When it comes to Jeep modifications, there’s a fine line between style and functionality. Our custom CO2 system firmly lands in the functionality category, delivering game-changing performance both on and off the trail. Designed to manage critical components like our Yukon Gear and Axles rear Zip Locker and the Off Road Only SwayLOC, this system has changed the way we handle off-road challenges and highway cruising alike.
The Heart of the System
At the core of our setup is a durable CO2 tank. Our bottle is a 10lb Nitrous Outlet N2O bottle that has been modified so that the CO2 gas goes through the pick-up tube instead of the liquid. Power Tank make a more purpose-built option that can be purchased in many different configurations.
Our bottle is securely mounted to the Jeep’s floor using a Nitrous Outlet billet bottle mount. This high-quality bracket is built for drag racing, so it is vibration tested and ensures stability, even during rugged off-road adventures. Whether we’re navigating rough trails or cruising the highway, the tank stays firmly in place—no rattles, no shifting.
The system integrates seamlessly with an Up Down Air 4-tire inflation system that we modified to add a distribution block, allowing for individualized component specific pressure regulation while still enabling us to inflate our tires after a long day on the trial with ease.
More importantly, the CO2 system connects directly to our Yukon Gear and Axles rear Zip Locker, offering precise control over the rear differential. It is also paired with our Off Road Only SwayLOC, which provides unmatched stability, whether the Jeep is on the trail or tackling daily commutes.
Safety First: CO2 System Reliability
A common concern with CO2 systems is safety, specifically the risk of tank over-pressurization on those hot summer rides. However, quality CO2 bottles are equipped with a pressure relief valve that will empty the bottle before pressure reaches a critical level. For added security, Nitrous Outlet offers an NHRA approved setup that allows that pressure to vent outside the vehicle, minimizing any risk to passengers. Being aware of the temperatures in our home state of Texas, we added a Nitrous Outlet purge kit to our system to relieve small amounts of pressure without emptying the bottle.
Another concern that we hear is fire safety. While a vehicle fire will cause the bottles pressure relief to open and empty the bottle, this could help your situation. CO2 is nonflammable and is used quite often as a clean fire extinguishing agent.
We’ve tested this system in all conditions, including the scorching Texas summer heat, without a single issue. Proper installation and maintenance are key to ensuring safety and reliability, making this setup a worry-free solution for Jeep enthusiasts. Here’s a few tips.
- Install your bottle in a manner that helps to prevent the liquid CO2 from reaching the valve. The liquid is extremely cold. You don’t want this running through the lines to your components.
- Install your bottle in a location that is out of the sun. Sunlight increases the surface temperature of the bottle and the overall pressure within the bottle.
- Never replace a burst pressure disk with a plug. Not even temporarily. This is how bottles explode. Use a proper burst disk or pressure relief fitting on your CO2 bottle.
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Always use a pressure regulator. You don’t own a tool, component, or tire that can handle the full pressure of a CO2 system. And remember, CO2 is 800+ psi. The regulator that controls that isn't the place to skimp out.
- Always ensure that the bottle valve is closed when not in use.
Custom Controls for Maximum Usability
The user interface of our CO2 system was designed with real-world practicality in mind. The control switches are neatly housed in a modified JPockets Dash Pocket, blending seamlessly with the Jeep’s interior while keeping all functions easily accessible. While we did not, If you have a Genesis Offroad dual battery setup, one could even add their G-Screen to the low-pressure side of their setup to further ensure that they are regulated to the proper pressure for their components.
Off-Road and On-Road Performance
The benefits of this system extend far beyond convenience.
Off-Road Performance:
The ability to quickly inflate tires is a game-changer. The CO2 system’s high-pressure capabilities make it easy to optimize tire pressure for any terrain. With the Up Down Air setup, inflating or deflating all four tires simultaneously saves us time and effort.
The Yukon Gear and Axles Zip Locker adds another layer of off-road capability. Instantly engaging the rear differential provides superior traction on rocky or muddy trails, while the ability to disengage it ensures smooth handling in less demanding conditions. There’s really no need to wait for a noisy compressor to build pressure though. With CO2, the pressure is already there. And, the Zip Locker wastes such a small amount of pressure, a 10lb CO2 could last more than 100 locker activations with ease.
On and Off-Road Stability:
The Off Road Only SwayLOC significantly improves highway handling. Engaging the sway bar enhances stability for daily driving, even with oversized tires. When disengaged, it allows the suspension to flex for maximum articulation during off-road adventures. While the system typically uses a level on the SwayLOC, they carry a remote operation option for usage with low air pressure. It just made sense for us to run regulated CO2 pressure to it.
Why Choose a CO2 System Over an Air Compressor?
Opting for a CO2 system instead of an onboard air compressor was a strategic choice.
- Speed: CO2 delivers high-pressure air instantly, making tire inflation faster than traditional compressors.
- Reliability: With fewer moving parts, CO2 systems require less maintenance.
- Efficiency: CO2 systems operate silently and do not strain the Jeep’s electrical system—perfect for vehicles running multiple accessories.
Additionally, the Nitrous Outlet bottle bracket allows for easy removal of the tank when not in use so that it is out of the way when not needed. For those seeking even more convenience, a quick-release chuck for the feed line is available from Nitrous Outlet as well.
Beyond tire management, the CO2 system is versatile enough to power air tools, operate the Zip Locker, and control the SwayLOC. It’s a multi-functional upgrade that enhances every aspect of our Jeep’s performance.
Final Thoughts
Our custom CO2 system has taken our Jeep’s on-the-fly capabilities to a new level. Whether it’s tackling challenging trails, attending Jeep meets, or cruising around town, this setup ensures we’re ready for anything.
If you’re considering a CO2 system for your Jeep, we highly recommend it. With the right components and a bit of customization, you can unlock a whole new level of performance.
Have any questions or do you want a detailed breakdown of our build? Let us know in the comments—we’re happy to share tips and advice to help you set up your own CO2 system!