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Story by Dave "Rock Wizard" Baker

Readers Rides Showcase
September, 2000

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Joseph Greenway's '87 YJ

Joseph's Jeep came to me with homemade nerf bars welded to the frame. We cut the bars off at the frame, cut a 15-degree angle and remounted the bars on the frame to run up against the rocker panels. The rear shocks were run off the rear of the bars to the rear axle at a 45-degree angle. Most shocks would not do well at this angle, but the RS 9012's are Rancho's adjustable masterpiece. At 34 inches extended length they are the longest shocks Rancho makes. Even with 34 inches of extended travel, the angle was necessary to account for the flex of a 1/4 elliptic suspension.

For the front of the Jeep, Joseph had chosen a Dana 44. We first outfitted the 44 with a custom crossover steering conversion using the same 1.25" seamless tubing and 3/4" heims. Next, we built the shock brackets to mount on the axle. A front bumper was custom built to accept the new width necessary to mount a full width axle and a Warn XD-9000i winch. The front spring hangers were built into the bumper. We built the front spring hangers longer than normal, approximately 4 inches longer. This allowed for the installation of the front axle without the addition of shims. Shims are a weak point, and will eventually allow movement when you least expect it. The elimination of shims while still providing correct driveline angles and steering geometry was important. There are several ways to do this, but we chose to run stock YJ springs on the front and the lengthened hangers allowed us to account for the height necessary to clear 38.5 inch tires under full flex with soft, flat springs and cut fenders.

The articulation in the front end was accomplished with stock, well-used YJ spring packs and a 3/4 elliptic set-up. The buggy springs, made from YJ main leafs, were approximately 18 inches long and conformed to the bottom of the frame. With the front end complete and installed, the custom shock towers were fabricated and welded on, as well as the shock brackets to the axle. We mounted the RS 9012's nearly perpendicular to the ground. Most people mount the shocks at an angle toward center. But the 3/4 elliptic front suspension allows the axle to droop forward during articulation, therefore, the more forward the shock is mounted - the more articulation that is achieved. Quite frankly, too far forward looked odd, so we settled on straight up and down. The installation of the shocks completed the front suspension.

A track bar system for the front was not utilized. This too may seem odd, but with the elimination of shims, the axle is setting strong on its stock axis. Axle wrap in this scenario was evident, but not a problem.

With the completion of the front and rear suspension and some major fender cutting, it was time for some in-house testing. We positioned the vehicle on a free-mount in-ground hydraulic lift. The passenger front tire was secured and the lift was raised. I was surprised to find the lift maxed out. The rear wheels and tires, upon compression, tucked right up in the cut fender wells. It was awesome! The extended shocks had approximately 1.5 inches of travel left and the compressed shocks had about 1 inch of travel remaining at full flex. Driveline angles remained the same throughout travel and the steering never bound or rubbed. At this point, Joseph called all his friends and the vehicle was put on the lift numerous times. What a cool feeling, I have to say I never got tired of looking at it. But this was just the appetizer. The main course was still to come.

A cage was born. We constructed a full custom Rock Armor cage and tied it into the frame. Due to the situations you can get yourself into with a Jeep that can go just about anywhere, the utilization of thicker tubing was a necessity. The fuel cell was then installed and hooked up (notice we waited to install the fuel cell until after the cage was welded in) and the drive shafts were custom made and installed.

The first place the Jeep saw, ironically, was not dirt. It was pavement. We took the vehicle outside the bay door, shifted into four wheel high, took her to about 6000 rpm and dumped the clutch! White smoke poured from all four wheels! I mean, we lit that sucker up! Everything held, Joseph. Here's your Jeep back - let's go riding.

It took a week or two for Joseph to get accustomed to his new Jeep. The ride was now different. On-road, the ride takes getting used to, as it was not designed for on-road daily driving. Offroad, the vehicle performed flawlessly. Like driving your grandma's Caddy. The first real test for the Jeep was a couple of months ago at the Rosser Roundup in Monteagle, Tennessee. We had a blast. I got to ride shotgun through creek bed trails and straight up hills. Although Joseph found a natural position for his right foot (on the floor,) we never broke out a winch or opened a toolbox. It was incredible. Sunday, after the raffle, hundreds of people gathered for the flex-off on Sports-in-the-Rough's 30-degree ramp.

Trucks went up and trucks went down. Joseph's Jeep went up and to the top then ran out of gas. Apparently, after the trail ride that day, we forgot to fill up. The gas was gathering on the passenger side of the fuel cell. The pick-up is on the driver's side. It was terribly embarrassing and infuriating. With the vehicle not running and 3 lbs. of pressure in the tires, it was stuck on top of the ramp. People started hollering and laughing. I got to see Joseph pissed off for the first time! He put the tranny in reverse and turned the ignition over to move the Jeep slowly down off the ramp. He looked around, stood up through his cage and declared, "I'm going fill this thing up. When I get back, I'm gonna drive over this SOB!" You know that got everyone pumped up.

We left, filled the tank until it overflowed, and headed back. I think everyone was surprised just to see us return. As Joseph pulled up, the crowd parted. There was a clear path for 20 yards straight to the edge of the ramp. You could hear the mumbling and snickers of the doubters. It was pretty nerve racking. As Joseph approached the ramp, he didn't bother with positioning or popular ramp angles. He drove to, up, and back on top of the 30 degree RTI ramp. People started screaming and yelling, cheering him on to drive over it. With the driver's side tire dangling off the edge, he looked over at me with a question mark stamped to his forehead. I said, "well, you know what ya gotta do." With that, he turned the steering wheel far right and goosed it. The Jeep went off the top of the ramp and "gently" slammed to the ground with the suspension perfectly absorbing close to a 6-foot drop. Absolutely incredible! People were cheering so loud you couldn't hear yourself think. I stepped away and watched from a distance. If you could have seen the look on Joseph's face that evening; you could begin to understand why I do what I do. He got his chest to stick out a full inch! (Good job Joseph! You earned it that night, pal!

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