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Old February 2nd, 2008, 10:10 AM   #1
bearlys2005
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I see so many guys projects on here I felt it necessary to make a post. I started with an 86 CJ which had the typical bad tub and bad frame. I had done a lot of work to the original jeep, SOA, SB Chevy, Dana 44 Axles, but the body and frame were shot so it was time to start over.

I found a rust free 94 YJ tub, frame, as my foundation and built from there. I went with the YJ frame because I run Dana 44's from a Scout II which is a perfect width match to a YJ frame. I stated with by having the frame blasted and then removed everything attached to the frame to include shock mounts, engine mounts, everything. Then I made plugs for all the factory holes in the frame, welded them shut and ground them clean. Those holes are what ruined the original frame, all the dirt and mud inside does a lot of damage. Then I built new cross member for the tranny, motor mounts, shock mounts, bumpers, spare tire rack, slide rails, cage mounts, then it was time for some paint and putting the chassis together. Suspension is all Rubicon SOA with long travel shocks. Stayed with Dana 44 axles, spool in the real and locked in the front. I tried to build my own hydro assist but the failed big time. So I decided to get a Rock Ram setup which works fantastic... To power the new rig, I found a 95 LT1 complete to include the harness. I sent the harness to a guy in Jersey who took 25 lbs of wire and turned it into 6 lbs. I stayed with the turbo 350 trans, Dana 300 twin stick to transfer the power.

The body was in beautiful condition. I cleaned it up top and bottom, coated it with POR 15, paint, and then bed liner for the floor. I was going to bed line the bottom but decided not to. I built the cage but used the original factory hoop for the foundation. The cage has seat mounts built right into it and the cage is tied to the frame for our safety. I used the front clip off my original jeep, they were i pretty good shape. I went with a 1 inch body lift to give a little more height. I got a new wiring harness from Ironman, don't remember the brand, but it was a complete harness. I didn't have to use anything from my old harness. Everything was marked the full lengh of the wires... couldn't get any easier. The engine harness was easy to attach to the jeep harness. I had 4 wires to attach either to ignition power or constant 12v. To keep it cool I got a be cool setup for CJ to LT1 and it keeps it running cool as can be. When I wired it up I turned the key and it started, it doesn't get any easier.

I know I'm forgetting a lot of stuff but it was a lot of fun. All the custom things I did have worked out perfectly. It's always nice to see things workout after you build them. There are still a lot of things I'm doing to it today like mounting off road lights, you know the nice things we all need in our rigs to make them ours. I strated the project in Nov 2006 and had it on the road in May 07. So I ran it all last summer and it performs perfectly. The LT1 was an excellent choice... Plenty of power and it runs no matter what. I was a bit worried about the distributor on the front of the engine but it hasn't been a problem. Nothing I did I'd change as of yet.
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Old February 2nd, 2008, 10:33 AM   #2
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Nice build-up! Lots of detail to all parts. I love to see rebuilds done right - from the frame up.
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Old February 2nd, 2008, 10:51 AM   #3
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Here are a few pic's of the finished Jeep... This was her first time out, we took her to the Mounds to see how everything worked. Everything works well and I'm very happy with how everything worked together. The things I enjoy the best are the LT1, Rubicon suspension, and hydro assist. The three things make it very enjoyable to off road with.
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Old February 2nd, 2008, 11:10 AM   #4
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Looks good what size tires are you running?
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Old February 2nd, 2008, 12:13 PM   #5
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Looks good what size tires are you running?
Thanks, I'm currently running 15x35x15's TSL's.
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Old February 2nd, 2008, 12:16 PM   #6
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I'm running similar susp setup and everyone on here are telling me my tires are too small but your rig looks good

http://www.greatlakes4x4.com/showthread.php?t=74285
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Old February 2nd, 2008, 12:20 PM   #7
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I'm running similar susp setup and everyone on here are telling me my tires are too small but your rig looks good

http://www.greatlakes4x4.com/showthread.php?t=74285
Well I had these tires prior to the rebuild and of course their currently on it. I have no problem running with guys running bigger tires. Most the guys I go with are running larger and I go everywhere they do. If/when I replace them I will probably go a little larger. What I like is that I haven't broke anything and I know that guys running bigger have. If I go better I will probably go with 36 Iroq's or something like that.
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Old February 5th, 2008, 08:04 AM   #8
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So now that this is built, the only original parts to the vehicle are the front fenders, hood, core support, and the transfer case. Everything else has been updated.
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Old February 5th, 2008, 08:11 AM   #9
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So now that this is built, the only original parts to the vehicle are the front fenders, hood, core support, and the transfer case. Everything else has been updated.
That's what makes it a real Jeep! Nice build!
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Old February 5th, 2008, 08:28 AM   #10
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Very nice...
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Old February 8th, 2008, 12:02 PM   #11
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Very nice...
Thanks guys, it's always nice to hear from others that things turned out pretty good.
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Old February 8th, 2008, 01:13 PM   #12
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Most the guys I go with are running larger and I go everywhere they do.
Cough... B/S.... cough
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Old February 8th, 2008, 02:12 PM   #13
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Cough... B/S.... cough
Well, that hurts... I climbed #3 up in Rose City... And everything else we're tried to go through since the rebuild... I have so many hurt feelings... DICK:tonka::tonka:
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Old February 8th, 2008, 02:17 PM   #14
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Man thats bad ass
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Old February 8th, 2008, 02:29 PM   #15
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Well, that hurts... I climbed #3 up in Rose City... And everything else we're tried to go through since the rebuild... I have so many hurt feelings... DICK:tonka::tonka:


Why are you calling me a dick? I don't have bigger tires than you.

Actually it turned out pretty good.
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Old February 8th, 2008, 02:55 PM   #16
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nice build
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Old February 9th, 2008, 08:33 AM   #17
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Why are you calling me a dick? I don't have bigger tires than you.

Actually it turned out pretty good.
Just having fun like you are.... besides your tires are taller than mine...
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Old February 9th, 2008, 08:56 AM   #18
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Just having fun like you are.... besides your tires are taller than mine...
Well, the lettering on the side says they are, that's about it.
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Old February 9th, 2008, 09:02 AM   #19
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you should be proud! i envy you's guys who can do this kind of stuff.
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Old February 9th, 2008, 11:55 AM   #20
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Well, the lettering on the side says they are, that's about it.
:tonka:
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