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Old January 10th, 2010, 01:08 PM   #1
jeepyj93
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NkLgIgL ReBuIld

I have been working on doing a rebuild of my 1993 wrangler this winter. I have done a lot of stuff with it over the time that I have owned it, But I decided that this year it was time to go a little more extreme than the minor adjustments that I had been doing. When first got the jeep a few years ago it was stock, and the engine knocked really bad, but I wheeled it anyways. The motor kept knocking and getting worse for about 3 years, then it finally gave out. I swapped in another 2.5L 4Cyl, and went right back to beating on it. I love how everyone says that you need a big engine, but I was keeping up with the best of them with a 4cyl, stock axles and gears, 33" Baja Claws, and a little bit of flex. I finally ended up with a 4" RC lift, 2" shackles, Lots of fender trimming. Now I have upgraded to some 35" tires, and got rid of the 4" lift. I am now going to be running wagoneer front springs, and XJ springs in the rear. I will be running them SUA with about 2.5"-3" of lift. I originally ran 33" tires with my stock suspension and some trimming, so i think this will work out just fine. Plus I have been known to roll my jeep fairly often, so the lower the better. Enough of the BS, here are some pics. I will upload more as I have time. Feel free to ask any questions.

Here is the jeep when I got it a little over 3 years ago.

This is how I wheeled it for a while. 31" TJ flares, and no lift.

Here is a pic of it when I was getting it ready for paint.

Here is a pic of the 33's with a 4" lift, and TJ flares

Here are the most recent pics of the jeep before the rebuild with 4" lift, 2" shackles, 33's, and tube fenders

This is how it looked when I rolled it in the barn to start tearing it apart this winter.

Last edited by jeepyj93; September 21st, 2012 at 07:42 AM.
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Old January 10th, 2010, 01:27 PM   #2
pistol pete
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nice project, i know what you mean about motors, (even though im running a 383 stroker) i have a friend from wisconsin that has a wrangler with 38.5 in swampers, full width 60 rear, full width dana 44 front, stock four banger and trans, custom four link suspension , that climbs stuff i wouldnt beleive possible if i didnt see it with my own eyes.
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Old January 10th, 2010, 01:55 PM   #3
jeepyj93
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Right now I have the jeep sitting SOA in the rear, but it is a little higher than I would like, so I am going to stick with the SUA front and rear, and around a 3" lift. I have the wheelbase at 102". 35" Trxus STS on explorer wheels. Working on DIY SYE. And YJ hood and grill are off, waiting for the CJ hood and grill.

Here is a list of the things that I still have to do, or am in the process of doing.
  • Ford 8.8 -lines,calipers, and pads
  • Cut and drill t/case output
  • Swap XJ D30-perches, rebuild, gears, shafts
  • remove cage mount spacers
  • valve cover gasket
  • coolant
  • refill transmission and t/case
  • rebuild spring packs-clean, and paint
  • CJ hood and grill swap
  • Build new tube fenders
  • rear shocks & mounts
  • tranny mount
  • trim the skidplate
  • tie-in the cage to the frame
  • add on to cage
  • mount seats to cage
  • clearance explorer rims to clear hubs
  • install winch power disconnect
  • build rear driveshaft
  • rebuild steering linkages
  • new u-bolts for front axle
  • paint
  • bedline inside
  • build radiator cover
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Old January 10th, 2010, 02:07 PM   #4
jeepyj93
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Here are some pics to show the progress up until now.

Here is a shot of the on board air setup that I built using an A/C compressor off a 4.0L.


Here is the 8.8 waiting to go in the jeep.


The Dana 35, and rear section of the frame off of the jeep.


After cutting the rear section of the frame off.


Ford taurus fan. Sure have alot of room with and electric fan and a 4 cyl.


My buddy helping me weld the new rear frame section.


Test fitting the XJ springs.


Frame welded into place, and waiting for some plating.


New frame/rear bumper/shackle mounts.


Rear axle in place.


Here are the new tires on the jeep. The rear is sitting SOA, but will be put back to SUA.


YJ hood and grill off. Waiting for the CJ hood and grill.



New front axle. Need to cut the brackets off, and weld on the new perches.
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Old January 11th, 2010, 07:49 PM   #5
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Got to do a little bit of work today. Switched the rear axle back to SUA, and got the t/case back in, and hooked up. I like the new look a lot. Still need to do some more trimming at the back of the rear fenders, and install some add a leafs in the rear spring packs.The front is sitting at about 3" of lift( waggy springs for 2" stretch+ 2" lift) and 1" lift shackles. The rear is sitting on stock XJ springs with the same shackles, but the shackles are mounted on the back side of the rear bumper, so not much lift from them.



