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Trying to get it mostly right the first time: A 5.9 Magnum and 46RE swapped, Tummy Tucked Daily Driven Jeep TJ
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<blockquote data-quote="Dan_Goodwin" data-source="post: 763262" data-attributes="member: 4960"><p>I took off work on Friday the 11<sup>th</sup> to spend working on the Jeep. The goal for the day was to get the transmission crossmember completed and start on the exhaust.</p><p></p><p>I purchased the Barnes 4WD Crossmember Mounting Set to serve as the foundation. Since the TJ frame tapers in and I wanted the bushings to be parallel with each other I used a straight edge on the UCF skid plate to mark and trim the mounting tabs. I am quite a ways from claiming to be proficient at tube bending, so take my building process as a grain of salt. My skid plate has a 1" drop (measured from the mounting flange to the top of the skid), so I cut 2 1" spacers and clamped up my level to use as a straight edge and figure out the bends. The tube had to be directly under or behind the front CV joint for it to clear the drive shaft, so I opted to put it directly under the joint.</p><p></p><p>[ATTACH=full]161096[/ATTACH]</p><p></p><p>After 2 bends and a few trips back and forth to the notcher, this was the final result:</p><p></p><p>[ATTACH=full]161098[/ATTACH]</p><p></p><p>I opted to use the factory transmission mounting plate as part of the crossmember. It's not as elegant as I wanted, but it was simple and worked. I cut and notched 2 short tubes to tie this mount to the crossmember. And no, I didn't weld those huge gaps – the tubes were readjusted after this was taken.</p><p></p><p>[ATTACH=full]161097[/ATTACH]</p><p></p><p>With the crossmember tacked together, the exhaust was the next piece to tackle. The Durango used 2.5" exhaust, and since I was utilizing the Durango manifolds and Y pipe I chose to maintain that size on my Jeep. Had I started from scratch I would have likely done a 3" all the way back.</p><p></p><p>The addition of the crossmember made routing the exhaust a tight squeeze, but a fairly simple ordeal. I welded on a pair of 3 bolt exhaust flanges from Summit Racing to mate the new exhaust to the Durango Y pipe and ran the new catalytic converter and muffler straight back to the factory exhaust hanger. An O2 sensor bung was added behind the cat to maintain the stock configuration. I'll let an exhaust shop bend a new tailpipe for me once I have this running and driving.</p><p></p><p></p><p>Spoiler alert: I didn't get ALL this done on Saturday. I can't have y'all thinking I work that fast....</p></blockquote><p></p>
[QUOTE="Dan_Goodwin, post: 763262, member: 4960"] I took off work on Friday the 11[SUP]th[/SUP] to spend working on the Jeep. The goal for the day was to get the transmission crossmember completed and start on the exhaust. I purchased the Barnes 4WD Crossmember Mounting Set to serve as the foundation. Since the TJ frame tapers in and I wanted the bushings to be parallel with each other I used a straight edge on the UCF skid plate to mark and trim the mounting tabs. I am quite a ways from claiming to be proficient at tube bending, so take my building process as a grain of salt. My skid plate has a 1" drop (measured from the mounting flange to the top of the skid), so I cut 2 1" spacers and clamped up my level to use as a straight edge and figure out the bends. The tube had to be directly under or behind the front CV joint for it to clear the drive shaft, so I opted to put it directly under the joint. [ATTACH type="full" alt="01e7ec1cf8fbedd06ea103c648d1889efd59cd119f.jpg"]161096[/ATTACH] After 2 bends and a few trips back and forth to the notcher, this was the final result: [ATTACH type="full" alt="0150ab11b4827bdf3e1b2e23b236817dc23ff30ef5.jpg"]161098[/ATTACH] I opted to use the factory transmission mounting plate as part of the crossmember. It's not as elegant as I wanted, but it was simple and worked. I cut and notched 2 short tubes to tie this mount to the crossmember. And no, I didn't weld those huge gaps – the tubes were readjusted after this was taken. [ATTACH type="full" alt="0143faf57b065f61259f407662b53a124e4358782d.jpg"]161097[/ATTACH] With the crossmember tacked together, the exhaust was the next piece to tackle. The Durango used 2.5" exhaust, and since I was utilizing the Durango manifolds and Y pipe I chose to maintain that size on my Jeep. Had I started from scratch I would have likely done a 3" all the way back. The addition of the crossmember made routing the exhaust a tight squeeze, but a fairly simple ordeal. I welded on a pair of 3 bolt exhaust flanges from Summit Racing to mate the new exhaust to the Durango Y pipe and ran the new catalytic converter and muffler straight back to the factory exhaust hanger. An O2 sensor bung was added behind the cat to maintain the stock configuration. I'll let an exhaust shop bend a new tailpipe for me once I have this running and driving. Spoiler alert: I didn't get ALL this done on Saturday. I can't have y'all thinking I work that fast.... [/QUOTE]
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