Refreshing the TJ - Build Thread

[GP'd]

This is a build thread for my ever evolving rig to keep myself motivated and to share thoughts and ideas related to this hobby.

I purchased this truck in 2007 as a stock 2000 TJ Sahara at around 60,000 miles and presently have around 135,000 miles on the ticker. Through needed maintenance I have begun upgrading the truck and ended up with a reliable vehicle that has taken me many places. Unfortunately, most of the suspension is factory and thousands of miles on fireroads and trails have taken its toll.

The plan is to replace and upgrade the entire suspension to ensure continued reliability, easy maintenance and address some weak points and downsides of the drivetrain while everything is torn apart. Clearly this list of modifications will not happen overnight, but I have built or am building most of the components out of the vehicle. I hope to keep this Jeep low and lightweight, yet have the capability to carry a comfortable load for extended trips for 2 people. Though it currently does that now, much needs to be addressed for what I picture as my ideal Overlanding TJ.

-Gianni

Note: I will do my best to reference locations purchased and part numbers of components I have picked up. If there are issues with these links or they are broken please let me know. I will also do my best to reference other builds and informational resources as I address them in the tread.

2000 Jeep Wrangler TJ - Before

Chassis
Frame / Chassis : Factory
Cage : None
Overall Wheel Base : 93.25”
Overall Length : Front Hitch to Tire ~160.00”, Front Hitch to Rear Hitch ~155.0”
Belly Pan Clearance : ~12.50 “ (lowest point of bottom skid)
Overall Height : ~79.00” (Highest point rear rack unloaded)
Wheel Track Width : ~59.25
Overall Weight : TBD
Front Shock Travel : 8.00"
Rear Shock Travel : 6.75"

Powertrain
Engine : Factory 4.0 Liter, Precision Auto Injectors (99Jeep4Upgrade) (http://www.precisionautoinjectors.com/product.sc?productId=32&categoryId=3), Flow Cooler Water Pump (1750) (http://www.quadratec.com/products/51212_60.htm)
Batteries : Optima Red (Part Number is faded)
Radiator / Fans : Flex-a-lite Puller (485) (http://www.google.com/url?q=http%3A%2F%2Fwww.flex-a-lite.com%2Fauto%2Fhtml%2Fjeep-wrangler.html&sa=D&sntz=1&usg=AFQjCNFCeGRS2ESr12ahRdorAzNxwogXlw)
Air Intake : Factory Intake, K&N Filter (33-2114) (http://www.google.com/url?q=http%3A%2F%2Fstore.knfilters.com%2Fsearch%2F product.aspx%3FProd%3D33-2114&sa=D&sntz=1&usg=AFQjCNHHF2s91PDj8Ba-OqQhzE2IuXWhng)
Exhaust : Factory
Muffler : Factory
Transmission : TF999 - 32RH (http://www.google.com/url?q=http%3A%2F%2Fwww.jeepforum.com%2Fwiki%2Finde x.php%2F30RH_%2F_32RH&sa=D&sntz=1&usg=AFQjCNHDVr4Slhpy7dJXKe6Fk4shYx8AeA)
Torque Convertor : Factory
Transfer Case : NP 231 J (http://www.google.com/url?q=http%3A%2F%2Fwww.novak-adapt.com%2Fknowledge%2Fnp231.htm&sa=D&sntz=1&usg=AFQjCNG1AdU5cmOOPWUDpfNX1doYH3s_dA)
Transfer Case Shifter : Factory
Fuel Containment : Factory

Body / Interior
Body / Body Panels : Factory
Body Modifications : Dents & Scratches
Skid plate / Material : Factory
Hood / Grille : Factory
Top : Factory Hardtop
Armor : Factory
Dash / Gauges / Switches : Factory
Steering Column / Wheel : Factory Tilt
Pedal Assembly : Factory

Drivetrain
Front Suspension : Factory Coils, Teraflex 2” Spacer (1245200) (http://www.google.com/url?q=http%3A%2F%2Fwww.teraflex.biz%2Ftj-budget-boost-1-5-w-shocks.html&sa=D&sntz=1&usg=AFQjCNFPN1oPLWk-pRn_q9uBKGC7JF0DPw) - Purchased Used
Front Shocks : Bilstein (24-024426)
Front Sway Bar : Factory, JKS Quicker Disconnects (20301) (http://www.google.com/url?q=http%3A%2F%2Fstore.jksmfg.com%2Fmerchant2%2F merchant.mvc%3FScreen%3DQRDISC%26Store_Code%3DJKS0 1%26Category_Code%3DSwaybar_Disconnects&sa=D&sntz=1&usg=AFQjCNHnXOfryD_SXzkakIZQNxxfB8XYYA)
Front Bump Stops : Factory w/ Homemade Extensions
Front Axle Housing : Dana 30
Front Locker : None
Front Ring & Pinion : 3.07
Front Differential Cover : Factory
Front Axle Shafts : Factory
Front U-Joints : Factory
Front Brakes : Factory Components, Crown Industrial 5 Layer Hoses (12706.422) (http://www.google.com/url?q=http%3A%2F%2Fwww.quadratec.com%2Fproducts%2F 12706_42X_PG.htm&sa=D&sntz=1&usg=AFQjCNF-ikQ1acVGAvwIzgXiFPROBWIvPQ), EBC Yellow Pads (EBCDP41255R) (http://www.google.com/url?q=http%3A%2F%2Fwww.ebcbrakes.com%2Fautomotive% 2Fyellowstuff_brake_pads%2Fyellowstuff_truck_brake _pads_index.shtml&sa=D&sntz=1&usg=AFQjCNHfpmcd0FlYxDNmB9OUO_15L1SGfg), Centric Premium Front Disc (CE120.67045) (http://www.google.com/url?q=http%3A%2F%2Fwww.thepartsbin.com%2Fcatalog%2 F%3FN%3D9179%26Nr%3DOR(AND(make%3AJeep%2Cmodel%3AT J%2Cyear%3A2000)%2CAND(universal%3A1))%26Vi%3D1557 %2B4294956248%2B4294963365%26y%3D2000%26mk%3DJeep% 26md%3DTJ&sa=D&sntz=1&usg=AFQjCNH7zKkg6U5ioMnUlbQ7bL5n1OeSFg)
Front Steering Setup : Currie HD Tie Rod System (CE-9701) (www.currieenterprises.com/cestore/product.aspx?id=1219)
Front Driveshaft : Factory
Rear Suspension : Factory Coils, Teraflex 2” Spacer (1245200) (http://www.teraflex.biz/tj-budget-boost-1-5-w-shocks.html)- Purchased Used
Rear Sway Bar : Factory
Rear Shocks : Bilstein (24-024433)
Rear Bump Stops : Factory w/ Homemade Extensions
Rear Axle Housing : Dana 35
Rear Locker : Factory LSD (rebuild after blowing up clutches)
Rear Ring & Pinion Ratio : 3.07
Rear Differential Cover : Factory
Rear Axle Shafts : Superior Dana Rear Axle (SAG-PA5947A, SAG-PA5947B) (http://www.polyperformance.com/shop/Superior-Dana-Rear-Axles-p-21362.html)
Rear Brakes : ZJ Disk, Crown industrial 5 Layer (12706.422) (http://www.quadratec.com/products/12706_42X_PG.htm), EBC Green Truck Pads (E35DP61606) (http://www.ebcbrakes.com/automotive/greenstuff_brake_pads/greenstuff_brake_pads_6000.shtml),Wilwood Knob Proportioning Valve(260-10922) (http://www.polyperformance.com/shop/Wilwood-Knob-Proportioning-Valve-p-72.html)
Rear Drive Shaft : Factory
Tire Make / Size : Goodyear Wrangler Duratrac 265/75-16 Load Range E
Wheel Make / Size / Bolt Pattern : Factory - Rubicon 16x10 - 5 x 4.5

Body / Interior
Seats / Harnesses : Factory
Electronics : Center Dash Mount Acer Aspire One, Garmin GPS Puck
Lights Interior : Factory
Lights Exterior : 4 x Off-Road Truck Light (3029) (http://www.harborfreight.com/off-road-long-range-truck-light-system-3029.html)
Safety - Fire Extinguisher : None
Winches - Front / Rear : None
Exterior Rack : Garvin Wilderness Rack (34098) (http://wildernessracks.com/jeep_exp.html)

Before Front :
http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/243542_957765857445_6401029_45452524_1498919_o.jpg

Before Side :
http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/257511_957765293575_6401029_45452510_2895679_o2.jp g
[/SIZE]
________________________________________

2000 Jeep Wrangler TJ -Current (4/4/2012 Update)

Chassis
Frame / Chassis : Factory
Cage : Synergy Suspension TJ Cage Kit - Proposed
Overall Wheel Base : 93.5”
Overall Length : Front Hitch to Tire ~160.00”, Front Hitch to Rear Hitch ~155.0”
[Belly Pan Clearance : 13.75” - Evaluating skid options
Overall Height : ~80.25” (Highest point rear rack unloaded)
Wheel Track Width : ~61” Front , 60.5” Rear
Overall Weight : TBD
Front Shock Travel : 11.50”
Rear Shock Travel : 10.75”

Powertrain
Engine : Factory 4.0 Liter, Precision Auto Injectors (99Jeep4Upgrade) (http://www.precisionautoinjectors.com/product.sc?productId=32&categoryId=3), Flow Cooler Water Pump (1750) (http://www.quadratec.com/products/51212_60.htm), Currie 1" Motor Mounts (CE-9200) (http://www.currieenterprises.com/cestore/product.aspx?id=1063)
Batteries : Optima Red (Part number is faded)
Radiator / Fans : Flex-a-lite Puller (485) (http://www.flex-a-lite.com/auto/html/jeep-wrangler.html)

Air Intake : Spectre CAI (9943) (http://www.quadratec.com/products/17006_7000_07.htm) (Shock towers now block factory location)
Exhaust : Magnaflow Performance Catalytic Converter (50209) (http://www.google.com/url?q=http%3A%2F%2Fwww.quadratec.com%2Fproducts%2F 51410_2000.htm&sa=D&sntz=1&usg=AFQjCNFNMaxrh84zl8Vno-BfT8ASYGaQDg)
Muffler : Dynomax Super Turbo (19391) (http://www.google.com/url?q=http%3A%2F%2Fwww.quadratec.com%2Fproducts%2F 17605_5002.htm&sa=D&sntz=1&usg=AFQjCNGO1YEVeVa7pyh6kLWV9pX7w1rLrA)
Transmission : AW4 (Modified Valve Body & Accumulators), RAD Designs Baja II Shifter (http://radesignsproducts.com/14Shiftcontrollers.aspx) - TransGo Shift Kit (T97165A) (http://www.wittrans.com/showfilter.aspx?Category=777&Section=171)
Torque Convertor : Factory
Transfer Case : NP 231 J (http://www.novak-adapt.com/knowledge/np231.htm) w/ Currie Tail Shaft Conversion Kit (CE-9069T) (http://www.currieenterprises.com/cestore/Product.aspx?id=1146)
Transfer Case Shifter : Advanced Adapters Cable Shifter (715543)
Fuel Containment : Factory

