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  1. #1
    Join Date
    Apr 2011
    Location
    Patchogue
    Posts
    4,032

    Grand WJ Rotted spring perch repair.

    So ive seen a few threads started asking about the front spring perches on the Grand Cherokee WJs (99 to 04s) and how they rot out under the rubber isolators on the axle. Ive seen many ask how to fix them but i had never seen a solution or DIY repair. Well Jason (Whosyodaddie02) had asked me some questions about his 99 WJ and what i thought. He was going to buy a set of used perches because apparently no one makes new replacements. Well me and Bob said why dont we make some from scratch. So Jason dropped it off at the shop to be our Guinea pig LOL.

    Started out by disconnecting the sway bar links and was able to remove the spring pretty easily. He has a Rough Country lift (4 inch i think?) The shocks are longer and gave plenty of travel so i did not have to un bolt them. then i removed the lower rubber bushings and found this.

    With the bushings still on



    Drivers side.




    Passenger.




    Just a bad design. The rubber holds in all the dirt and moisture. The plan was to cut the perch off and grind it down flat. Then plate the bottom and use 3 inch tubing as a new perch. We used 1/4 inch plate for the base and 3 inch black pipe for the tube. We went a little overkill on the thickness but the 1/4 plate we had and the black pipe from a plumbing place was alot cheaper than DOM. Black pipe is soft but for this purpose it was more than enough. We also decided to make the pipe be 4 inches rather than the 1 inch stock height to act as a spring retainer.

    First the cutting and prep of the axle. Cut the raised perch with a sawzall and ground it down flush.



    So we cut out the round plate base and the tube. Thats it just sitting before being welded up.



    Notched out where the bushing lines up with the hole.



    Welded the base plate in.

    Last edited by Goonies.nsd; 09-23-2011 at 11:23 PM.
    JUMPIN JEEP!
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    99 Cherokee XJ
    http://www.outlawedoffroad.com/showt...ot-99-XJ-build

    88 Comanche MJ
    http://www.outlawedoffroad.com/showthread.php/2167-Goonies-88-Comanche-MJ-Build




  2. #2
    Join Date
    Apr 2011
    Location
    Patchogue
    Posts
    4,032
    Now that the base was welded in i worked on the tube. I resisted the urge to plate the top of the tube. I knew water would find a way in. So why try to make it water tight. i left the top open. But how will the water and dirt get out. AAHHH make some drains.



    Test fit.



    Now burn it in.





    Not bad for a 120 welder.

    Shot it with some black paint.




    Now the rubber bushing. I had to cut the center out for a snug fit around the pipe.




    Now its time to put it all back together.






    Not bad. Not beautiful but to be honest the spring and bushing hide it all anyway. But now Jason has a stronger than stock lower spring perch and a spring thats not going to spit out on the trail when the suspension is at full travel. I was happy with how it came out LOL. Figured it out as we went.

    COST?
    About $60 bucks for material. We went a bit overboard and bought a a couple feet of pipe and a 2 x 4 sheet of 1/4 inch is not cheap. First timer would take a few hours. get some good sawzall blades and plenty of grinding wheels. Plus a quality welder Doi.

    There ya go. Whos next.

    P.S. Forgot to get a good pic of the botom of the rubber bushing and how the water drains out. I had to trim the bushing and some more of the base but did not get any good pics.
    Last edited by Goonies.nsd; 09-23-2011 at 11:27 PM.
    JUMPIN JEEP!
    http://www.youtube.com/watch?v=8A8wP...layer_embedded

    FACEBOOK
    https://www.facebook.com/goonies.nsd?ref=tn_tnmn

    99 Cherokee XJ
    http://www.outlawedoffroad.com/showt...ot-99-XJ-build

    88 Comanche MJ
    http://www.outlawedoffroad.com/showthread.php/2167-Goonies-88-Comanche-MJ-Build




  3. #3
    you kno nicole needs herss done well just add tht to the listt
    oh shit did i mention the spot

  4. #4
    Join Date
    Oct 2010
    Location
    Somewhere on Long Island
    Posts
    2,103
    Looks good.
    It's a Bronco thing........95 Bronco--6" Lift--37's--Hefty Fab Front bumper--BroncoAir rear bumper--SAS in the works

  5. #5
    Join Date
    Sep 2010
    Location
    Islip
    Posts
    476
    impressive, nice job!
    Always capitalize your "J"...

