It's time for the crossmember!
Here is the the finished piece - ready to drill and mount into the rig. It's a thing of beauty. This crossmember has several design elements from Blaine that are absolute treats ...
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If you look at the TJ frame, it angles near the skid plate ..
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The cross member follows the shape of the skid. When Blaine bent the cross member and designed the flanges, he cut the ends at two angles, one to follow the angle of the frame and then the second on the end for the mounting flange so it would end up parallel to the eventual bottom flat section of the skid.
A straight edge on the ends, left side and right side , showing how even things are side to side.
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He then made the matching frame side flange that is nicely welded to the frame .. and 3 bolts connect them together on each side. This pic below shows the final installation showing how everything looks at the finish, but of course, getting everything situated exactly where they needed was not trivial.
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This was the process to get to the final pics above ..
The crossmember was first bolted up to the transmission mount with the mock up crossmember piece holding it up. This was used to figure out the height for the final setup, and it looked like shims totaling about 3/8” in thickness were needed to put the case up where it needs to be height wise. Blaine split that into 2 pieces each 3/16” thick, one on top of the trans mount and then one under the trans mount. These are shown with green arrows below. The reason to split the shims was the studs from the 2-part trans mount from earlier would have been too short if all the shim was at the bottom.
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After the shims were welded in, the crossmember was installed to correct height again. Then the frame brackets were clamped in place, tack welded, and then drilled in place through the holes in the flange on the crossmember.
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One very nice piece of detail work on the recessed holes in the crossmember. Blaine sized the holes were by fitting impact socket inside them to ensure that no special tool would be needed to remove the nuts on the transmission mount. Blaine cut pieces of tube, stuck them in the holes, welded around them and then ground them flat. Below is the end result .. the amount of work that went into making what seems simple from the outside just blows me away.
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With all the care taken to make sure the heights are exactly what they needed to be, we ended up with ample space at the top of the Atlas case (yellow arrow) and no chance whatsoever of the t-case contacting the tub. You can fit your entire palm in there easily.
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After finishing all this up, Blaine started on the belly skid .. and that will be a separate post since the spectacular work there deserves it's own post!
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