Body / Interior
Body / Body Panels : Factory
Body Modifications : Factory
Skid plate / Material : Factory
Hood / Grille : Factory
Top : Factory Hardtop
Front Bumper : Under Construction
Rear Bumper : Planning
Armor : Evaluating make vs buy skid options
Dash / Gauges / Switches :Compressor, Locker & Transmission Control Switch - In Progress
Steering Column / Wheel : Factory Tilt
Pedal Assembly : Factory

Drivetrain
Front Suspension : OME 2.0” (2933) (http://www.polyperformance.com/shop/Old-Man-Emu-97-06-Jeep-TJ-Wrangler-2.0-Lift-Springs-p-28519.html), Currie Johnny Joint Control Arm Set (9100) (http://www.polyperformance.com/shop/Currie-TJ-LJ-JohnnyJoint-Control-Arm-Set-p-24155.html), Currie Johnny Joint Track Bar (CE-9120TJS) (http://www.currieenterprises.com/cestore/product.aspx?id=3487)
Front Shocks : FOA 2.0 12" Reservoir Shock - Medium Compression & Light/Medium Rebound (FOA-12) (http://f-o-a.com/shop/index.php?main_page=product_info&cPath=24_34&products_id=17), Extending Shock Mounts - TBD
Front Sway Bar : Factory, JKS Quicker Disconnects (2030) (http://store.jksmfg.com/merchant2/merchant.mvc?Screen=QRDISC&Store_Code=JKS01&Category_Code=Swaybar_Disconnects)
Front Bump Stops : TBD
Front Axle Housing : Dana 30, Superior Front Axle Tube Seals (EV70FSL) (http://www.polyperformance.com/shop/Superior-Front-Axle-Tube-Seals-p-21102.html)
Front Locker : ARB Air Locker ARB (RD100) (http://store.arbusa.com/ARB-Air-Locker-Dana-30-27-Spline-373-Up-RD100-P3497.aspx), ARB High Output Compressor (CKMA12) (http://store.arbusa.com/ARB-On-Board-High-Performance-12-Volt-Air-Compressor-CKMA12-P3572.aspx)
Front Ring & Pinion : 4.56
Front Differential Cover : ARB Differential Cover (0750002) (http://store.arbusa.com/ARB-Differential-Cover-For-Dana-30-Axles-0750002-P3576.aspx)
Front Axle Shafts : Factory
Front U-Joints : Factory
Master Cylinder: Factory
Front Brakes : Factory Components, Crown industrial 5 Layer (12706.422) (http://www.quadratec.com/products/12706_42X_PG.htm), EBC Yellow Pads (EBCDP41255R) (http://www.ebcbrakes.com/automotive/yellowstuff_brake_pads/yellowstuff_truck_brake_pads_index.shtml), Centric Premium Front Disc (CE120.67045) (http://www.thepartsbin.com/catalog/?N=9179&Nr=OR(AND(make:Jeep,model:TJ,year:2000),AND(univer sal:1))&Vi=1557+4294956248+4294963365&y=2000&mk=Jeep&md=TJ)
Front Steering Setup : Currie HD Tie Rod System (CE-9701) (http://www.currieenterprises.com/cestore/product.aspx?id=1219)
Front Driveshaft : Factory
Rear Suspension : OME 2.0” (2942) (http://www.polyperformance.com/shop/Old-Man-Emu-97-06-Jeep-TJ-Wrangler-2.0-Lift-Springs-p-28519.html), Currie Johnny Joint Control Arm Set (9100) (http://www.polyperformance.com/shop/Currie-TJ-LJ-JohnnyJoint-Control-Arm-Set-p-24155.html), Currie Johnny Joint Track Bar (CE-9120R) (http://www.currieenterprises.com/cestore/product.aspx?id=1358)
Rear Sway Bar : Factory
Rear Shocks : FOA 2.0 12" Reservoir Shocks - Medium Compression & Medium Rebound (FOA-12) (http://f-o-a.com/shop/index.php?main_page=product_info&cPath=24_34&products_id=17), Synergy Suspension Coilover Bracket (PPM-5001) (http://www.polyperformance.com/shop/Synergy-Suspension-TJ-LJ-Rear-Coilover-Bracket-Kit-p-650.html)- TBD
Rear Bump Stops : TBD
Rear Axle Housing : Ford 8.8
Rear Locker : Factory LSD
Rear Ring & Pinion Ratio : 4.56
Rear Differential Cover :TBD
Rear Axle Shafts : Factory
Rear Brakes : Ford 8.8 Explorer Disk, Crown industrial 5 Layer (12706.422) (http://www.quadratec.com/products/12706_42X_PG.htm), Wilwood Knob Proportioning Valve (260-10922) (http://www.polyperformance.com/shop/Wilwood-Knob-Proportioning-Valve-p-72.html)
Rear Drive Shaft : TBD
Tire Make / Size : Goodyear Wrangler Duratrac 265/75-16 Load Range E
Wheel Make / Size / Bolt Pattern : Factory - Rubicon 16x10 - 5 x 4.5

Body / Interior
Seats / Harnesses : Factory
Electronics : Center Dash Mount Acer Aspire One, Garmin GPS Puck, Yaesu (FT-1802M/E) (http://www.yaesu.com/indexVS.cfm?cmd=DisplayProducts&ProdCatID=106&encProdID=B545CB413DF5ED13CBD157F1DD078EF5&DivisionID=65&isArchived=0)
Lights Interior : Factory
Lights Exterior : TBD
Safety - Fire Extinguisher : None
Winches - Front / Rear : Warn HS9500i w/ Expedition Portal Edition Viking Line (http://www.expeditionportal.com/forum/threads/55909-New-Release-Expedition-Portal-Limited-Edition-Viking-Winch-Line)
Exterior Rack : Garvin Wilderness Rack (34098) (http://wildernessracks.com/jeep_exp.html) - Possible Change

Parts Laid Out Before Starting (Few Months Ago):
http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/173037_836345360095_6401029_44690059_3331010_o.jpg

[GP'd]

Ford 8.8 31 Spline, Disk Brake, 3.73 w/ LSD - As pulled from junk yard.

http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/41269_762974565755_6401029_42833129_6982045_n.jpg

Brackets Starting to go on:

http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/241182_956600582665_6401029_45435351_1103162_o1.jp g

http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/258867_956600767295_6401029_45435358_855879_o1.jpg

http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/243155_956600707415_6401029_45435356_5991961_o1.jp g

Not the greatest welds, but they'll keep the tube from spinning :)
http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/256009_956600737355_6401029_45435357_5091287_o1.jp g

Setting up the Ring and Pinion
http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/241792_956600792245_6401029_45435360_7226688_o1.jp g

Bolting the Carrier to my mill table because I couldn't get enough torque on the bolts.
http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/244103_956600867095_6401029_45435363_665849_o1.jpg

Makeshift Bearing Press w/ a HarborFreight Tubing bender and my factory jack
http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/257486_956602229365_6401029_45435367_772529_o1.jpg

Checking Backlash (had to pull the pinion and back it out one more time after this photo)
http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/258775_956602568685_6401029_45435375_7456243_o1.jp g

[GP'd]

AW4 - When I brought it home
http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/36806_762974465955_6401029_42833118_5364226_n.jpg

Being Pulled Apart
http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/259273_957227032255_6401029_45444817_888592_o.jpg

Bolt Reference Image
http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/259557_957226393535_6401029_45444800_6100887_o.jpg

Making sure I know where each bolt goes back
http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/259333_957226348625_6401029_45444799_5920706_o.jpg

Valve Body Pulled
http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/257881_957226887545_6401029_45444813_3230052_o.jpg

http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/255865_957226762795_6401029_45444810_7260331_o.jpg

Accumulator Control Reference Image
http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/242613_957226812695_6401029_45444811_3975885_o.jpg

Accumulator reference Image
http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/257169_957226438445_6401029_45444801_6280914_o.jpg

AW4 Wiring taken out of the storage box for harness planning.
http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/258959_959718738855_6401029_45495085_4260923_o.jpg

[Mr. D]

I like your reference diagrams.

[GP'd]

I like your reference diagrams.

Hah, thanks. I've lost, misplaced and put bolts in the wrong way enough times that I ended up finding a system that works for me. Cardboard and camera!

[Nigel Caffiene]

Looking forward to your build progress Gi. I, as well, like the bolt diagrams. Good Luck!

[GP'd]

Dana 30 cleaned up and ready to swap knuckles from my current axle.

http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/240624_956600537755_6401029_45435350_7909058_o1-1.jpg

http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/257433_959718838655_6401029_45495089_8293851_o.jpg

8.8 Painted w/ brake brackets on (Reversed for shock clearance). Waiting to swap brakeline over from the D35. Sure wish ARB made a cover for this. Does anyone have any suggestions for a durable diff cover with drain hole and dipstick?

http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/242712_959718668995_6401029_45495083_3058284_o.jpg

[bldeagle10]

im glad to see you cleaned up everything before you put it back in. thats one of my major pet peeves. i cant stand when people throw a dirty old axle or really anything dirty under their rig. nice build up, i shall be subscribing and following this!

[goldenbeagle]

Im standing by...looks like a solid build in progress.

[mochodurazo]

So organized, great build up.

[GP'd]

im glad to see you cleaned up everything before you put it back in. thats one of my major pet peeves. i cant stand when people throw a dirty old axle or really anything dirty under their rig. nice build up, i shall be subscribing and following this!

Thank you. Pet peeve of mine also, though I can't say I'm doing it to the fullest extent I want. Initially starting this project my intent was to upgrade or replace everything while it was apart. Budgetary constraints quickly shoot those ideas down though. New transmission clutches, ball joints...etc... add up fast! Though those and other components still have life left I wanted to do it for peace of mind to start this new drivetrain at 0. The fiscal peace of mind won on this one!


Im standing by...looks like a solid build in progress.


So organized, great build up.

Thanks guys!

[GP'd]

Today my plan was to put the new valve body gasket & shift kit into the AW4. Unfortunately both parts ordered were wrong. Time to deal with returns and hope I get the right part the next time.

In lieu of transmission work, I started making some real progress today. Just pulled the D35 out of the back. Time to mock up the 8.8 out-boarded Shock Brackets and attach brake lines.

Measurement of old set up D35 at full droop - Shocks attached
http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/257372_961734564125_6401029_45527306_7030455_o.jpg

Measurement of old set up D35 at full droop - Shocks removed
http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/257585_961731904455_6401029_45527186_8296513_o.jpg

Axle Out
http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/256959_961731974315_6401029_45527188_3013007_o.jpg

[GP'd]

Was able to install the 8.8, Currie short arms/rear track bar and removed the factory coil spring upper mount. The brackets will be reused and relocated a few inches to the rear correcting the coil spring contour under compression... I then took all of my compressed, extended and ride height measurements and will be ordering shocks this week for the final out boarding process steps. I also need to run brake lines to the calipers.