  6. #6
    Join Date
    Sep 2010
    Location
    North Massapequa,NY
    Posts
    565
    Looks good

  7. #7
    Join Date
    Apr 2011
    Location
    Patchogue
    Posts
    4,032
    Quote Originally Posted by Tat2dfreak View Post
    Looks good.
    Thanks. Figured it out as i went along LOL. Went a bit overboard on the all the way around welds and the thickness of the steel. But when i weld i get carried away.
    JUMPIN JEEP!
    http://www.youtube.com/watch?v=8A8wP...layer_embedded

    FACEBOOK
    https://www.facebook.com/goonies.nsd?ref=tn_tnmn

    99 Cherokee XJ
    http://www.outlawedoffroad.com/showt...ot-99-XJ-build

    88 Comanche MJ
    http://www.outlawedoffroad.com/showthread.php/2167-Goonies-88-Comanche-MJ-Build




  8. Likes Bandit1 liked this post
  9. #8
    Join Date
    Jan 2011
    Location
    westbrookville, ny
    Posts
    1,531
    Nice welds!!! , so if i send my jeep to you on a trailer while im in afghanistan, you can put my rear 4 link and coils in? Any experience building an exo cage? Actually being serious here bud!! Im looking to get some stuff done while im gone.
    1995 XJ
    Lifted, Geared (456), Locked F+R, Warn winch

    Outlawed Offroad May 2011 4x4 OTM.
    January 2012 Jeepforum XJ OTM.

    Been on fire, flooded, and jumped......still running strong
    http://www.outlawedoffroad.com/showthread.php?t=670

  10. #9
    Join Date
    Apr 2011
    Location
    Patchogue
    Posts
    4,032
    Quote Originally Posted by egodfrey View Post
    Nice welds!!! , so if i send my jeep to you on a trailer while im in afghanistan, you can put my rear 4 link and coils in? Any experience building an exo cage? Actually being serious here bud!! Im looking to get some stuff done while im gone.
    Ya know alot of people say my welding is good. But there are a few things im a real perfectionist with. Welding and exhaust. I didnt even want to post the pics because it didnt look like a roll of dimes LOL. I always worry about structural welding. This was just to hold it in place. Im sure they are there to stay LOL.

    Ive never built a cage. Done some welding on the figure 8 car chassis. Actually a friend of ours Ralph Tasso wanted to do this job in the worst way. He has his own figure 8 car and built his chassis from scratch. But i wanted to do it cause i love to weld. If i had the raw metal i would be welding up crap for the Jeeps like crazy.

    I would totally build you a cage if we could get a nice pipe bender for the shop. i would love that.

    Dont worry me and Ralph have another welding project in mind soon. 2x6 box steel rocker filler/ slides for the XJ.
    JUMPIN JEEP!
    http://www.youtube.com/watch?v=8A8wP...layer_embedded

    FACEBOOK
    https://www.facebook.com/goonies.nsd?ref=tn_tnmn

    99 Cherokee XJ
    http://www.outlawedoffroad.com/showt...ot-99-XJ-build

    88 Comanche MJ
    http://www.outlawedoffroad.com/showthread.php/2167-Goonies-88-Comanche-MJ-Build




  11. #10
    Join Date
    Jan 2011
    Location
    westbrookville, ny
    Posts
    1,531
    Well i like your welds, and im looking for someone to put in a clayton 4link rear 3 link front kit while i am overseas, of course with a nice set of 14bolt 60 axles. My dad will prolly trailer to whatever shop does the work. Once i obtain the axles and kit while deployed ill shoot you an email. Will be easy work, because youll be able to take as long as you want LOL! That s as long as you'll do it.
    1995 XJ
    Lifted, Geared (456), Locked F+R, Warn winch

    Outlawed Offroad May 2011 4x4 OTM.
    January 2012 Jeepforum XJ OTM.

    Been on fire, flooded, and jumped......still running strong
    http://www.outlawedoffroad.com/showthread.php?t=670

 

 

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