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By Norm Larch, photos courtesy of Andrew Holliday
In our last two issues, we showcased the Coty Built TDI conversion, which is certainly a cool upgrade, but beyond the potential for newfound fuel economy, the dream of mud slinging, rock crawling torque comes into focus. In its native format, this 2007 JK X rates only average for off-road usage. The X designation saw a factory Dana 44 outfit at the rear with the NSG370 6-speed on the floor. At 58,000 km, the OEM rubber has done its time and is not up for much more action than being recycled into playground mats. Marcel Horn of Coty Built has his sights set to debut this build at the 2015 Moab Easter Safari. To do so, there is a lot that needs to be addressed to convert this average trail rig into a Rubicon rival.
The largest complaint of any JK owner is that while the body (for the most part) was designed to take 35-in tires, once monster rubber is installed the get up and go is lackluster. Even worse is the penalty paid at the pump for the less than thrilling acceleration runs back and forth to the trailhead. To show off the entire range of the TDI conversion, Coty Built plans to install a set of 20-in rims and 37-in tires. This will be the largest set of tires the team has fit onto a build, but they want to push the TDI to the limit and see the real world impact of such trail gear on the TDI’s known mileage.
As you can see from the pictures, to kick off the aftermarket assault on the 2007 JK X chassis, the Coty Built team pulled off the OEM fender flares to open the wheel arch gaps with a modern interpretation of a retro thin flare and rock sliders set from Rugged Ridge. Being an early model JK*, the rear fender arches have an extension on the pinch weld that will cut into a 35-in or larger tire under full articulation. The team trimmed 2-in along the lower seam and welded it closed to offer maximum opening and clearance for the inbound rubber. *On 2013 and later JK’s this pinch weld has been removed from the factory.
With an extra inch of clearance, Rugged Ridge’s Hurricane fender flares also provide additional tire coverage. The Hurricane Flat Fender Flare is injection molded and constructed of durable TPE, which creates a flexible yet very strong fender flare.
The Rugged Ridge brand was established in 2005 and is a division of Omix-ADA. Rugged Ridge has designed and manufactured over 3,000 products for the Jeep market and offers the Coty Built team a one-stop shop for kitting out their JK X.
One of their most interesting and patented products for the JK is the XHD modular bumper system; a great fit for any trail rig. This unique system allows the enthusiast to design the bumper to meet their targeted needs. Coty Built’s team was looking for a great approach angle and a tough look so the bumper end caps were omitted and a double X striker bull nose was added to round out the winch mount for the front of the JK.
Rugged Ridge’s 8,500 lb winch was mounted and features a durable 5.5 HP wound motor for long life and extra pulling power. The winch has an automatic load holding brake system in the drum brake system.
At the rear, the XHD Gen 2 swing-away bumper and tire carrier give the structure needed to support a 35-in or larger spare. The neatest thing about the Rugged Ridge tire carrier is that the Gen 2 allows owners to mount a 37-in tire and operate both the carrier and tailgate simultaneously without any hassle. Just push the button and you can open the rear door without needing to break out a tool kit.
Selecting tires for your build is no easy task. With the growing popularity of 20-in and larger rims for the JK, you have to decide if you want a lower profile sidewall, which is associated with aesthetic curb appeal or a more trail oriented and purposeful tire. Coty Built called on BFG to skin Rugged Ridge’s new 20-in Drakon rim with a set of 37x12.50R20 KM2’s. The Krawler-inspired treads on these tires have a unique dual groove pattern, which gives them the ability to flex in off-road situations while still providing traction on soft ground. With their incredible sidewall strength, these tires can really take a beating.
Standing back, you can see the TDI JK starting to take form. The body is now accepting of the new 37-in tire and wheel package, the spare sits securely on the rear bumper mount and the front is begging to attack the BC outback.
Follow along in our next issue as we address gearing that will speak to both the powerband of the TDI and the rolling diameter of the 37’s along with wrapping up the trail Kit for the JK X.