You can see that the brackets on the 8.8 have the calipers to the front. This is reversed from factory to clear the shocks in the rear. I am able to run the extended braided cable (listed in the first post) to the 8.8 in the rear with the TJ mounting hardware, however, it is installed backwards and the crimp/hose connection to the distribution block seems a bit exposed from rear rock damage oriented this way. Searching for plumbing alternatives...

http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/257023_962316592735_6401029_45540473_4256019_o.jpg

[GP'd]

After work today I decided to get a head start on a long weekend of brake plumbing, pulling the transfer case and tranny and whatever other projects I can do while I wait for shocks and a few other parts.

I decided to pull the fenders so that I could gain access to the front shock towers for modification and so that I can replace my bent fenders and start on my homemade highline fenders. I also hope when this is apart to relocate some critical electronics (Computer & Fuse box) in a waterproof case elsewhere under the hood. (Thoughts/Recommendations welcome)

DS Fender Pulled

http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/271513_965572932005_6401029_45598028_652320_o.jpg

PS Fender Pulled (Getting Dark)

http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/258145_965565262375_6401029_45597900_758594_o.jpg

[GP'd]

Pulled the transfer case this morning and began tearing it down to install the SYE

http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/259537_966168932615_6401029_45610535_6201100_o.jpg

Stuck at this stage until I fix my compressor which for some reason won't turn on.

[thejafe]

Subscribing to this thread :) . Can't wait to see the finished product...

[That One Guy]

This is really nice, that front axle especially looks beautiful. You should powdercoat your wheels the color of the front ones... They actually look great that color, even though they're dirty. Subscribed!

[GP'd]

Subscribing to this thread :) . Can't wait to see the finished product...

Thanks! Trying to get as much done in as little time as possible so that I can actually get out and travel more.


This is really nice, that front axle especially looks beautiful. You should powdercoat your wheels the color of the front ones... They actually look great that color, even though they're dirty. Subscribed!

Thank you. I have considered changing the rims to black, however, I think i'm going to keep my dust look for a while. Now that I have Explorer disks in the rear I can get EBC Yellow pads. The EBC Green's I've been running on the Jeep Disk Brakes just don't give off that authentic dust look. Now my rims will have a consistent dirty color. :)

[That One Guy]

Now my rims will have a consistent dirty color. :)

Awesome!

[socaljeeper]

Nice build so far and you can't go wrong with the Currie parts. I plan on starting my 98 TJ soon. Why did you decide to use the OME 2" springs instead of using the Currie springs? Is it becasue the the additional 2 inches? Looking forward to watching this one.

[GP'd]

Nice build so far and you can't go wrong with the Currie parts. I plan on starting my 98 TJ soon. Why did you decide to use the OME 2" springs instead of using the Currie springs? Is it becasue the the additional 2 inches? Looking forward to watching this one.

Granted I have yet to drive on most of my Currie parts; I am incredibly pleased with the products they offer and the reputation they have built for themselves as users under abuse. Buy once philosophy.

I didn't end up with Currie springs because I know the OME 2" (Heavy Duty) will give me more like a 2.5-3" lift. I have been running 2" Spacers w/ sway bar disconnects for years and they have gotten me everywhere I need to go. When I decided to tackle this build, OME's were the first to come to mind because of their solid reputation for ride and quality. I also don't need more than a 2.5" lift to clear my 32" tires. The suspension travel I hope to net with my set up should be around 10 - 12", and I'd rather lift fenders to clear tires than raise the Jeep up any higher.

[GP'd]

Well, the progress during the last week has been fairly slow. Too busy with work during the week, and this past weekend I was in Mammoth Lakes fly fishing and spending time with friends at their cabin. Fortunately some required pieces came yesterday so I was able to install the shift kit and put new gaskets on the valve body.

Transmission Work Left: Clocking the transfer case and making the wiring harness

Rear Suspension Work Left: Install the rear buckets and coil pads and finalize the 8.8 suspension this weekend so I can start focusing on the front.

If I can finish those this weekend I should be in a good spot!

Pictures and more information to follow.

[thejafe]

I think that with flat fenders up front you're gonna end up with TONS of room for 32's. 32's and a 2.5" OME kit clear no problem with stock fenders ;) . Are you planning on adding a swingout tire carrier or mounting the spare to the stock location?

Also, be prepared to run a CV/SYE kit as you're likely to experience rear driveline vibrations. Yes, you can drop the transfer case with washers but in my experience with running the OME 2.5" kit washers weren't enough to iron out the vibes. I got the CV/SYE and problem solved. I was even fortunate enough to be able use the same CV/SYE kit when I bumped up to my current 3.5" Rubicon Express coils.

[GP'd]

Jafe: Nice looking rig!

Answers to comments below:


I think that with flat fenders up front you're gonna end up with TONS of room for 32's. 32's and a 2.5" OME kit clear no problem with stock fenders ;)

I will be modifying factory fenders to be high-line fenders. My current ones are already bent and dented so I picked up a set a few months back to replace them. Yes I may have room without modification, but with the 1.5"-2" engine lift, running factory or less bump stops, the 32"s will be close and if I upgrade to 33's it will be closer. I might as well address the rubber/metal collision issue while the truck is torn apart!


Are you planning on adding a swingout tire carrier or mounting the spare to the stock location?

Is one planned for the future? Yes. Currently I am running the 265/75-16 in the OEM location....barely.... I'm focusing on suspension and drive train critical components now. Accessories come later!


Also, be prepared to run a CV/SYE kit as you're likely to experience rear driveline vibrations. Yes, you can drop the transfer case with washers but in my experience with running the OME 2.5" kit washers weren't enough to iron out the vibes. I got the CV/SYE and problem solved. I was even fortunate enough to be able use the same CV/SYE kit when I bumped up to my current 3.5" Rubicon Express coils.

Already planned. Transfer case is in pieces on my bench at home right now for the SYE install. Goal is to have a 1.5" to 2" Engine Lift and flat bottom skid. With the AW4 swap I need to readdress the tranny mount anyway. Once I swap the tranny and transfer case back in, I can figure out the extended and collapsed for ordering. I set the pinion on the 8.8 at 15 Degrees.

[GP'd]

Last week I rebuilt the valve body on the AW4 and installed the shift kit.

A few pics:

Another bolt orientation diagram.
http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/272890_991608940635_6401029_45750618_7939104_o.jpg

Lower Body.
http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/278410_991608800915_6401029_45750613_4674148_o.jpg

Check Ball Locations.
http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/280126_991608990535_6401029_45750620_7331015_o.jpg

Transfer case coming apart for the SYE.
http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/259537_966168932615_6401029_45610535_6201100_o1.jp g

And today the project will be finishing the rear and outboarding the shocks that just came in.
http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/265855_991608890735_6401029_45750616_6979558_o.jpg

[GP'd]

Driver side frame cut and bucket placed. Time to go to the passenger side.

I put tinfoil in the gap on the tank so that no grinding sparks were trapped near the plastic.

http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/266319_991649873605_6401029_45751671_1940226_o.jpg

[GP'd]

Well the rear buckets are tacked and shock limiting droop and compression were taken...

Cancel this thought: I think I should've gone for 10" shocks in the back. Not sure where my head was at taking the measurements, but I think going from a 18.3" (12" Current) Collapsed to 16.3" (10" Proposed) collapsed shock may be worth the 20% restocking fee. Thoughts? I forgot I added a factor for the collapsed coil size.

Bucket tacked in.

http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/P1020942.jpg

Future upper coil mount location.

http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/265415_991774024805_6401029_45754274_5570056_o.jpg

Side Full Compression (Shock Bottomed)

http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/278314_991774239375_6401029_45754279_1400686_o.jpg


Side Full Droop (Shock Extended)

http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/279269_991774154545_6401029_45754276_6509261_o.jpg

[GP'd]

Posting more photos during my breaks between projects. It's nice to have a computer in the garage.

Upper coil brackets tacked, shocks installed and tires on. I definitely need to get some spacers for the wheels. With the narrower 8.8 and the new coil buckets and shocks I think I will need a 1.25" spacer to clear comfortably. I hate wheel spacers, but in this situation I am left with no choice.

Coils will be retained top and bottom. In this photo they are just about to unseat, giving me ~10.5" of travel at the moment. Time to figure out how I will be re-mounting the track bar...

http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/272160_991830032565_6401029_45755521_4210064_o.jpg

[thejafe]

Posting more photos during my breaks between projects. It's nice to have a computer in the garage.

Upper coil brackets tacked, shocks installed and tires on. I definitely need to get some spacers for the wheels. With the narrower 8.8 and the new coil buckets and shocks I think I will need a 1.25" spacer to clear comfortably.

Keep up the good work! For your wheel spacers definitely look into Spidertrax (http://www.spidertrax.com/) if you haven't already. Very popular spacer and I personally ran 'em for years without issue:

http://www.spidertrax.com/core/media/media.nl?id=26&c=407909&h=8662e0eaaa7c276f7078

[MattScott]

I would love to see your ideas for relocating the fuse box and computer.

[bob91yj]

Looking good. I wish I outboarded my shocks when I went through my last round of upgrades.

I'd put the track bar in and cycle the suspension to make sure you have no clearance issues. My junk about drove our crew chief crazy when he put my Jounce bumps in. He kept having to re-rack the Jeep because it walked over a bit with each suspension cycle. One of these days I'm going to get rid of the track bar with a three link or triangulated 4 link. The factory 5 link design sucks at speed in the dirt.

I've heard good things about FOA shocks. I'll be interested to see what you think of them.

[GP'd]

I would love to see your ideas for relocating the fuse box and computer.

Matt, will do! Sooner I get through this drivetrain stuff the sooner I can focus on what I would consider more overland related projects!



I'd put the track bar in and cycle the suspension to make sure you have no clearance issues. My junk about drove our crew chief crazy when he put my Jounce bumps in. He kept having to re-rack the Jeep because it walked over a bit with each suspension cycle. One of these days I'm going to get rid of the track bar with a three link or triangulated 4 link. The factory 5 link design sucks at speed in the dirt.

Today I am going to mock up a mount to fit between the outboarded bucket and the re-positioned upper coil mount. Suspension will be cycled and tested before final welding.With coilsprings retained, I don't think I should have any major binding in that 10.5" of travel.



I've heard good things about FOA shocks. I'll be interested to see what you think of them.

I have too and the price was right. I'll do a mini review of them on the packaging cosmetics shortly, followed by the real information after the Jeep is back on the road.

[jscusmcvet]

Are you happy with the Garvin Wilderness Expedition Rack? Thanks, John

[GP'd]

Are you happy with the Garvin Wilderness Expedition Rack? Thanks, John

Yes, I am happy with the Garvin Rack. I have used it a few times for 'Overland' Purposes, however, most if its use comes as a lumber rack or furniture moving rack.

Only thing that has bothered me is that after moving to the San Francisco area the powdercoating has started to bubble and allow rust underneath. I guess that comes from living a 1/2 mile from the ocean.

[GP'd]

Been pretty busy with work and other hobbies lately but everything is slowly moving along. This coming weekend is going to be another one of those 16 hours on Sat and 16 hours on Sunday type weekends. I'm tired just thinking about it.

