Kevin's Offroad

Kevin's Offroad

Thought you guys might like to check out some video of a very cool KJ Liberty SFA ( solid front axle ) project we’re doing here at KOR this week.  The plan is to develop a bracket system that allows KJ owners to more easily do a SFA swap, and convert to long coil-overs to add TONS of flex to the front end.

On this one, we’re installing the axles that were under our black shop ZJ before we parted it out and unceremoniously discarded it’s carcass.  The rear axle is a cast iron version of the Dana 44 , out of an ’87 XJ Cherokee with the tow package, and upgraded to 33 spline Alloy USA shafts, carries an OX Locker, and has 4.56 gears.

The front axle is an import from Venezuela, which was a brand new High Pinion Dana 44 housing purchased from a Venezuelan Jeep dealership, and imported to the US for us.  It received a 30-spline Alloy USA inner and upgraded outer kit, dust seals, and slotted rotors before it was installed under the ZJ.

UPDATE:

Due to lower than expected demand, and the price of the components, we killed off the “SFA Install Package” portion of this build after the prototype was built.  The fabrication staff that worked on the project is not around any longer, so we can’t answer any specific questions, but here’s the line items from our customer’s invoice, in case it’s helpful to you in your own build:
Front:
Clayton 36″ long lower front arms
U-Turn steering Upgrade:
http://www.kevinsoffroad.com/cart/uturn-xjzjtj-repl-tie-rod-drag-link-kit-p-412/
Custom fab and bent track bar
10″ or 12″ Fox Coil-overs (don’t remember which one we used…we
purchased both to test)
Ballistic Fabrication HD Flat Bottom shock tabs for coilover mounts
Steering gear box from Bronco II, Pitman arm unknown, but MAY have
been from an XJ.
Custom power steering hoses from HosePower, made to spec
Borgeson p/n 013452 1″ DD to 3/4″ – 36-spline u-joint for steering
linkage to Bronco II box
XJ/ZJ/TJ 28″ front SS brake lines

Rear:
Clayton WJ rear upgrade kit, which included the triangulated setup
using their rear frame brackets from a WJ:
http://www.kevinsoffroad.com/cart/clayton-long-arm-barebones-9904-wj-grands-rear-half-only-p-785/
OME 863 rear coils – 80-series Discovery
Bilstein BE5-6248-H5 rear shocks (10″ travel)
XJ rear stainless steel braided 18″ brake line
Addco ZJ rear anti-sway bar with custom endlinks

Drivetrain:
Tom Wood front and rear driveshafts, custom length
Omix ADA Slip Yoke Eliminator older-style 231 case, early XJ

Hope this helps.  We wish we could help you with specific answers to your
questions, but we got rid of everything, including specific details,
measurements, and so on.  The two portions of the build, mentioned above, are the only items we can provide you with currently.

It was a fun build, and a lot of fun to drive after it was complete.  If you take it on, figure 60+ hours worth of work, including the SYE, the custom fab of parts, welding, paint, trimming the fenders, custom fab of the steering box bracket, post-install tire fitment issues, etc.