Project KJ: Fuel Cell and Body Prep
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.
BDS Project KJ: Body mods and Coilovers prepped
Project KJ Update: Lots of progress for the day, the rear window chop is getting capped off as well as the tailgate. Â 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.
Project KJ: What color would you pick?
Project KJ is coming together and its almost time for paint/wrap/graphics. What color would you pick?
Project KJ: The Fab Life
Project KJ Update: The Fab Life
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.
BDS Project KJ: Parts/Progress on the Daily
BDS Project KJ: Parts/Progress on the Daily
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.
BDS Project KJ Progress, Rear Fabrication
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.