Tomorrow I hope to clock the transfer case and get it back together and painted.

A few things I have gotten done :

AW4 cleaned up and painted Chrysler Red, Neutral Safety Switch Rebuilt and new plumbing started. Photo makes the transmission look a bit oranger than it is. It is a nearly identical match to the ARB diff cover.

http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/280235_998456922225_6401029_45889220_2343415_o.jpg

http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/278308_998456777515_6401029_45889217_6321696_o.jpg

[Scott Brady]

Gianni,

Nicely done as always. If even some of your mad skills with the Ranger Hoodie manifest themselves in your Jeep it will be awesome!

Also nice to see how much of the work you are doing personally. You will know the truck front to back and everything in between.

[BigAl]

, Neutral Safety Switch Rebuilt

I love the rear shock set up, i will definitely be copying that when my rear shocks start leaking again. I have too much droop for all the more length my stock position can give.

I just grounded my park/neutral switch b/c it was so much trouble, although it did make a good anti theft device, some days i couldn't drive it:sombrero:

[GP'd]

Gianni,

Nicely done as always. If even some of your mad skills with the Ranger Hoodie manifest themselves in your Jeep it will be awesome!

Also nice to see how much of the work you are doing personally. You will know the truck front to back and everything in between.

Thank you for the kind words Scott! I have learned a TON about the drive-train so far in this build...especially with the re-gearing and transmission modifications.

I just hope once it is back together I will spend my time driving it, rather than trail fixing it.


I love the rear shock set up, i will definitely be copying that when my rear shocks start leaking again. I have too much droop for all the more length my stock position can give.


Great to hear! The upper buckets and lower shocks from Poly Performance were top notch. I'm really excited to get it on the road and see how much it changed the ride and travel.

[GP'd]

Changed gears today and welded the relocated coil buckets in so that I could plan the track bar mount.

http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/282445_999301399885_6401029_45903440_178825_n.jpg

[GP'd]

Some updated progress:

Rear Track bar bracket mocked up

http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/287665_10100103957979235_6401029_46039162_996922_o .jpg

http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/281619_10100100959393425_6401029_45981684_1569482_ n.jpg

http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/229597_10100103957784625_6401029_46039152_4378949_ n.jpg

AW4 Tailhousing clocked 11° for transfer case.

Template

http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/287857_10100103957939315_6401029_46039159_4158448_ o.jpg

Drilling

http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/287606_10100103957839515_6401029_46039154_5651645_ o.jpg

Completed

http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/288623_10100103957899395_6401029_46039157_7600374_ o.jpg

[GP'd]

32RH Dropped

http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/291458_10100107734161735_6401029_46105485_3008396_ o.jpg

Torque Converter still attached.

http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/292758_10100107734096865_6401029_46105483_5377435_ n.jpg

Now it's time to replace the rear main seal.

Does it end?

[GP'd]

Changed my mind mid day again. I was to tired to pay attention to the details of installing a rear main seal so I pulled the old D30 out instead.

http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/287325_10100107805598575_6401029_46106504_7315161_ o.jpg

http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/262858_10100107805553665_6401029_46106502_6950482_ n.jpg

http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/290991_10100107805718335_6401029_46106507_5441067_ o.jpg

On hour 9 in the garage today... so I'm going to go pull the arms off, clean up, make myself some food and have a beer. It's exhausting doing all of this solo.

Hopefully I'll have have more build and less tear down photos shortly!

[GP'd]

Beautiful night, so the D30 went in. Still have to paint the old knuckles, install them, and drill out the stock TB mount for the Currie track bar 5/8" bolt.

http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/294462_10100109101915745_6401029_46137536_6940991_ n.jpg

[GP'd]

Been solving front steering and suspension issues for the past 2 nights and finalizing them today.

Lets just say the combination of heavy duty components with less than a 3 inch lift and the want to retain factory bump stops causes issues.

ARB and Currie Track Bar Collision with ~4.5 " to bump stop. Time to grind away and clearance it.

http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/291502_10100111484790445_6401029_46175696_2614839_ o.jpg

Factory Diff Cover. Whats strange about a few of these collisions is the factory bumpstop doesn't protect from them...

Upper Control arm vs Lower Radiator Hose. I think I am going to cut another hose open and double wrap this section to protect it.

http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/287587_10100111484975075_6401029_46175702_3614114_ o1.jpg

Axle Tube and Housing vs Oil Pan
http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/324636_10100111485024975_6401029_46175704_2038090_ o.jpg

Currie HD Steering & Currie Tie Rod - Drag Link, Tie Rod, Track Bar all touching at full bump. Minor tweaking was done and everything clears now.

http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/323133_10100111484895235_6401029_46175700_7412235_ o.jpg

Passenger Side Bump

http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/312280_10100111487006005_6401029_46175759_2537483_ n.jpg

Driver Side Bump - No wonder my oil pan is dented. Axle hits the pan before the bumpstop. My engine lift will solve this.

http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/310889_10100111484745535_6401029_46175695_5347883_ n.jpg

How I ground the ARB Cover. I have a bit more clean up to do and then I'll pant it. With this ground I am able to fully stuff both side of the axle at the same time as well as clear during full articulation. I'll post up final images when the cover is painted and everything is in.

Profile:
http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/338226_10100111487814385_6401029_46175771_4836312_ o.jpg

http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/303581_10100111487794425_6401029_46175770_7365009_ n.jpg

[GP'd]

Diff cover painted and installed after final grinding and clean up:

http://i53.photobucket.com/albums/g79/gdonati/322758_10100112127327795_6401029_46188143_8043673_ o.jpg

New front stance

http://i53.photobucket.com/albums/g79/gdonati/301608_10100112127013425_6401029_46188132_1551999_ n.jpg

New stance profile

New ride height with OME 2.5" Springs.

Front: 6.5" up travel, 4.5-5" down travel
Rear: 5" up travel, 5" down travel

Clearance to belly : 19"

http://i53.photobucket.com/albums/g79/gdonati/323633_10100112127198055_6401029_46188140_4842174_ o.jpg

On the rear I need to finish bending the passenger side brake line and hook up the e-brakes. Other than that it is done.

On the front, I need to start building the front shock towers so that I can run 12" shocks.

Biggest part of this build left is getting the transmission and transfer case back in and having drive shafts made. Everything else is cosmetic and can happen after the vehicle is running again.

Anyone in the bay area have a transmission jack I can borrow? I think i'm going to need to pick one up this week because the motorcycle jack I used wasn't ideal for pulling the tranny out. I would never be able to get the splines aligned well enough during reinstalling.

***Sorry about the pictures sizes jumping back and forth. I have no idea why they are doing that after uploading.

[Kelly 4x4]

One quistion whire is the rubber bumper in the bumpstop should be about 2"long. Kelly

[xkid]

Dude,that is sweet work,in ur driveway.If I was down there visiting my sister,I'd come and lend a hand.Looks like fun.Congrats.

[GP'd]

One quistion whire is the rubber bumper in the bumpstop should be about 2"long. Kelly

Kelly, I removed them when checking all the components for clearance. Under a hard hit they fully compress anyway and it is best to assume they aren't there and the metal is the hard stop.


Dude,that is sweet work,in ur driveway.If I was down there visiting my sister,I'd come and lend a hand.Looks like fun.Congrats.

Thank you!

[imagrsmnky]

Great build... Really appreciate your attention to detail. Nice TIG work.

One thing I Have learned is that the factory upper panhard mount in the front is not sufficient once the leverage point is moved down. the whole cast piece rips out of the frame:Wow1: That point sees a lot of force.

I have had to retrieve multiple tjs off the trail using two ratchet straps to locate the axle.

My recommendation is either gusset it really well or replace it with one that wraps the frame. Also putting that joint in double shear gives a lot better piece of mind.

just my .02

[MattScott]

Any updates? I love this thread!

[GP'd]

Great build... Really appreciate your attention to detail. Nice TIG work.

Thank you! I hope to improve from here. I love operating a TIG but my cosmetic results leave much to be desired! Overhead and vertical have been the biggest pain on some of these brackets.



One thing I Have learned is that the factory upper panhard mount in the front is not sufficient once the leverage point is moved down. the whole cast piece rips out of the frame:Wow1: That point sees a lot of force.

I have had to retrieve multiple tjs off the trail using two ratchet straps to locate the axle.

My recommendation is either gusset it really well or replace it with one that wraps the frame. Also putting that joint in double shear gives a lot better piece of mind.

just my .02

Seen this happen too and it is something I plan on solving in the future. For now I just want the Jeep driving again!


Any updates? I love this thread!

Well I should get some more posts up soon! Thread has been dead because I've been so swamped at work the past month and then I spent 10 days on vacation pronghorn hunting up in Montana.

I did get the transmission and transfer case in, but nothing is wired in yet.

This weekend I hope to get the skid plate done. I'm very close, just finding the time is tough right now.

[GP'd]

Well guys, it's been a while since I posted.

The past month and a half has been crazy busy with 2 work trips, a 10 Day hunting trip, sisters engagement party and this last weekend's Overland Rally. Weekends are my get everything done days...running grinders, air tools and welders during weeknights doesn't lead to happy neighbors.

The next week or two is the final stretch of this project's drivetrain phase, and I have a lot of catching up to do on this thread about what I've done.

Stay Tuned and thanks for all the support so far!

[MCObray]

Very meticulous work you got going on here. I could only wish that my mechanical knowledge was up to par with yours. Keep up the good work and I look forward to seeing the finished project!

[GP'd]

Very meticulous work you got going on here. I could only wish that my mechanical knowledge was up to par with yours. Keep up the good work and I look forward to seeing the finished project!

Thank you! I've only gotten better over years by buying the tools to do it myself. It hasn't always been easier or cheaper, but the knowledge has been worth it.

To keep pictures flowing...last night I mounted the rear reservoirs. I debated mounting them inside the fender well, but thought it was too high profile for tampering. I decided to cut a hole in the tub and run them inside under the lip. You can see in the photo I have 2 rubber stoppers there temporarily. I'm probably going to pick up some firewall grommets from the junk yard or push in style grommets from McMaster : http://www.mcmaster.com/#push-in-grommets/=epd2lm.

Before I drive I'll split a hose and run them over the hydraulic line.

http://i53.photobucket.com/albums/g79/gdonati/Facebook/Jeep%20Build/308769_10100165689024725_1002198324_n.jpg

http://i53.photobucket.com/albums/g79/gdonati/Facebook/Jeep%20Build/391002_10100165686165455_1099222563_n.jpg

Some other updates:

Drive shafts : Will be here Monday.
Exhaust : My down pipe, 3 catalytic converters & muffler were stolen from side yard. They must've been sticking over fence or the wind blew the tarp off the top making it visible. I just realized this a few days ago when I went to grab them to re-install. Frustrating & Expensive. Haven't decided which route to go. California emissions doesn't leave me with many options.

I'll update the parts list at the beginning of the thread later tonight; the weather is beautiful and there are lots of small things to do before I can start the Jeep up again next week!

