After 3 years and close the 30k miles, its finally time to upgrade the stock steering components. After shopping around a bit, I wasn't happy with the prices on aftermarket units available so I chose to build my own tie rod and drag link. After doing my research, I ordered DOM tubing, TRE's and bungs for a total of $270 with shipping. Everything was purchased from Ruff Stuff with the exception of the offset TRE's which are currently on backorder on the site.

I decided to document the whole process to serve as a guideline for others looking to replace the stock components without breaking the bank. I will separate this write-up into two posts for those only looking to replace one component at a time.

Tie Rod

Parts:
54" Length 1.5" .25 Wall DOM
(1) LH 7/8" Hex Head TRE Tube Adapter 18TPI
(1) RH 7/8" Hex Head TRE Tube Adapter 18TPI
(1) LH GM 1 Ton Offset TRE
(1) RH GM 1 Ton Offset TRE

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1) Take a measurement of the stock tie rod from the center of the tie rod ends. This measurement does not have to be exact since the new tie rod is adjustable. In my case, my tie rod was set at 59 inches.
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2) Assemble the offset TRE's with the jam nut threaded all the way forward and 1/2" of threads exposed in front of the bung. Measure the length of the TRE assembly from the center of the joint to the end of the bung. In my case, this measured 3.75".
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3) Now mark your tubing for the cut. It will be the overall length of the stock tie rod - (2) length of TRE assembly. In my case this is 59"-(2 x 3.75")= 51.5"
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4) Tape off the cut line and make the cut with the tool of your choosing (chop saw, ban saw, cutting wheel)
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5) Clean the edges of the tubing and grind a 45* bevel with your grinder. This will help ensure adequate penetration during welding.
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6) Slide the bungs in the tube and weld using the machine of your choice. I will be using my Miller Diversion 180 TIG for this application (Go easy on me. This is my first real TIG project).
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7) Prep your metal and paint the finished product. Allow 24 hours curing time before installing the TRE's and installing on the Jeep.
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