’t 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.

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More goodies arrived today for Project KJ, the ’05 Liberty CRD being built to take on the 2013 Ultimate Adventure. This special delivery comes from our friends 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. Follow along with the build up at BDS Project KJ buildup.


Special Delivery just came in from our friends at, 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 Project Liberty CRD. Stay tuned for more…

IMG_5003BDS Project KJ Update: This week the guys are busy working on the suspension of our little Liberty CRD. Up front, lower control arms are fabbed up and the unibody has been reinforced to mount the LCA brackets. Upper arms and track bar mount going in soon. In the rear, a triangulated 4-link has resides to improve suspension travel and eliminate the need for a rear track bar as space is limited. Fox Racing 14” remote 2.5 coilovers and 2.0 bumps are in route to the shop to install next week.

After cycling the rear suspension, its becoming apparent that much more trimming will be necessary to clear the 40” meats. It’s something we had planned on with a modest preliminary cut, but the extent to which we will need to trim and rework the fenders will be extensive so we can get the full potential out of our new suspension.

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BDS Project KJ: Suspension, Cage, & DrivetrainBDS Jeep Liberty KJ

It’s been a few weeks since we checked in on Project KJ, the ’05 Liberty CRD being overhauled in BDS’s R&D shop for this year’s Ultimate Adventure (UA). When it comes to building a rig for the UA, it’s got to be capable on any terrain; mud, rocks, dirt, sand, snow, and even asphalt. Reliability is key as each day of the week long 1000+ mile adventure is filled with trails, highway time, and varying weather conditions. The rig needs to carry driver/co-driver, food, camping gear, and spare parts.

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BDS Project KJ Update: Cage Mocked Up

Judging from the forums comments and some of the phone calls we got in the last day, we may have lost some of you with our last update about the roof chop. Group consensus was to go for it and we’ve got a couple ideas on how to cleanly finish it off that we’ll address a bit later in the build. With the roof off the guys got busy working on the rest of the cage. One thing we’re still deciding on is what’s the best option for mounting a fullsize spare. We don’t want to stick it off the back like a Wrangler and we don’t want it to half-hazzardly strap it to the roof. At this point we’re looking at options to get it inside behind the rear seats so it’s easily accessible but still gives the driver a line of sight out the back window. It’s times like this we wish we didn’t have 40s.

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