[GP'd]

Bumpstops squeezed into the rear coils. Use dish soap!

http://i53.photobucket.com/albums/g79/gdonati/Facebook/Jeep%20Build/379468_10100168861117825_1895909050_n.jpg

Rear Bumps fully installed. By the looks of the picture I have about another inch or so before full droop. I went a different way than some of the Jeep Speed guys do with their bumps by mounting them instead of leaving them loose.

http://i53.photobucket.com/albums/g79/gdonati/Facebook/Jeep%20Build/317022_10100168861302455_95290967_n.jpg

Front end is dirty! Using a bolt to slowly adjust and check all clearances before welding new extensions so that the prothane bumps can be used and my shocks are properly protected.

http://i53.photobucket.com/albums/g79/gdonati/Facebook/Jeep%20Build/333823_10100168863832385_1385971078_o.jpg

Here you can see one of my tierod bolts is hitting. These need to be no further than 45 degrees back to prevent this contact. This view also shows the max articulation on the currie JJ track bar & the clearance i'm leaving under full bump between the track bar and linkage. Yes I forgot the washer on the top of the track bar bolt. I will be installing it before driving.

http://i53.photobucket.com/albums/g79/gdonati/Facebook/Jeep%20Build/298785_10100168861477105_1913795757_n.jpg

Looking up from under the car. Here you can see how much I carved out of the ARB diff cover to comfortably clear the JJ track bar. The drips on the bottom of the cover are water not poor painting!

http://i53.photobucket.com/albums/g79/gdonati/Facebook/Jeep%20Build/322430_10100168865139765_1581901786_o.jpg

Absolute max articulation on the JJ.

http://i53.photobucket.com/albums/g79/gdonati/Facebook/Jeep%20Build/290230_10100168865269505_283947278_o.jpg

Full bump clearance between the Axle and Engine. This is with a 1" Currie motor mount. I certainly wont be hitting my oil pan with the axle anymore.

http://i53.photobucket.com/albums/g79/gdonati/Facebook/Jeep%20Build/323706_10100168865479085_890550331_o.jpg

Driver Side fully stuffed. Looks like I need run highline fenders with 32" tires.

http://i53.photobucket.com/albums/g79/gdonati/Facebook/Jeep%20Build/339493_10100168866257525_431502660_o.jpg

PS full droop (jack replicating limit)

http://i53.photobucket.com/albums/g79/gdonati/Facebook/Jeep%20Build/328924_10100168866462115_2037944004_o.jpg

DS full bump.

http://i53.photobucket.com/albums/g79/gdonati/Facebook/Jeep%20Build/325619_10100168866626785_514998053_o.jpg

Rear Driveshaft from Coast installed. Coast put the Currie adaptor flange on one end, the 8.8 adaptor on the other. The finished unit came out great.

http://i53.photobucket.com/albums/g79/gdonati/Facebook/Jeep%20Build/303971_10100168867185665_707126822_n.jpg

Front driveshaft loosely installed for length check. Clearly I received the wrong driveshaft and it is about 2" too short. Bill at Coast Driveline and Gear already sent me the label to return this one and has one being made before the first is returned. Great customer service! I can't say enough about how easy they were to deal with.

http://i53.photobucket.com/albums/g79/gdonati/Facebook/Jeep%20Build/378752_10100168867210615_1231583448_n.jpg

Side of AW4 for tub clearance and mockup.

http://i53.photobucket.com/albums/g79/gdonati/Facebook/Jeep%20Build/376635_10100168885159645_334520696_n.jpg

Dark photo, but shows the full drivetrain assembled under the car. Still have wiring and hydraulics left.

http://i53.photobucket.com/albums/g79/gdonati/Facebook/Jeep%20Build/322415_10100168885224515_810266594_o.jpg

[Unlimited04]

damn nice work!

[GP'd]

Well it's driving! Been taking the past few weeks to tinker during the re-gearing 500 mile break in.

There are still a lot of things to straighten for me to feel complete with the Power/Drive train upgrades; Exhaust, ARB Compressor, AW4 TCM Wiring, however it drives freaking great!

On road the Jeep is more stable, more responsive and incredibly predictable. I think this has a lot to do with the 3" widened stance in the front, 1" widened stance in the rear, shocks being outboarded, and coils corrected to vertical travel. It is a bit stiff on the road without any load, however once I put a couple gas cans and tools in the back, the coils and shock valving soak everything up and keep it stable. Couldn't be happier. Obviously there is still tuning required, but for a first try I'm ecstatic.

A few things I've done to get the jeep a Daily Driver again:

Cutting template to modify the factory skid plate to bolt to the AW4:

http://i53.photobucket.com/albums/g79/gdonati/Facebook/Jeep%20Build/390131_10100198452276905_1793426676_n.jpg

Cut and welded in the new location:

http://i53.photobucket.com/albums/g79/gdonati/Facebook/Jeep%20Build/374123_10100198452296865_1965723368_n.jpg

First front shock tower tacked:

http://i53.photobucket.com/albums/g79/gdonati/Facebook/Jeep%20Build/386100_10100198452331795_1810868428_n.jpg

Both Towers tacked:

http://i53.photobucket.com/albums/g79/gdonati/Facebook/Jeep%20Build/383628_10100198452246965_1787837476_n.jpg

Fitting over cut factory shock tower:

http://i53.photobucket.com/albums/g79/gdonati/Facebook/Jeep%20Build/376781_10100198449457555_1707378220_n.jpg

New Stance:

http://i53.photobucket.com/albums/g79/gdonati/Facebook/Jeep%20Build/390034_10100198449412645_898893166_n.jpg

Some Articulation Testing:

http://i53.photobucket.com/albums/g79/gdonati/Facebook/Jeep%20Build/322534_10100219729242695_591711147_o.jpg

http://i53.photobucket.com/albums/g79/gdonati/Facebook/Jeep%20Build/322680_10100219729407365_1715871046_o.jpg

Still a few inches of fender to tuck

http://i53.photobucket.com/albums/g79/gdonati/Facebook/Jeep%20Build/340196_10100219729631915_1452096779_o.jpg

http://i53.photobucket.com/albums/g79/gdonati/Facebook/Jeep%20Build/325103_10100219729991195_120047785_o.jpg

10.5/11.5" of front travel

http://i53.photobucket.com/albums/g79/gdonati/Facebook/Jeep%20Build/324205_10100219730125925_1662002557_o.jpg

Zip ties are only to reinforce the hard mounts.

http://i53.photobucket.com/albums/g79/gdonati/Facebook/Jeep%20Build/337814_10100219730290595_278944319_o.jpg

http://i53.photobucket.com/albums/g79/gdonati/Facebook/Jeep%20Build/328865_10100219730535105_1020872103_o.jpg

http://i53.photobucket.com/albums/g79/gdonati/Facebook/Jeep%20Build/334616_10100219730694785_1424544729_o.jpg

[X-plorenow]

Fantastic Job, beautiful work. Makes me miss my 02 TJ Sahara.

[GP'd]

Fantastic Job, beautiful work. Makes me miss my 02 TJ Sahara.

Thanks X-plorenow! Looking at the current fleet in your signature I'm sure you don't miss it THAT much!

Update:

Clearly have been busy the past 4 months, but have been doing small projects here and there; mainly tuning and tweaking all the changes.

Some of the bigger ones which I will update later:

Installed a rear catalytic converter
Wired the AW4 into the TJ computer
Wired the TJ computer to think it has the factory transmission behind it to prevent CEL Codes.
Passed SMOG after modifications above.
LCA Bracket re-welded after cracking and almost tearing off completely on a recent trip to the mountains. Currie LCA Brackets are waiting for a weekend to pull the axle and weld in. Debating trussing the D30 while I am at it.
Installed Spectre intake through the cowl, as the shock towers now block the factory location. Working on routing a pre-filter before it, possibly a snorkel....
Building the GotTrikes.com tubing bender to make my bumpers. I have to admit, the Milwaukee Dry HD Dry Cut saw is one of my favorite tools. It cuts cleanly, accurately, and most importantly makes easy work of 2.5" x .75" steel bar!
http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/IMG_20120404_195747.jpg
http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/IMG_20120404_195510.jpg
Bumper/Winch - Acquired a Warn HS9500i and picked up the Expedition Portal Edition Winchline. Currently working on a bumper for the front.
An Early Mock Up: Excuse the duct taped cross bar and lack of level...It was quicker than tacking and just for visual purposes!

http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/IMG_20120310_172157.jpg

Current Mock Up will be this design but the lower aluminum skid supports will be wider to match the frame rails:

http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/b1.jpg

Winch somewhat cleaned up. I need to re-paint the motor fins and check all the electrical connections.

http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/IMG_20120404_200618.jpg


I hope to be active in this thread again shortly!

[montyjk]

Some Articulation Testing:

http://a7.sphotos.ak.fbcdn.net/hphotos-ak-snc7/374685_10100219729242695_6401029_47052883_59171114 7_n.jpg

http://a2.sphotos.ak.fbcdn.net/hphotos-ak-ash4/373899_10100219729407365_6401029_47052886_17158710 46_n.jpg
[/QUOTE]

nice looking build. wondering where the testing grounds were? looks like a nice trail ride with sweet views of the ocean. any info on it would be appreciated. thanks.

[GP'd]

nice looking build. wondering where the testing grounds were? looks like a nice trail ride with sweet views of the ocean. any info on it would be appreciated. thanks.


Thanks Mike! This is a small hill along the coast outside of San Francisco. It was closed off recently with gates so my 2 mile drive for quick testing grounds is now extinct.

[GP'd]

My 1" and 7/8" drill bits are in the mail keeping me from the next stages of the tubing bender so I played around in Solidworks planning a Dana 30 Truss instead.

Given that I need to pull the axle and install Currie LCA Mounts after tearing one, I might as well beef it up while it is out. I am planning on cutting one wall off of a 2"x2"x.120" and cutting groves for the mounts...but this design defiantly needs some more adjusting and thinking. Do I really need a truss? Likely not...but while I have everything apart...AGAIN...I feel like it is the next step. I have the tubing laying around as well.

Note: The truss will be underneath the tubes on both sides. (the other side was hidden while I saved this image)

Decisions....decisions...

http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/axletruss.jpg

[montyjk]

Thanks Mike! This is a small hill along the coast outside of San Francisco. It was closed off recently with gates so my 2 mile drive for quick testing grounds is now extinct.

bummer. thanks tho. can't wait to see the tj finished.

[CV1073]

Man amazing build thread! Your skill are top notch! Also congrats on being in TAD's newsletter! :-)
Say hi to Pat and all the crew from the Italian USNers aka me..

BTW, I guess you already know but your name is a very Italian one

Ciao

Cris

P.S. I almost forgot: may you all have an amazing Easter

[GP'd]

Thanks Cris!

I'll tell everyone you said hi!

PS: Username 'YldWahp' over on the USN

[GP'd]

The 1.000" and .875" bits and shafts came in today...these things are giant! Looks like I will be trying to finish the tubing bender this weekend. I am following the Got Trikes Bender Plans (http://www.gottrikes.com/Tube_Bender.htm)but will be making some slight modifications which will be posted later.

