K.O.R.E. Build -Troy's TJ

[TJ Ken]

Well...we don't have an official project name for this build yet...but we're open to suggestions!!   

  We've had this build going on in the shop recently and thought we'd share some pics of our work & upcoming products.

  So anyways...bring on the pics!

We started with this:

 A '97 Jeep Wrangler with an I-6, Auto, 4" Skyjacker lift, HP 30, & 8.8 Rear Axle.








  Troy drove down from Illinois with the Jeep & a pile of parts on the trailer.

Some of those parts included:
 - HP 60 front with Detroit & 4.88's
 - HP 60 Rear with Detroit & 4.88's
 - 39" Irocs
 - 17" Trailready Beadlocks





 Plans for the build Include the following:

- 105"-108" Wheelbase

- PSC Full Hydraulic Steering

- Custom 4 Links front & rear

- KORE Flat Belly Skid Plate

- Atlas II 3.8

- Coilovers all Around

- Fuel Cell

- KORE 7075 Aluminum Control Arms

- New KORE bracketry for front & rear axles including trusses

- Frame Tie-Ins for existing Cage

- Swaybars Front & Rear

[TJ Ken]

Rear Axle Cleaned up...Removed old junk Truss & brackets

 Ready for New Stuff!





 Axles mocked up at appropriate wheelbase





 Closer Look At the Rear.

We're using a set of Blank Corner Guards so that we can cut the wheelwell opening exactly where we want it for a clean look

[TJ Ken]

A few more buildup pics....

Rear 4 Link Setup

Used a set of our new Frame Brackets to make that side super easy to install 





 Rear 60 Truss Installed





 We had to 'C' Notch the frame to get the Coilovers to tuck in nicely






  I'll have more pics soon of the finished rear 4 link.  As well as brake line routing, sway  bar mounts, & fuel cell install.

  It's turning out pretty clean, if I do say so myself...LOL


-Kenneth

[TJ Ken]

We made a ton of progress this week!

 Last night, we finished up the rear bumper that I thought turned out pretty cool.

CNC cut from 3/16" plate & then formed on our press brake.

  Two 5/8" thick D-Ring mounts are welded to the bumper.  These get passed through the face of the bumper and are welded to a plate that is roughly 3"x8" that will spread the load along the bumper.
  Obviously the D-Ring tabs are welded to the face of the bumper too.






  Only the one teaser pic for now!! LOL


Gotta run.  I'll get more pictures up soon.


  We should be driving this thing by Tuesday.


-Kenneth

[TJ Ken]

Ok....I'm going to fill in the gaps!  LOL

 We got this rig done & took the Owner to Clayton for a shakedown run.  Other than just a bleeding issue with the full Hydro steering, it works flawlessly!

 
  Here's the rest of the buildup pics...Enjoy

 Closeup showing what we had to cover up with the rear corner guards...









  Our new Hi-Clearance Skid Plate getting mocked up






  TIG Welded the Sway Bar Links






Fuel Cell Setup





 Rear Truss Area all cleaned up

[TJ Ken]

Some More Front Truss Pics





















  Custom Bracket we made to hold the orbital




  Front Coilover Mount





  Another View of the Rear Bumper









  The matching front bumper we fab'd up 

[TJ Ken]

Couple of Flex Pics before Paint/Powdercoat






















  Now some with Paint/Powdercoat























  It sits a little tall, but we've got some shorter top coils coming so it can be dropped down about 2-3"

[TJ Ken]

Couple More.....





















  The Wheeling Pics from Clayton, Ok.....

We didn't snap a ton of pictures while wheeling.  We were in a group of just 3 rigs, so we covered a lot of ground fast & kind of forgot to get pics!

  Got too excited wheeling....We don't get out of the shop much! LOL