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Old February 25th, 2014, 05:26 PM   #1
RDK_YJ88
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My Mild-ish YJ build

It's time for me to retire the XJ to another owner, it was a fun build and its been a great Jeep. However, I'm ready for something different, with a real frame and removable top and doors.

The goal for the YJ is to keep it street-able, 33-35" tires, linked front and rear, 1/2 ton axles, lcg, roll cage, armor, highline tube fenders, etc. As much as I want a buggy, I like to be able to drive the Jeep to work, around town, Snofari, Dunes, etc.

The starting platform is a 1991 Jeep Wrangler Islander. Body was in pretty good shape, with no major dents or rust. Most of the rust was in the rocker panel area which is being replaced with sliders. The Jeep came with a 4.0l-tf999-231, the 4.0 was out of an XJ so it has all the wrong accessory mounts. The plan for now is to run the stock setup, but that may change to a GM V8 with an overdrive auto trans. Still on the fence with that, but I have some time.


First things first here is the Jeep as I received it (sorry for the crappy cell phone pics and messy garage) :








The rust



Clean floor pans





To start the build, I began with the rock sliders. 3x3 square tubing, I cut 4.5" up from the bottom on the rocker, and 2.5" into the floor pan. So I gained about an 1.5" ground clearance, and it will stick out around .5". The passenger is finished up, once the drivers side is done they will get some tube slider/steps. The plan is to tie these into the frame and roll cage.

Cutting out the rocker:



Mock up:





Welded up:



All done, small patch of rust to repair:




Finishing up the drivers side then moving on to cleaning up the frame and designing link brackets.
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Old February 25th, 2014, 06:23 PM   #2
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I'm looking forward to seeing this build. Sounds like you're doing what I started with, and should've stuck with.
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Old February 25th, 2014, 07:58 PM   #3
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cool.
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Old February 25th, 2014, 08:06 PM   #4
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Getting the old spring mounts cleaned up. Here's the template for the flat belly/lower link mounts. Hangs down 2.25" inches from the bottom of the frame. Not too concerned with getting hung up on it because it will be a smooth transition from the links to the flat belly.


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Old February 26th, 2014, 06:33 PM   #5
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I'm also looking forward to seeing how this turns out.
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Old March 2nd, 2014, 12:24 PM   #6
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Started cutting out the link/belly brackets.





Mocked up on the frame. Close to where it will go, but not exact.




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Old March 2nd, 2014, 12:54 PM   #7
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You said linked front are you gonna do a 3 or 4 link?
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Old March 2nd, 2014, 01:25 PM   #8
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3-link with a panhard in the front, 4-link in the rear.
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Old March 4th, 2014, 05:09 PM   #9
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Looking good. Hopefully you don't have issues with link clearance to the frame under compression like I do. My links are also huge, but I know you like to keep things low like I do.
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Old March 4th, 2014, 07:42 PM   #10
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I'll be keeping the stock frame, so i'm planning on the links being flat at full bump. If the frames in the way, it will get modified.
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Old March 7th, 2014, 02:38 PM   #11
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Trying to teach myself AutoCAD. Figured my link brackets were an easy project to start with.





Hopefully more progress this weekend.
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Old March 7th, 2014, 03:04 PM   #12
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If you want a basic CAD tutorial, I'm stuck at home for another week and have my work laptop with me with a few different CAD programs(AutoCAD 2D, Inventor 3D, Solidworks 3D). Then again, looks like you've got a good start already.
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Old March 7th, 2014, 05:03 PM   #13
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I had a few classes in High school in AutoCAD and Inventor, so I'm semi familiar with them. Youtube has helped me find a few shortcuts also. Thanks for the offer though.
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Old March 10th, 2014, 09:12 AM   #14
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Got the other side cut out and tacked together. Need to finish cleaning the frame so I can tack these in place and build the skid/ trans mount.

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Old March 16th, 2014, 05:17 PM   #15
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Pulled the front axle out of the XJ. Have had zero interest in selling it, so it's getting parted out.

Looks like the Links from the XJ are a little short, but hopefully when I replace the bushings on the axle end with heims I'll get a little more length out of them.



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Old March 16th, 2014, 06:22 PM   #16
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Nice!
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