Drill bits and cross shafts with Sharpie for size reference:
http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/460238_10100386663649805_6401029_47817979_54133758 2_o.jpg

I also received a linear flange bearing and shaft for my integrated shifter project. You may recall a few pages back, I was running a RAD Designs shifter with no TCM. To pass smog, I had to wire the TCM into the factory computer and during this process I removed the manual shifter. The linear bearing and shaft are part of a design that will incorporate both the mechanical and electronic shift capabilities of the AW4 and bolt into the stock location. The TJ is small enough inside as is, having to add another shifter to my center console once my interior is back together seems a bit cluttered.

Pictures of course as it progress....need to find more time....

[GP'd]

What hours I've had out of work and life over the past week have been focused on the tubing bender. Some pictures....

Match drilling the swing arm holes. Tried with and without cutting fluid, couldn't seem to get clean holes. The 2"x2"x.250" wall seemed like sheet metal to drill through after the stacked .75" steel arms.

http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/P1030608-1.jpg

http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/P1030610.jpg

I hopefully will finish it this weekend so I can get to building my bumper and install my winch. I had planned on working for another 2-3 hours last night but had a little scare. It was raining outside while I was welding so I only had the garage cracked for airflow. Well it started really pouring then hailing, so I let off the pedal and looked toward the door through my welding helmet (Auto Darkening). Well suddenly lightning flashed and my mask darkened. Scared the s**t out of me. I quickly unplugged the welder and called it a night. Talk about asking for a strike on the house!

Bender as it stands last night. You can see the die on my incredibly messy bench in the rear. I have to say there is a lot more work going into this bender than I anticipated.......

http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/P1030616.jpg

[GP'd]

A few updates over the past week.

Installed the ARB High Output Onboard Air Compressor (CKMA12) after it has been sitting in a box for the past 4 months. Its awesome to finally have the front ARB locker working and a way to fill up tires. Not sure why it wasn't done sooner; quick and easy install.

The bender is almost finished! I have about 40 inches of weld left and final clean up and paint. Can't wait to get this thing working! I had planned on finishing it this past weekend, but given that I only had Saturday to work on the Jeep, the decision to use the time for something a bit more important on the vehicle...my lower control arm brackets, was made. Not to mention my 90 lb of argon is almost out, and I couldn't risk running out on a weekend building the bender, when I had the axle out of the jeep.

Friday night I pulled the axle in 56 minutes solo. My new personal record. I think I've done it enough times in this past year setting up the suspension that it is mindless. Anyway, here is how the control arm brackets looked.

Passenger Side after I had hammered it back and re-welded it a few months back. I think these cam bolt channels are a bit tired. They had a good 140,000 mile run.

http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/P1030617.jpg
http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/P1030619.jpg

Driver Side not in the greatest condition either but still better than PS

http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/P1030620.jpg
http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/P1030621.jpg

Somehow I forgot to take pictures of the new Currie Lower Control Arm brackets but will post some up next week.

Heading up to Mammoth lakes tomorrow for some fly fishing and relaxation. I'll get some photos of the jeep out there!

The essentials for the mountains waiting to be packed up tonight!

http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/IMG_20120418_215621.jpg

[thejafe]

Awesome! Thanks for the updates, G. Have fun up in the mountains. Cant want to see some shots of your rig out in the wild.

BTW, who makes those black cases in your pic?

[GP'd]

Awesome! Thanks for the updates, G. Have fun up in the mountains. Cant want to see some shots of your rig out in the wild.

BTW, who makes those black cases in your pic?

Thanks Andrew! I hope I can get some good shots!

The cases are older model Pelicans. I want to say a 1450 and 1550, but will need to confirm. Couldn't have paid more than $15-20 a piece for them used through craigslist. The smaller one with the stickers has all of my tools organized with small nylon bags and Off Road trail tools flexible rails (Link) (http://www.offroadtrailtools.com/shop/index.php?l=product_detail&p=68). The larger case carries a complete oil change and necessary fluids as well as hose, belt, thermostat and other odds and ends.

[GP'd]

Had a great time in the mountains with the jeep the other weekend. I finally installed my ARB compressor, and having a front locker to play around with was a blast! The suspension felt great but the 9,000 foot altitude really kills the powerband! My only complaint with the truck up there was my lack of manual transmission control. Following my re-wiring to pass smog, I removed the manual shifter, and have to say that the transmission deciding to shift at 2700 every time really kills the fun of fast corners where you need to be at 2900-3200 to maintain momentum. The torque convertor also turns on when combined with a 2-3 shift causing some issues. I think I am going to temporarily mount the shifter again until I finish my integrated one.

Still waiting to download a high res photos from the camera, but here are a few from the better half's instagram.

Taking a trail up behind Convict Lake for some scenic lunch views:

http://i53.photobucket.com/albums/g79/gdonati/319879_10100417406575735_6401029_47922314_20737642 98_n.jpg

My other favorite thing to do in the mountains. Trying to hit a hole with some #22 Nymphs on hot creek.

http://i53.photobucket.com/albums/g79/gdonati/IMG_1843.jpg

Beautiful coloring:

http://i53.photobucket.com/albums/g79/gdonati/533980_413844188635336_180459001973857_1583879_976 384373_n.jpg

Hand in hand:

http://i53.photobucket.com/albums/g79/gdonati/536707_10100418975706185_6410019_47931986_17789590 04_n.jpg


Meanwhile on the build....The bender is at the point where it is bending, though it still needs a lot of finish work. Base needs to be built, and I have about 15 inches of weld still to do. In the interest of time and trying to get this bumper done before Overland Expo, I switched to focusing on the bumper.

First bend off of the bender; 180º No Kink Bend on 1.50" x .120" wall.

http://i53.photobucket.com/albums/g79/gdonati/416588_10100426432672365_6401029_47967090_16968045 88_o.jpg

A slow video of the bender working and my compressor working even harder!

http://i53.photobucket.com/albums/g79/gdonati/th_VID_20120428_183404.jpg (http://s53.photobucket.com/albums/g79/gdonati/?action=view&current=VID_20120428_183404.mp4)

Grinder had its final day, though Home Depot pro replaced it without questions and without receipt.

http://i53.photobucket.com/albums/g79/gdonati/463162_10100428506596205_6401029_47979531_78969120 6_o.jpg

Where the bumper is at. Cross bar is placed on the vertical supports and the 90º corners will be horizontal to the ground and cut to match the fenderline. I need to work on the fairlead mount next, the lower skid cross bar and start attaching the trick tabs for the aluminum skid. The rest of my tubing should be here tomorrow so that I can do the upper radiator support. Sure wish I had a full cage to tie it into. Not sure if I am going to get this done before leaving for the Expo next week between work and what I need to finish on the TJ.

http://i53.photobucket.com/albums/g79/gdonati/559630_10100444258898465_6401029_48032359_31183365 5_n.jpg

The bumper I'm using for inspiration, though I'm taking some liberties in adjusting it for my less cool vehicle.

http://image.4wdandsportutility.com/f/10740953+w750+st0/0812_4wd_07_z+1998_jeep_wrangler_desert_race_car+f ront_detail.jpg
http://image.4wdandsportutility.com/f/10741043+w750+st0/0812_4wd_01_z+1998_jeep_wrangler_desert_race_car+l eft_front_angle.jpg

[GP'd]

The garage is a mess right now! Tonight I think it needs a re-organization so that I have the space and sanity to finish all of these projects before next week. I did a bit more mock up on the bumper last night. Set up the lower cross bar, two vertical fairlead supports, trimmed the upper cross bar, set up the skid for cutting...

Tonight I will drill the fairlead holes, and cut out and prep the skid. Hoping to get one more mock up on the front end and start welding, but there is still a lot of little finish work to do before I go to throwing beads.

http://i53.photobucket.com/albums/g79/gdonati/IMG_20120509_223148.jpg

[GP'd]

More bumper....

Mock up of the pieces; hoop material hasn't arrived yet.

http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/P1030654.jpg
http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/P1030653.jpg

Welded up, sitting on a beat up work bench I found at a garage sale last weekend for $5. I bought it just for this project. Completely worth it. My welding sucked that night. Kinda disappointing.

http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/P1030655.jpg


Adjusting the mill to notch the hoop bar. I realized after I took the photo the head was 10 Degrees too far.

http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/P1030657.jpg

Hoop set on cross bar for mock up. Not sure how I like it. Trying to decide. Any thoughts?

http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/P1030671.jpg
http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/P1030670.jpg

Testing the clearances of steering components and bumpers.

http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/P1030667.jpg

Side view

http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/P1030672.jpg

Currie Anti-Rock Install

Cut Link for my measurements & re-welded. Currie provides links set up for a 4" Lift. Major material removal needed for a 2.5"

http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/P1030665.jpg
http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/P1030666.jpg

Anti-Rock installed.

http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/P1030668.jpg

[GP'd]

Well between my last minute push of building before Overland Expo, the week on the road for OEX, coming home for 2 days, spending the weekend on the lost coast and then finally coming back to a few hundred too many e-mails, I finally have time to post up some shots from the trip. I hope to have more 'build' information soon to get this thread and my Jeep back on track!

These select shots are courtesy of Marc Fiorito, Creative Director of Gamma Nine Photography (http://www.gammanine.com/). They were taken on Broken Arrow Trail, various back roads of Sedona and along the Mojave Preserve/Kelso Dunes.

http://i53.photobucket.com/albums/g79/gdonati/DSC_7935.jpg

http://i53.photobucket.com/albums/g79/gdonati/DSC_7907.jpg

http://i53.photobucket.com/albums/g79/gdonati/DSC_7787.jpg

http://i53.photobucket.com/albums/g79/gdonati/DSC_7382.jpg

http://i53.photobucket.com/albums/g79/gdonati/DSC_3750.jpg

http://i53.photobucket.com/albums/g79/gdonati/DSC_4000.jpg

http://i53.photobucket.com/albums/g79/gdonati/DSC_3474.jpg

http://i53.photobucket.com/albums/g79/gdonati/DSC_4323.jpg

[thejafe]

These select shots are courtesy of Marc Fiorito, Creative Director of Gamma Nine Photography (http://www.gammanine.com/). They were taken on Broken Arrow Trail, various back roads of Sedona and along the Mojave Preserve/Kelso Dunes.

http://i53.photobucket.com/albums/g79/gdonati/DSC_7787.jpg

http://i53.photobucket.com/albums/g79/gdonati/DSC_4000.jpg

Woah, some fantastic stuff there man. For real. The above images are my faves :sombrero: .

For me half the fun is capturing the adventure in photos then reliving it over again from the comfort of home. Of course, it's always nice to have a personal photographer (that also happens to be a professional) along for the ride, lol :ylsmoke: . Seriously though, some truly epic shots. Will have some of my own to share come September...

[MattScott]

updates please :)

[gt88norm]

Uh??? . . . Yeah!?!?!
Surely somethin's happened since June!

Norm

[MattScott]

Uh??? . . . Yeah!?!?!
Surely somethin's happened since June!