Last edited by jeepyj93; January 11th, 2010 at 10:51 PM.
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Old January 12th, 2010, 06:06 PM   #6
Xj Wheeler
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why a cj grill? IMO they are ugly
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Old January 12th, 2010, 06:17 PM   #7
92comanche4x4
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that thing looks good.
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Old January 12th, 2010, 07:20 PM   #8
dreezy
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Looks good. Are you staying with 4.10's?


Quote:
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why a cj grill? IMO they are ugly
Opinions are like assholes, and you need to wipe.
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Old January 12th, 2010, 09:19 PM   #9
jeepyj93
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Quote:
Originally Posted by dreezy View Post
Looks good. Are you staying with 4.10's?




Opinions are like assholes, and you need to wipe.
For now I will be staying with 4:10's to get it up and running as cheap as I can. Then after I get some more money saved up, I will do gears.
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Old January 16th, 2010, 11:12 PM   #10
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Sold some parts tonight, so I picked up the new hood and grill late tonight. I had to bolt the hood in place, and set the grill in place to see how it was going to look. I really like it, so far. Going to try to get alot more stuff done tomorrow, and monday morning. I will add some new pics as soon as I get some more tasks completed.
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Old January 17th, 2010, 08:47 AM   #11
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cj grills ugly? they look better than the square head lighted wrangler. i think its cool that you switching it to a cj grill and hood. nice work rebuilding the rear frame ,cant wait to see more
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Old January 17th, 2010, 09:09 AM   #12
bigdogwaggy
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lookin good dude keep it up!
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Old January 17th, 2010, 12:28 PM   #13
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subscribed to this build
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Old January 19th, 2010, 12:35 AM   #14
jeepyj93
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I got a few more things marked off the list today. Got the hood, and grill on, and lined up. Finally got the radiator mounted to where is clears the steering, and the hood still closes with clearance between the cap and the bottom of the hood. Now I just need to start building a new set of tube fenders for the front, and start doing some work on the roll cage. Also going to start building my new rear driveshafts soon. I am building a trail spare out of a stock rear driveshaft, and some square tubing. I am also going to be cutting down a wrangler front driveshaft to make one that is more balanced for the road. I will post pics tomorrow.

Last edited by jeepyj93; January 19th, 2010 at 01:42 PM.
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Old January 19th, 2010, 01:46 PM   #15
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Here are some pics that I snapped this morning. Sorry there is a bunch of junk floating in the air. i got done cutting out an area on the passenger side to replace that, and then blew everything off when I was done.



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Old January 21st, 2010, 04:18 PM   #16
jeepyj93
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Today we got some new metal put in where the holes where, sanded down a few spots, and used a little bondo. I also got the roll cage tie in plates done, and the tube fender mounts done. Just need to get some new drill bits, and drill a couple more holes in the front fender mounts. Started go get fed up with the dull drill bits, and started doing some sanding on the jeep. We ended up getting the whole thing sanded down. I think I am going to end up painting the jeep as soon as I get the money. I want to do it while it is all apart, that way the only thing i need to tape off is the steering wheel, dash, and windshield. I am going to paint the hood, grill, and doors while they are off of the jeep. Then when I get it all back together I will do any touch up paint that needs to be done. I am ready to see what this is gonna look like in all one color.
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Old January 21st, 2010, 04:25 PM   #17
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sweet build so far but what is on the front of the bumper? a kinked push bar?

you will like the Cj front clip

Last edited by Pokerob; January 21st, 2010 at 04:34 PM.
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Old January 21st, 2010, 04:39 PM   #18
jeepyj93
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Yeah, it is just a bar that i had in the scrap pile. I put it on there to be able to put my winch hook on. I think I am going to bend up a nice stinger, and grill hoop, and get rid of that. I really like the CJ hood and grill, and can't wait to see it all one color.
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Old January 21st, 2010, 04:45 PM   #19
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Quote:
Originally Posted by jeepyj93 View Post
Yeah, it is just a bar that i had in the scrap pile. I put it on there to be able to put my winch hook on. I think I am going to bend up a nice stinger, and grill hoop, and get rid of that. I really like the CJ hood and grill, and can't wait to see it all one color.


i had to notch the CJ grill where the steering hoses were to get it to fit.

you wont have to do that if you have a body lift though.
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Old January 21st, 2010, 05:50 PM   #20
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looks awesome with the cj grill and hood
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