Skidplate
Most currently offered long-arm kits require some drilling and welding to attach the skidplate and link mounts to the frame. Ours would be the same with weld-in bosses that pierce the frame. A flat, sturdy skidder would be ideal. The center would be removable, allowing tranny or transfer case access without disassembling the suspension, much like the three-piece assembly Rubicon Express uses on its long arm kits.
Springs and Shocks
Pretty much every manufacturer offers only one coil rate with its Wrangler lift kits. Unfortunately, most of our Jeeps don't weigh the same. A 4.0L-equipped Wrangler with a winch, spare parts, recovery equipment, camping gear, a trail rack with an 80-quart cooler, and a fullsize spare hanging off the back tips the scales at quite a bit more than the bare minimum 4-cylinder model. The lift height and ride will differ.
To combat this problem, our ultimate lift kit would feature 10- or 12-inch, travel-adjustable 2- or 2.25-inch coilover shocks with remote reservoirs up front. These can be adjusted to compensate for engine and winch weight differences. But if you have a really heavy rig (V-8 swap, for example) you could simply change out the easy-to-find coils for some heavier ones and adjust accordingly. The mounts would either be made from DOM tubing, like those from Fabtech, or a tastefully-done-in flat plate (pictured), like those from Currie Enterprises. They could be welded or bolted in place after cutting out the factory coil buckets.
The rear is a little trickier. Unlimited Wranglers have enough room to mount coilovers underneath the tub in the pocket just behind the rear passenger footwell. A bolt-in or weld-in crossmember would hold them in place on our ultimate lift. New shock mounts would need to be welded to the axle housing. The shorter Wranglers would be stuck with standard coils in the stock buckets, but there should be a light and a heavy spring rate available - or at least a progressive-rate coil.
Sway Bars and Steering
Unless your only wheeling involves the RTI ramp at the fairgrounds, you need sway bars on your 1997-2006 Wrangler. It's pretty well known that some of us on staff aren't fans of totally disconnecting the sway bar on the front of TJs for off-road use. Having coil springs all around can make for an unstable ride with it disconnected. That's not to say that the factory sway bar is ideal, though. It's just that the vehicle is much more predictable off-road with at least a light sway bar in place. What would be even better is a two-position sway bar; something that had a light rate for off-road and a stiffer rate for on-road use. The factory sway bar should remain connected in the rear.
The steering and front track bar on 1997-2006 Wranglers work together. You can't modify one without making changes to the other; bumpsteer will result if you do. A dropped pitman arm shouldn't be used unless the track bar is dropped the same amount. Likewise, the tie rod assembly, drag-link geometry, and configuration shouldn't be modified unless you're making up for it by relocating the track bar and visa versa. Our ultimate Wrangler lift kit would feature a heavy-duty, adjustable-length track bar that bolts to the factory mounts. It would utilize the stock pitman arm and also include a new heavy-duty, stock-like tie-rod system. This would be similar to the Currie Enterprises assembly, which is made from stronger, larger-diameter material and features tie rod ends that provide more angularity for suspension travel than the stock pieces.
Where is it?
So why doesn't this fantastic, ultimate, do-all Wrangler lift kit exist? Truth is, it will probably never get built. It would simply be too expensive as a complete kit. However, many of the features and components we like can be found in the many lift kits that are readily available. Mixing and matching these components could get you pretty close to our dream suspension kit. A little skill, along with the right fabrication tools, and you could get even closer. If any suspension company owners are reading, how about giving us the scoop if you build it?