Norm

:(

[GP'd]

Hey Guys!

Thank you for the interest in this build! A lot has happend since June, however it has mostly been maintenance and discovering the weak links in the build last year. The better half and I have been drawing up what we need out of an adventure vehicle lately so the next stages are not far off!

I had an article published in the October/November JP Freek Magazine if you would like to read up on my latest adventure.

Pictures of the Jeep are on the cover, title page and article in Page 18.

October/November JPFreek
(http://currentissue.jpfreek.com/publication/?m=16482&l=1)

I hope to have more up lately; thank you again for the support!

[GP'd]

Well. Stage 2 has officially begun:

140790

Garvin Wilderness Rack has been removed. Gas mileage increase ~1-1.5 MPG @ 75 MPH on a recent trip.

Interior has been torn out to make way for a roll cage.

It will be part Synergy Suspension Cage (PPM-5203 (http://www.synergysuspension.com/Synergy-Suspension-Jeep-LJ-TJ-Cage-Kit-p-20215.html)) part custom fabrication. In addition I will be using Synergy's A-Pillar Cage Tie in (PPM-5205 (http://www.synergysuspension.com/Synergy-Suspension-Jeep-TJ-LJ-Cage-Tie-In-Kit-p-17945.html)) and Harness Bar (PPM-5200 (http://www.synergysuspension.com/Synergy-Suspension-Jeep-TJ-LJ-Shoulder-Harness-Bar-for-Stock-Cage-p-26265.html)). For the B & C pillars I will be using SWAG Offroad's Roll Cage Tie in (http://www.swagoffroad.com/Universal-Roll-Cage-Frame-Tie-Ins-Seat-Belt-Mounting-kit_p_14.html). My hopes are to also pull a tube from the A Pillars through the firewall and attach them to the front frame near the coil buckets.

New Tools for the project :
Pro Tools 105 Die (1.75" x 6" CLR x 90º (http://www.pro-tools.com/diesets.aspx))
JD Squared Notchmaster
(http://www.jd2.com/p-63-notchmaster.aspx)Swag Offroad Reach Around (http://www.swagoffroad.com/JD2-Notch-Master-Reach-Around_p_49.html)

Once the cage is in place, I will design the rear drawer system and storage solutions.

Cage Build Goals:
Provide the most amount of passenger security.
Keep entry and exit into the vehicle comfortable.
Increasing storage compartmentalization and organization.

More details to follow.

[GP'd]

...4 Hours later...

the factory roll bar, if you can call it that, is out. I had originally planned on integrating the front roll cage into the factory bar and reinforcing where I saw fit. After removing all the padding and lifting the cage out of the jeep without issue, I am glad I didn't. Flimsy piece of metal.

A few tips if you find yourself diving in this far.

The B-Pillar base is covered in a foamy glue.

Use a cold chisel and follow the outline of the bolts and washers and base plates.

140785

Use a dental tool or awl to pick what you can out of the torx hole. Then gently hammer the torx bit into the bolt. I used a 1.5" foot piece of tubing as a breaker bar to knock these guy loose. One of the vertical tub side bolts stripped on me, so I had to drill out and cold chisel the head off then used a bolt extractor to get the thread from the tub.

140786

There is a large security torx upright on the B Pillar. If you don't have the bit use a large vicegrip.

Now with all bolts out, drive the cold chisel under the B-Pillar plate. The glue you have removed around the plate is also below sandwiched between the floorboard. A few 5lb sledge whacks and it should break loose.

Now lift the cage out and you'll be here:

140787

Now to grind away all glue on the interior and move on to mocking up the A-B Hoops.

EDIT: 30 Minutes in, I fried the replacement Milwaukee grinder from a few months ago. Only Milwaukee I've ever had problems with is this model grinder. Frustrating. We'll see how the 2nd replacement grinder does.

[thejafe]

Now to grind away all glue on the interior and move on to mocking up the A-B Hoops.

Nice update, G. Wondering why you're removing all of the foam/glue... is it because your roll cage setup needs to mount flush to the floor, or because you'd rather not roll the bed liner on top of it? I know that crap is all over the interior of my TJ and I was planning to roll my liner right over the stuff because I'm sure it'd take forever to get it all 'outta there.

[GP'd]

Nice update, G. Wondering why you're removing all of the foam/glue... is it because your roll cage setup needs to mount flush to the floor, or because you'd rather not roll the bed liner on top of it? I know that crap is all over the interior of my TJ and I was planning to roll my liner right over the stuff because I'm sure it'd take forever to get it all 'outta there.

Removing it in the corners where the new plates from SWAG are going to go. You are correct in that I want the most flush mounting surface.. (Image Below)

140792

I haven't heard of anyone having problems rolling liner over the glue/foam stuff, but I would never attempt to get into those corners around the B-Pillar if the cage was still installed. With a wire cup brush and no cage it, it is a cake walk, though my grinder did just fry again. UGH.

[thejafe]

So, any updates? C'mon man, I gotta live vicariously through this project until it isn't 18º in NY anymore, lol. Got plans for the spring but about all I can do right now is acquire parts and plan things out until things start to warm up around here.

[JeepN95YJ]

...A few tips if you find yourself diving in this far.

140785


I've removed several cages and the best method for me is to go straight to the welder. I use a cup brush to clean the goo from the torx bolts. Then use a sacrificial large hex nut which I weld through the center hole to the torx. (I have a large assortment of used fasteners in a bucket. My favorite size to use generally comes from an old ring and pinion nut.) The combination of the heat from welding plus the large size of the new nut makes them easy to remove.

HTH

[GP'd]

I've removed several cages and the best method for me is to go straight to the welder. I use a cup brush to clean the goo from the torx bolts. Then use a sacrificial large hex nut which I weld through the center hole to the torx. (I have a large assortment of used fasteners in a bucket. My favorite size to use generally comes from an old ring and pinion nut.) The combination of the heat from welding plus the large size of the new nut makes them easy to remove.
HTH

Thanks for the advise Jerry! I'll remember that next time!

[GP'd]

Well....

Last Sunday, I had a seemingly embarrassing, very scary, freak accident occur in the garage. While tapping a bolt through a bracket, a 4mm shard of metal shot through my contacts and cornea, embedding itself into my Iris. I ended up in surgery a few hours later with the shard removed and 7 stitches in my eye.

Normally, I am overly paranoid about safety glasses in the garage, but unfortunately I had them on my forehead this time. Needless to say, they didn't really help. Given the frequency that I use a welder, mill, belt sander, grinder, tubing bender, and other 'dangerous' tools in my garage, the simple task of tapping a bolt in a hole nearly blinded me.

A week later, I am very lucky to be recovering beyond doctors' expectations. I will have stitches in my eye for the next 3-6 months and will wear safety glasses in lieu of an eye patch. Fortunately, after all of this, I will likely have correctable vision similar to what it was before. Given that the shard was about 1mm from deflating my eye like a flat tire, and I'll come back from this with only minor vision and cosmetic issues, let this be a lesson to everyone messing with tools: SAFETY GLASSES AT ALL TIMES.

141860

Needless to say, during my recovery over the next few weeks, I will not be able to make progress on the cage. Hopefully I can get some smaller projects done though.

[JeepN95YJ]

WOW!

Hope things heal quickly. I've been out of commission since November 2nd from a fall. I can tell you it is NO FUN being confined to the house. As of tomorrow I am allowed put full weight back on my leg and hope to get into the garage for a little while.

Take your time and follow the doctor's advice!

[GP'd]

WOW!

Hope things heal quickly. I've been out of commission since November 2nd from a fall. I can tell you it is NO FUN being confined to the house. As of tomorrow I am allowed put full weight back on my leg and hope to get into the garage for a little while.

Take your time and follow the doctor's advice!

Thanks Jerry. Heal up too.

[GP'd]

Progress. Finally. Almost 2 weeks after the accident, my eye has a decent bill of health as long as I don't get anything in it or bump it in any way.

Started replacing the factory cage the past couple nights.

B-C Pillar Constructed
B- Pillars Constructed

Now I just need to get another pair of hands to mock all of this up inside the jeep so I can start on the rest.

http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/P1040530_zpse6ef2379.jpg

[jscusmcvet]

Glad to hear your eye is going to be OK. It always seems to be the simple tasks that get us. I have enjoyed your thread, best of luck with it.

John

[mekcanix]

Well i have been enjoying the thread, glad to hear your eye is healing up. after reading this I think I will be re purposing my forehead protectors to safety glasses. Thanks for the build thread:sombrero:

[GP'd]

More updates coming up soon. Next is to get the upper B and C spreader bent and notched one of these nights. Once that is completed I can ratchet strap everything in and start tacking and mocking up the other pieces.


Glad to hear your eye is going to be OK. It always seems to be the simple tasks that get us. I have enjoyed your thread, best of luck with it.

John

Thanks! It is the simple tasks! <Still frustrated it happened>


Well i have been enjoying the thread, glad to hear your eye is healing up. after reading this I think I will be re purposing my forehead protectors to safety glasses. Thanks for the build thread:sombrero:

Thanks! Smart move.

[GP'd]

Made a bit more progress over the past two weekends. The A-B-C are tacked in!

Next are the visor bar, overheads, B Pilar X, seat brackets and rear triangulation. It's great to see progress. Over the next two weekends I hope to get everything but paint done.

Big thanks to Chris for helping over the weekend with the two man moving jobs!

http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/IMG_20130310_185946_zps26d7b42e.jpg

[thejafe]

Made a bit more progress over the past two weekends. The A-B-C are welded in!

Next are the visor bar, overheads, B Pilar X, seat brackets and rear triangulation. It's great to see progress. Over the next two weekends I hope to get everything but paint done.

Big thanks to Chris for helping over the weekend with the two man moving jobs!

Lookin' good, brother. Any lingering effects from the eye incident or are you all healed up? Also, what size Pelican case have you got there?

[GP'd]

Lookin' good, brother. Any lingering effects from the eye incident or are you all healed up? Also, what size Pelican case have you got there?

Thanks Andrew!

Still healing. Had 2 of the 7 stitches pulled last week and it is getting more comfortable on a daily basis. Vision is about 80-90 percent of what it was, but until the stitches come out in another month or so I won't start knowing what kind of adjustments are needed. Doctors say it can take up to a year for the eye to settle before taking corrective action. Looking forward to getting the stitches pulled out of my eye!

The box is an Underwater Kinetic 718 being used as a welding seat.

[MattScott]

What are your plans with the engine?

[GP'd]

This past weekend was a busy one! Though it may not look like it, I moved from tacking all the pieces, squaring them up to fully welding most of the cage structure. Please excuse the cell phone pictures. I have been horrible at using a camera in the garage lately.

http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/IMG_20130316_152121_zps7a67d09f.jpg

Currently I am working on all the support bars and triangulation which has moved much quicker than building the main structure. The B-C Pilar horizontals, harness bar, A-B Pilar horizontals and then the B-B/A-A Seat bracket horizontal bars were all cut and tacked in place waiting for final measurements and some tweaking with tie down straps.

