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Project Jimmycon (full width tons jk) REAL Cost!!

13K views 101 replies 28 participants last post by  indy 
#1 · (Edited)
My Jk started life as a 2010 Mountain package Unlimited. Before I signed on the line I upon test drive I had already taken it through a rather large ditch, I decided I liked it so I bought it! The ORV sticker went on it first then the plate. It was purchased in Houghton lake where it was easy to drive back to our cabin through the woods (St. Helens.)
After having rigs in the past with gears and lockers I relized quickly that I should have just bought a Rubi and been done... Right.... Wrong!! It came with the typical d44/30 setup with 3:73 gears. !!k miles on it I had lifted it and put 35" KM2s on it which leads me to now! After pricing how I wanted to setup a Rubi 44 and getting sticker shock at the 4500 bucks I was getting ready to soak into a thin tubed 44 I WOKE up!! I then called Currie and Dynatrac for prices on there 60s, Wrong not an option for this blue collar worker!
I ended up buying Bustabizz's fullwidth 79 Dana 60s. The front is setup with 5:13 gears, ARB, Alloy 35 spline inner/outers CTM joints and Solid knuckles and spindles. The rear is setup with a 35 spline spool, Which will get switched with an ARB ,5:13 gears, disc brakes, and Alloy FF axle shafts. Clearly this is alot of axle for a daily driver, but if I've learned one thing in my past 20 years of building is that this is expensive to do once, but twice as bad to build it twice! Wheels will be Diamond racing 16x10 5.5 backspace with Stauns. The tires will be 38x14.50x16 Toyo mt, not geeked about this (its still my wifes DD!) So I'm keeping the tires resonable! As far as lift goes I currently have a standard duty Rubicon Express 3.5" lift. My thoughts were to keep the stock control arms to keep it a little more road friendly, but quickly realized that I may want a bit more adjustability, so today I orderd the Rubicon Long Arm upgrade to add to my lift! The fun stuff CNC cutting brake! Thats all my wife wants!
As it sits the rear axle is tacked up, and waiting for sandblasting, the front well thats another story we'll say its stripped and ready for sandblasting!
Stay tuned for current updates, finish date is Snofari 2012!
 

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#37 ·
I just finished the front ABS brackets, I ended up using Dynatrac supplied brackets which I used my backyard Bridgeport (Metabo) to modify as needed.
Later tonight I will be finish welding the front axle and messing around mounting the Stauns and tires to the wheels.
All is looking good for final install this weekend!!
 
#51 ·
Crazy it worked! Extra parts needed for this install are:
1. Adjustable front and rear track bars.
2. 2" rear spacers. rear full float 60 is 65" WMS, Front is 69.75
3. My wheels are 16" with 5.5 BS. 17" would save some grinding on the calipers.
4. Sector shaft brace. Mine had some play in it after only 22k miles.
The high steer arms did work with a touch of Hillbilly trickery!
 
#53 ·
Just orderd Spacers, new rear (Synergy) track bar and Rock Solid front track bar with steering brace. Allpro offroad 1.5" wheel spacers, and JE REEL driveshafts.
I spoke with Jim Reel, he was great to deal with! I tried to keep my money local but, after all the questions and needing compressed + extended lenghts the choice got easier. I told them what lift and type it was, how much lift, gave them running lengths and a credit card! I ended up with a rear 1350 double cardan shaft with the canyon crawler option. This takes the wall thickness from .083 t0 .120. Due to a smaller tire I wanted a bit more insurance under me. The front is also a 1350 double cardan setup.
The downside is they were swamped and can't ship them untill Friday or Monday! this puts a delivery date of the 20th, and me bolting shafts in it while it sits on the trailer for Snofari!
 
#63 ·
thats a sweet build. any updated pics?
 
#65 ·
Drove it today about 100 miles!! It could use a steering stabilizer thats about it. I do have the ABS light on and the BAS lights, I need to do some fine tuning of the sensors and set the steering wheel to zero.
The speedo is working and about 9-10 mph off. The ride quality is better than stock, Well better than the 3.5" standard rubicon lift anyway. I may consider putting the stock springs back in. The 38s look like bike tires!
 
#70 ·
Toe is set at 1/8" in, These tires are 14.50 wide so its not an issue all of the time only at slower speed.
Project manager (wife) put a halt on the budget so no ram assist YET, there not 42s. Instead of doing a build with small axles and big tires, I did a build using big axles and streetable tires!
 
#74 ·
This build is done for now, I have put about 75 trail miles on it and my wife hass put about 1000 road miles on it. I thought I would put down the real cost of what a person could build there own 1 ton jk for. I've seen alot of debate so here it is.
Cost of Jk= your choice
cost of 1979 Dana 60s (4500) in my case a person could get out way cheaper!
Cost of Currie rock jock brackets (most of them worked) 750
Cost of JE REEL drive shafts 1300. I added the Canyon Crawler upgrade for an extra 100 on the rear.
Cost of Teraflex Master cylinder 195 (without it the pedal is mush)
Cost of wheels (Cuz your gonna have 8 lugs not 5 now) 400
Steering 120 (3) 7/8x 14 fk rod ends 120
Tone Rings for ABS 280
Total cost $7545.00
I did not include the cost of Stauns tires or my lift because those were my choice.
I think atleast a budget boost is needed.
In my opinion if you already had a set of Ford 60s this could be way cheaper!
I set out to build something way stronger than a Rubi and be close to the original cost and have it still be my wifes DD (tested to 75mph). All ABS works as well as traction control! The air pressure light is on due to Stauns I can't use the pressure valve stems.

I would do this again in a heartbeat, My only regret is not buying 40" tires! With 3.5" of lift there is plenty of room for them! In time!
Happy Building!!
'
 
#81 ·
awesome write up! jk looks sweet
 
#82 ·
Thankyou, I must say I'm very pleased with the streetability of this. I give my wife props because if the thing vibrated I would hear about it!!!!
Though this gets used for trailriding about twice a month its nice to drive it during the week too!
 
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