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One More Beer....I mean time / Mild TJ build (updated with final pics)

45K views 283 replies 63 participants last post by  itchy 
#1 · (Edited)
Well.....I'll save all the bullshit and lies for Pirate 4X4. Picked this nice little 97 TJ up last October to fix and sell. It needed a new gearbox that the owner supplied with the sale. Quick fix and ship it down the road. And after it sat in my garage a few weeks I started drinkin and thinkin:beerbang: Like I needed another project. I wasnt going to do a build thread till this was 99% done, but that may be another 2 yrs. so what the hell.



My plans for the jeep were to keep very mild. 35"-37" tire, dana 44 & 8.8, link it with c/o in the front, stock springs out back, stretch it, and blah, blah, blah.


Picked up a few brackets from Ballistic Fab for the suspension. Started with the 8.8. My initial plans were to build everything to save some extra cash, but its just not worth it to me to make all these brackets, for the price they sell for. After what seemed like 5 days of grinding, I got started on the axle. Bent up the truss out of 1.75 x .120 wall DOM, and made a couple little braces for the ends out of 3/16 plate. Hopefully it doesnt shoot off the first time my foot slips off the clutch.:sonicjay:



You guy's have any problems with the welding, you can take it up with this guy. He's got a temper though.















 
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#7 ·
Got most of the rear done within a few days while I waited on the wheels to come. Got a killer deal on a new set of old style 37X12.50X17 MTR's from Rubicon1, and ordered a set of 15X8.5 TrailReady HD beadlocks. (more on this later)
Picked up the GenRight stretch kit with the corner armor, rockers, and tank. The tank sure is nice, but how the hell can they justify the price? I love how the rear came together with the extra 5" stretch.















 
#11 · (Edited)
Started to gather parts for the front, and things kinda stalled for a bit. I was having a minor melt down with my decision on the axles. At this point I didnt have a front axle, and started looking at 1 tons. Old habitts are hard to kill. But made a decision, and sstuck to it, and for those of you that know me, this was a monumental decision. Well.....I just didnt want to have to buy new wheels(more on that later).
Anyway, I ended up going with a G2 Dana 44. I know it just an expensive Dana 30. Whatever...I'm happy with it.

Trac bar bracket was just for mock up........




Pitman arm is from an Asro van. unsure of the year, but I did have to file out the locating splines, so it would clock on the gear box in the right spot.














Decided that I wanted to run coilovers, and stretch the front axle mid way thru setting up the front suspension. So this meant I had to figure out something for the steering. Ended up rotating the box up a little, and moving it foward 5". What I didnt realize at the time was, while moving the box to its present location that I would not be able to bolt a winch plate, or a bumper of any kind to the front.
 
#13 ·
A lot of these pics are a little rough looking. Havent finished cleaning, and welding everything up at this point.










This what I came up with for the front bumper, and winch plate. Front bar is 2X4X 1/4" wall that I put a little bend in the front for a little flare.

















Bought me a new little tool. Cant believe I've been doing this stuff for this long with out one. Cant wait to actually buy a good one:sonicjay:






 
#18 · (Edited)
Most of the suspension is tacked together, and ready to explode at any moment at this point, but good enough to check clearence on everything. Had to move a few things around, like rear shocks, and a couple brackets for the c/o's, but all in all everything seems to work and flex pretty well. Messed around with the upper springs on the c/o's, but dont want to get to excited till I get the cage and, and everything else done before I start messing with the rates.
Couple poser pics.























Then I started on the rear bumper and tire carrier, but after the exhausting week of wrestling with my Model 3 bender, and it shearing the upper and lower plates, and almost killing me, I'd had enough excitment for one week. So I took a much needed break form working on the jeep, and decided to drink my self into a self induced comma of pitty and remorse. After I sobered up I ordered a new bender, and got back to work, but all the BS took a little steam out of me, so I decided to just buy a rear bumper, and finish up the carrier.










Moved on to the fenders.












 
#25 · (Edited)
thanks guy's.
Just about done with the cage, and then I need to move back to my wheel delima. Ugggh. I'm using the WJ knuckles and brakes, and never installed the calipers on the knuckles while working out the bugs with the front axle. Thats what I get for not looking into things before jumping in head first I guess. Found out the hard, and expensive way that 15" TrailReady wheels will not fit over the WJ knuckles/brakes. I wasnt about to re-do all the steering if I was to switch back to the TJ knuckles, so I sold the wheels and tires. Soooooo back to trying to find wheels and tires. Tires are next to impossible to buy right now. I havent been able to find any one that has, or knows when they will have the 37" MTR's. And Super Swamper isnt going to be making tires till end of May.
WTF?
 
#28 ·
Looks great! Would've looked better as a Scrambler, but we don't need to go there:teehee:

I'm digging the front bumper/winch mount design with the stretched steering box, I plan to do something very similar with mine.
 
#31 ·
:sonicjay: Ya well in hind sight, I would have been better off doing the deal with you than building this, but were way past that point. Remember I didnt want another huge project? I think there is a little something wrong with all of us. Been keepin an eye on your build as well. Its lookin real nice.
 
#33 ·
Just a few misc pics of the front c/o hoops, and rear shocks. Still need to come up with rear bump stops yet. I had some mocked up, but dont think they are going to work. Had it inside the coils, but with the stock spring it reaching full bump to soon, so I think Im going to go with a set of air bumps for the rear as well.















 
#35 ·
LOL...We'll never learn Sean. I've resorted to lifting the wifes JK so we have something to wheel for Memorial Day weekend, so I can do a couple different things that were not part of the original plan. I want to run a flipped 300 case now, so I have to do some research on what all I need to make this work the right way.
 
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