The harness bar is a tricky one with a lot on the line. Granted I am still running factory seats and seat belts with hopes to upgrade to suspension seats and harnesses in the future, if I am building a cage to this level I want to be sure it can support those features. Harness bar height is the complication, and one I've seen far too many builds online do incorrectly, which could result in serious injury. I have been using this image as the bible for proper installation:

http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/harnessmounting_zps40e215c5.jpg

And this is where I ended up:

http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/IMG_20130317_1503171_zps4cb9131e.jpg

Measurements for the bar were taken with both myself and my better half in the driver seat. I used a level off of the top of the shoulder laid to a line on the harness bar to get the height. At 6'2" and 5'4" it gives about 0º for her and -10º for me, however I fear the level is too high when moving to a suspension style seat, so I will be using tube tabs from behind the seats in double shear to allow the ability for the belts to be dropped 2 " from the current location if needed.

RuffStuff Tube Tabs (http://www.ruffstuffspecialties.com/catalog/merchant.mvc?Screen=PROD&Store_Code=ruffstuff&Product_Code=TTAB&Category_Code=)

I'm waiting on these to arrive after ordering them this weekend, so more pictures of this detail to follow.

http://www.ruffstuffspecialties.com/catalog/graphics/00000001/Tube%20tabs.jpg

The other issue with the vertical height of this feature is the below bar height of 26" from the cargo deck. This allows fridge / stove mounting on the right, much like Adventure trailer's Combo slide and provides plenty of room for a two drawer system on the left for tool, kitchen and hard good storage.

The horizontal bars will be the platform for an aluminum shelf to store softgoods on without having to unpack them to access tools, fridges and other features below the deck.

For the rear C-C cross member I picked up these Tube Couplers (http://www.ruffstuffspecialties.com/catalog/merchant.mvc?Screen=PROD&Store_Code=ruffstuff&Product_Code=TC-DUB&Category_Code=). They will allow a structural bar in the rear of the cage, but still allow me to remove it if needed for larger storage and future installations.

http://www.ruffstuffspecialties.com/catalog/graphics/00000001/tube%20couplers%20double.jpg

On another note, I added a few new tools to the garage fleet in the past few weeks:

Harbor Freight 20 Ton Press:

http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/534958_10100752371523295_263938293_n_zps6d4c850d.j pg

BillyBob (Pirate4x4) Dimple Dies: (You can also see the tube couplers in this image)

http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/445_10100789356375355_1389519417_n_zps6d80d624.jpg

[GP'd]

What are your plans with the engine?

Engine is going to remain 'stock' at the moment. Currently all that has been changed are 4 port injectors and the intake system. At 150,000 ish miles, it still has a lot of life in it, but the pipe dream of the Golen 4.6 always looms! 270 HP and 320 ft/lbs of torque sure sound nice!

Golen 4.6 (http://www.golenengineservice.com/engines/jeep/4-6270hp-jeep-long-block)

WEEEEEEEEE
http://www.golenengineservice.com/wp-content/uploads/2011/12/jeep-4-6-stroker1.png

I just can't justify the money on something like that until this engine as seen the end of it's life. Plus 91 Octane isn't cheap these days. Maybe someone has tuned it for regular/plus by now?

The next big performance upgrade is one of these two guys. I will be rebuilding and reinforcing the extra Dana 30 I have in my garage and plan on doing the front brakes as well. There is a lot of info on the Vanco Big Brakes, and they are my top choice, but Wilwood just came out with the YJ-TJ Conversation at the beginning of the year which is tempting to say the least. I have yet to hear anyone running them...

http://shop.savvyoffroad.com/product.sc?productId=80&categoryId=15
http://shop.savvyoffroad.com/images/DSC_2369.jpg

or

http://www.wilwood.com/BrakeKits/BrakeKitsProdFront.aspx?itemno=140-12576

150672

[GP'd]

Mocked up some of the rear triangulation today while there was a little light out. Due to the harness bar height I had to rethink the perfectly centered B-Pillar X. After bugging some buddies for their opinion, it is hard to decide on which will be 'stronger' in a serious incident, so Option 2 is most likely. Less notches and measurements sounds good to me too.

Option 1

http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/IMG_20130318_190508_zps0c8c256f.jpg

Option 2

http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/IMG_20130318_190705_zpsac77eadd.jpg

Rear window triangulation

http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/IMG_20130318_191524_zpsb8315801.jpg

[GP'd]

Looks like a lot of the older images aren't loading anymore. I'll get to updating those shortly. Sorry!

[GP'd]

To say I have more than a few gussets and brackets left is an understatement....

http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/IMG_20130321_084119_zpscc01dec4.jpg

For anyone curious what they are and where they are from see list below. It always bothers me when this is excluded from builds!

From top left across rows:

Row 1:
Taco Gussets 1.75" - Poly Performance
Taco Gussets 1.5" - Poly Performance
3/4x3/4" Heim w/ 1.25" Tube Insert @ Jam Nut - Ruff Stuff
Wide Misalignment spacers - Ruff Stuff
Row 2:
1.75 Tube Flange - Ruff Stuff
1.75" Poly Bushings - Poly Performance
1/2" Bolt Tabs - Ruff Stuff
C - Pillar Frame Tie in Plates - Swag Offroad
Seat Belt/Limit Strap Brackets - Ruff Stuff
Row 3:
2" Poly Bushings w/ Bracket for Frame Tie in - Ruff Stuff
Cage Tie in Kit (Bracket/Bushing/Tube) - Poly Performance
1.75" Tube Tab - Ruff Stuff
1.75" Double Lock Tube Coupling - Ruff Stuff
Row 4:
Cage Handles - Poly Performance
Seat Belt Bracket - Swag Offroad
Frame/Tube Landing Plate - Poly Performance

[GP'd]

http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/599516_10100800989582315_565174357_n_zps522dbcb6.j pg

More progress over the weekend.

Rear B-C Windows and Cross Bars completed.

Below bar height of 26" set for drawer systems and fridge/stove slide set up. Above the fender wells will be a perfect for something like the Artec Quart Crates (http://www.artecindustries.com/Racing-Quart-Crate--6-qts-brake-PS-2-gallons_p_174.html). I have been eyeing them for a while to organize and store all the fluids in one location. Prior it was using a pelican box that just couldn't hold everything I needed. As I move to a drawer based rear cargo system with soft storage above the horizontal bars, I think it will be the best way to organize bottles.

Has anyone else used these?

[GP'd]

I've been chipping away a bit more over the past couple weeks, and managed to score a couple of new parts.


In the front, I installed the seat cross bars and cut out the factory tub reinforcement so I can get a 3" drawer underneath.
In the rear, I installed the upper C-Pillar crossmember.
Ordered Dave's Customs Boat Tail Rockers
Managed to find slightly used AEV Highlines!

This weekends projects with my buddy in town:

Finish the B-Pillar Cross
Finish the Upper B-C Pillar Triangles
Mock up and tack all the taco gussets.


Really excited to get all of the parts installed so I can wrap up the cage tie in mounts and get back on the trails.

[GP'd]

Spent a few hours in the garage this weekend.

Built the upper B pillar V. This took 6 hours to mock up before we could finally tack it in. Granted I'm new at this so I expect some frustration, but man are 5 tube junctions a pain. Add onto that a 15º bend and clocking the bottom notch correctly to the harness bar tube, and you have about 4 hours of just mocking up and fitting.

http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/IMG_20130421_174200_zps99a9a727.jpg

Now to build the lower V and finish the roof B-C V before I can pull the cage out and finish welding it all.

[GP'd]

Seat Brackets:

Built and drilled simple seat brackets out of 1.5" x .250" cold roll. Using the factory brackets we transfered the pattern with a center punch then used the mill to drill through all 4 brackets at one time. These four 18" pieces will span the cage floor bars and secure the factory sliders. This will allow me to use factory seats or any aftermarket seat with a TJ adapter.

http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/P1040696_zpsb89d12e9.jpg

My friend checking center on the next hole.

http://i53.photobucket.com/albums/g79/gdonati/Jeep%20Build/P1040695_zpscdb59878.jpg

[GP'd]

Friday Night I installed Poly Urethane Body mounts (Energy Suspension 2.4107G) so that the cage frame tie ins and body flex at the same rates.

I did not take photos of this process but it was a quick install completed under an hour and a half. The trickiest part of the install were hammering the body mounts straight and putting in the front grill bumpers. If you ever have to do this, grease the rubber bumper posts first!

Bent body mounts were due to a slight misjudgment at the dunes. This incident 6 years ago resulted in a bent fender as well. Fortunately that was all. At least I have a picture of it.

Younger and dumber self behind the wheel. Don't listen to friends with cameras.

http://i53.photobucket.com/albums/g79/gdonati/Facebook/Jeep%20Build/310016_10100834497472235_411771368_n_zps3d9717e3.j pg


Bent Mounts required hammering and filing to get the metal sleeve to pass through and seat correctly.

http://i53.photobucket.com/albums/g79/gdonati/Facebook/Jeep%20Build/386937_10100834498450275_265877323_n_zps018dfc9c.j pg


On Sunday I also started on my boat side rockers and tacked my seat brackets in. The drivers seat still needs a bit of adjustment. No pictures of seat brackets yet.

http://i53.photobucket.com/albums/g79/gdonati/Facebook/Jeep%20Build/524685_10100836268682715_1249786597_n_zps024a2a03. jpg

[GP'd]

It looks like my Beams Tri-Lock Seat belts shipped today. Hoping to have them to install next weekend.

[Septu]

Bent body mounts were due to a slight misjudgment at the dunes. This incident 6 years ago resulted in a bent fender as well. Fortunately that was all. At least I have a picture of it.

Younger and dumber self behind the wheel. Don't listen to friends with cameras.

http://i53.photobucket.com/albums/g79/gdonati/Facebook/Jeep%20Build/310016_10100834497472235_411771368_n_zps3d9717e3.j pg



And it is a great picture!

[swift7777]

Yee - Haa, great & expensive picture.

[GP'd]

And it is a great picture!


Yee - Haa, great & expensive picture.


Hah! Thanks. $150 dollar picture. Found a set of used fenders a few years later for cheap. I bent the newer set a few months ago wheeling in Big Bear.

Still waiting on some used AEV fenders or will just bite the bullet and buy new ones.

[GP'd]

I was able to get the Lower B Cross bars in. The upper B-C Cross bars were made but not tacked in this image. A couple hours of tweaking left with it in the tub and I can pull it later this week/weekend for final welding and paint. I hope it can be lifted with just 3 guys. I'll know after I calculate the weight later tonight.

http://i53.photobucket.com/albums/g79/gdonati/Facebook/Jeep%20Build/IMG_20130503_142716_zps140e2945.jpg

[GP'd]

PROGRESS! The notching and bending is over! Over 3 dozen different tubes went into this.

Next : Finish seat/seat belt brackets and pull it out of the tub for final welding and gusseting. Frame Tie ins. Boat sides. Truck Bed lining.


http://i53.photobucket.com/albums/g79/gdonati/Facebook/Jeep%20Build/IMG_20130511_135847_zps53963973.jpg