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

Ken_00 · Jun 22, 2008

Well...we don't have an official project name for this build yet...but we're open to suggestions!! 8)

We've had this build going on in the shop for a lil while now 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

Ken_00 · Jun 22, 2008

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

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... :afro:

-Kenneth

Ken_00 · Jun 22, 2008

Just 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.

Will be finishing up a matching front bumper with grill hoop/stinger tomorrow. As well as pulling everything out for final weld/paint & then hopefully reassemlby tomorrow night (Long Day Tomorrow!)

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

We should be taking this thing Tuesday to the exhaust shop.

-Kenneth

Rescue1 · Jun 22, 2008

Looks good man.

Bones · Jun 22, 2008

WOW you do nice work and make some trick brackets. 8)

Baustin · Jun 24, 2008

Looks good Ken

Ken_00 · Jul 3, 2008

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

Ken_00 · Jul 3, 2008

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

Ken_00 · Jul 3, 2008

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"

Ken_00 · Jul 3, 2008

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

Beyer · Jul 4, 2008

Jeep looks good. Any shakedown issues?
Did you take your jeep?

Ken_00 · Jul 4, 2008

Beyer said:
Jeep looks good. Any shakedown issues?
Did you take your jeep?

Thanks.....
The full hydro still had a little air in the system Friday. Saturday morning we topped the fluid off & it was fine. Other than that, just had to adjust the t-case linkage one last time, & tighten bolts Friday night.

Negative on my Jeep. That thing may be up for sale soon...got some ideas running around in my head. LOL

Ken_00 · May 25, 2011

UPDATES!!

Here we go....

He has wheeled this thing quite a bit over the last couple of years & it's been put through the paces...Lol

After this roll happened, he decided it was time to change things up quite a bit so....

- A '10 LS3 was installed along with a Built TH350 then mated to the already in place Atlas T-Case

Ken_00 · May 25, 2011

After that roll....Troy replaced the Body & then brought it to us for the rest.

We lowered the suspension down drastically & added FOA Air bumps to all 4 corners.

You can see here how it was a tight fit to get everything packaged in there

We had to bend the Swaybar Arms for clearance around the new front Coilover Hoops

Ken_00 · May 25, 2011

When Troy installed the LS3, he had a transmission cooler installed but it was installed inside the tub in the rear cargo area.

He wanted us to move it to a different location so he could gain that storage space back.

We decided to stuff it under the tub. We had to strategically place it where it would clear the upper control arms at full compression.

Also, because it would now be under the Jeep & potentially in harms way....We designed & built a removable, protective shroud for it.

Here it's mounted under the tub.

Ken_00 · May 25, 2011

Here's a couple overall shots of the Jeep completed

Sitting Low on 40's

We also added some of our TJ Tube Fenders to the Jeep while it was here.

Front Diff got some Heavy Duty Protection from one of our KORE Diff Covers. Also in this picture you'll notice our Frame Notch Kit that we installed. We designed these a while ago to allow to lower the suspension of the Jeep & still keep the steering up out of the rocks. (Call for more details...We haven't added this product to our website yet)

PSC Double Ended Ram mounted on our Truss System