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cooperzj
11-25-2008, 11:37 PM
http://i256.photobucket.com/albums/hh169/cooperzj/WessJeep005.jpg

http://i256.photobucket.com/albums/hh169/cooperzj/WessJeep002.jpg

http://i256.photobucket.com/albums/hh169/cooperzj/WessJeep010.jpg

http://i256.photobucket.com/albums/hh169/cooperzj/WessJeep014.jpg

http://i256.photobucket.com/albums/hh169/cooperzj/WessJeep017.jpg



http://i256.photobucket.com/albums/hh169/cooperzj/WessJeep007.jpg

http://i256.photobucket.com/albums/hh169/cooperzj/WessJeep013.jpg

Here's some of the photos from the work I've been doing with my friend Wes.

So far we've:

Removed and replaced the rear axle with a stronger one- welded all the tubes to the housing.
Re-Geared that axle with lower gearing 4.88
Put a Aussie locker in that axle
Built a new driveshaft with 2.5" x 1/8" DOM tubing 2x + as stronger than stock.
Removed the front axle and prepped it for new gears and Aussie locker- welded tubes to housing.
Removed the old exhaust
Made new exhaust and installed it all the way from the exhaust manifold to the tailpipe from scratch w/ a glasspack- welded the whole thing myself- looks awesome. (took out 3 bends and gave it better clearance from the driveshaft.) Sounds great.
Cut the rear fenders (comp cut) and cut out a bunch of body rust (more to go).
Began prepping for a paint job- going to be olive green.
Removed step moulding
Removed old tires and remounted with 36" INTERCO Bias Swampers Replaced old shocks with new ones.
Fixed up the engine- found vacuum leak and removed a bunch of useless garbage in there.
Removed old tire carrier (to be modified to mount the larger tires.
Removed stock bumperettes.
Removed stock pitman arm and replaced with dropped one.
Adjusted the Central axle disconnect mechanism to actually engage front axle.
Painted wheels black.
Put on a 8k# winch

To do:
Get new carrier for the front axle (in the mail)
Install gears in front axle
Install locker in front axle Install axle and weld up the perches.
Install new rear driveshaft- possibly have to go to a CV style shaft due to extreme driveline angle and get new U joints.
Ignition coil wires are loose- need to get them more secure.
Secure transmission to crossmember (discovered that it was just sitting on there- missing 2 bolts)
Hook up rear brakelines- bugger is still not coming loose after days of powerblaster (you can see my wrench on the bolt)

At this point, it should be ready to rock.

But, we'll keep prepping for a paint job- repair rusted parts- bondo and welded in sheet metal.
Then paint it. Doing a military theme- so it will have serial numbers stenciled in with black spray paint and a star on the hood. Maybe a military style gas tank if we can find one.

Also, I'm going to weld in some 10K # D-rings on the bumpers for recovery from tractor supply.

Going to look great. Lots of man hours- plenty of welding wire and gas. But it'll be worth it.

Hoping to have it rolling this weekend- if we get the carrier in time and if the driveshaft angle isn't too bad. I'm thinking we'll get a double cardan joint from the pull-a-part and then shim the axle to make it work if the single cardan doesn't work. Those are BIG ifs, but it's a goal. If not- there's always next week. We're trying to make it to the River Rock charity ride.

cooperzj
11-25-2008, 11:37 PM
Well,

Ran into a problem. The driveline angle was too high for a single cardan shaft to work- kept binding. So...

Off come the perches and shock mounts. and on go some new ones- ordered today.

Build a new CV drive shaft with slip yoke.
Took a while to figure out the donor vehicle- but ended up with the H Yoke from the front of an Explorer. Used the same 1330 U joints. Went together very smoothly.

With the double cardan joint, the pinion will point upward 21 degrees from where it is now. That means shims were out of the question. That's the reason for cutting off the old (new) ones and ordering new(er) ones. Oh well, I learned a lesson, don't weld up anything until the driveshaft is completely installed for a mock up. This mistake cost time and money.

Also went by Tractor Supply and got some of those 20K pound shackles. Cut up the rear tow hitch and welded those suckers up. Look great- and will be very funtionial. The mount will double as a foot step. The plate bolts on in 5 places to the frame- I think it should do the job. Uses the same mounting places as the tow hitch.

Got a HiJack lift too- gonna need it now.

Also, picked up some sheet metal for repairing the rust spots. My plan is to cut it to shape (just a little larger than the hole it will fill. Slide it behind the metal that's there- and tack it every two inches or so. Then flap disk it down and then even it all out with bondo. Is that the right way?

Anyhow here's some pics of today's progress.

http://i256.photobucket.com/albums/hh169/cooperzj/JY/Jeep001.jpg

Shackles

http://i256.photobucket.com/albums/hh169/cooperzj/JY/Jeep002.jpg

Double Cardan driveshaft.

http://i256.photobucket.com/albums/hh169/cooperzj/JY/Jeep005.jpg

Derek33
11-25-2008, 11:40 PM
Cool lookin rig. What size tires are those?

cooperzj
11-25-2008, 11:45 PM
Cool lookin rig. What size tires are those?

36" BIAS Ply Interco Swampers

dangerousdave
11-26-2008, 11:09 AM
My brother has a yj thats waiting to go under the knife. They are a lot of fun and there are a ton of parts for them.

cooperzj
11-26-2008, 09:21 PM
Cut out the rest of the rust on the tub.

Found out that someone before me had done some repair work- ran into alot of filler.

Tacked in the 22 gauge sheet on the passenger side. Still need to work on the driver's and, of course, shape the sheet metal on the wheel well area.

Also finished hanging the exhaust. Just waiting for a D30 carrier for the front and new spring perches.

http://i256.photobucket.com/albums/hh169/cooperzj/JY/patchjob001.jpg
Still need to shape the wheel well area.

http://i256.photobucket.com/albums/hh169/cooperzj/JY/patchjob002.jpg
See the filler?

http://i256.photobucket.com/albums/hh169/cooperzj/JY/patchjob003.jpg
made one plug weld to secure it a little better.

http://i256.photobucket.com/albums/hh169/cooperzj/JY/patchjob004.jpg
Can you spot the 3 tacks I did with the gas off? Dooh!