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BigDaveZJ
07-02-2004, 01:25 PM
9/21/08 Update
Rig's got a new name. Was thinking Huggy, cuz it's kind of half buggy, but it also smells kinda funny, so Dirty Diaper it is. One of these days I'll try to go through and update all the pics too.


1995 V8 Jeep Grand Cherokee
150,000 Miles

Modifications:
Front Suspension - RE 3.5" Coils, RE superride adjustable LCA's, Kevin's Trackbar Conversion with ORGS adjustable trackbar
Rear Suspension - RE 3.5" Coils with 2" spacers, RE superride adjustable LCA's, ORGS adjustable trackbar
Rusty's Hydro shocks from 3" ZJ kit
Removed swaybars front and rear
Fenders trimmed front and rear for tire clearance
15x8 AR 767's with 4" Backspacing
33x12.50 BFG Mud Terrains
Removed front bumper for increased approach angle
Rocky Road Outfitter's Rocker Protection
Swapped in a 231 t-case and got rid of the 249
Custom built front and rear driveshafts by Front Range Driveline
Ford 8.8 from an Explorer w/ a mini-spool and Crane cover
Stock 30 front with upgraded shafts
Converted front driveshaft to u-joint style
Turbo City Dual Intake w/ hi-flow filters
Mopar ECU
CarSound Cat
Magnaflow Muffler
Hella 500's mounted up front
"Human Cooling System"
Pioneer DEH-46DH CD Player
Pioneer 6.5" speakers
Sirius Satellite Radio
Cobra CB w/ Firestik antenna
Occasionally remove the front doors
And a Harley Davidson foot peg for when the front doors are off

http://www.imagestation.com/picture/sraid119/p4a7592386aeed75cf6528af9b5fb9183/f878b804.jpg

http://www.imagestation.com/picture/sraid115/p5d338ea63fc1cc357acb8ffb171a63d4/f8cd7c90.jpg

http://www.imagestation.com/picture/sraid115/p74c10c0ba823db6451526a445a88dcd5/f8cd776e.jpg

http://www.imagestation.com/picture/sraid115/p45630d9a33fa24fab472e286231e729d/f8cd7586.jpg

http://www.imagestation.com/picture/sraid110/pf1977e85c90df01b6bbffb0af3bc86dd/f922b126.jpg

EDIT: 12/15/04

Changed the name of the rig to "The Wife" for pretty obvious reasons. Here's a recent pic too of Corey taking it up an RTI ramp cuz I was too drunk to drive.

JpRngr
07-02-2004, 02:41 PM
Rice Crispy?

BigDaveZJ
07-02-2004, 03:38 PM
Rice Crispy?

Yeah, cuz it goes Snap, Crackle, and Pop!!

Trancezj
07-02-2004, 04:17 PM
Rice Crispy?

Yeah, cuz it goes Snap, Crackle, and Pop!!
hey motha fucka! you gotta mic in my jeep? That's my line.

Rock Limo
07-02-2004, 10:10 PM
Why would you off road a ZJ? :oops:

OverkillZJ
07-03-2004, 01:51 PM
Why would you off road a ZJ? :oops:

...Dave, it's you're thread so I'll leave you to decide if this gets deleted or not :shock:

BigDaveZJ
07-03-2004, 02:00 PM
Why would you off road a ZJ? :oops:

...Dave, it's you're thread so I'll leave you to decide if this gets deleted or not :shock:

Mark and I must've overloaded your sarcasm detector last night!!!

OverkillZJ
07-03-2004, 03:26 PM
Why would you off road a ZJ? :oops:

...Dave, it's you're thread so I'll leave you to decide if this gets deleted or not :shock:

Mark and I must've overloaded your sarcasm detector last night!!!
http://www.fccsonline.com/pic/ju/thefinger.gif

OverkillZJ
07-03-2004, 04:43 PM
Why would you off road a ZJ? :oops:

...Dave, it's you're thread so I'll leave you to decide if this gets deleted or not :shock:

Mark and I must've overloaded your sarcasm detector last night!!!
http://www.fccsonline.com/pic/ju/thefinger.gif

Get off the damn computer and go fix your clock spring so we can blow shit up tonight!!!


Clock spring: fixed
Evil UCA bushing: replaced
Rear gears: Mark doing again, no backlash on the first try
rain getting into ZJ: Hole plugged w/ silicone, but still drying
Brakes: bled and nipples replaced
About to go lube up the chasi, should be ready soon.

MrFreeze5
07-06-2004, 09:20 PM
[quote="BigDaveZJ"]
http://www.imagestation.com/picture/sraid119/p4a7592386aeed75cf6528af9b5fb9183/f878b804.jpg

Not only did we have to do all the work pulling that damn thing up the rock but dave's big ass was inside too! That made it even harder! :flipoff2:

KsZJ
07-06-2004, 09:29 PM
Not only did we have to do all the work pulling that damn thing up the rock but dave's big ass was inside too! That made it even harder! :flipoff2:

Funny... :lol:

Hay Dave... Nice bumper

http://people.ku.edu/~jalexand/GSW%2004/slides/IMG_1564.JPG

KsZJ
07-06-2004, 09:32 PM
Why would you off road a ZJ? :oops:

...Dave, it's you're thread so I'll leave you to decide if this gets deleted or not :shock:

If you only knew Evan... This thing has built and tore down 4 times.

chadjans
07-07-2004, 11:47 AM
Funny... :lol:

Hay Dave... Nice bumper

http://people.ku.edu/~jalexand/GSW%2004/slides/IMG_1564.JPG

My god I look like a goof

Chad

BigDaveZJ
07-07-2004, 11:52 AM
My god I look like a goof

Chad

Umm, yeah, what was up with that hat?

chadjans
07-07-2004, 12:33 PM
It is one of my welding hats. It was all I had. Forgot a regular hat. And I keep a welding hat in the jeep for trail repairs.

Chad

BigDaveZJ
07-07-2004, 12:36 PM
It is one of my welding hats. It was all I had. Forgot a regular hat. And I keep a welding hat in the jeep for trail repairs.

Chad

That's what I love about having a shaved head. Just slap some sunscreen on the dome and all is good!

chadjans
07-07-2004, 02:30 PM
sun screen doesn't work for welding spatter.

Chad

BigDaveZJ
07-07-2004, 02:35 PM
sun screen doesn't work for welding spatter.

Chad

True, but it keeps me from looking like a goof on the trail!!

Rock Limo
10-12-2004, 11:57 PM
Why would you off road a ZJ? :oops:

...Dave, it's you're thread so I'll leave you to decide if this gets deleted or not :shock:

If you only knew Evan... This thing has built and tore down 4 times.


Oh dont worry, its going up again! :roll:

BigDaveZJ
04-14-2005, 04:24 PM
Been a WHILE since I've updated this, and I have no clue what pics I had in here before since ImageStation was acting all funny. Hell, don't even know why I linked them from ImageStation.

Anyways . . . . on to the update


Back in October or so I got bored. I was unemployed, bored out of my mind, and had a few sawzall blades lying around.

Before:
http://www.mallcrawlin.com/wheelinpics/choptop/choptop%20008.jpg

After:
http://www.mallcrawlin.com/wheelinpics/choptop/choptop%20010.jpg

The unibody didn't care much for that, and the rear section of the unibody would shake pretty severely at anything over 40mph or so. So I devised a unibody stiffening sytem. Version 1.0 was just the bar across the roof, and Unibody Stiffening Device V2.0 is what you see here:

http://www.mallcrawlin.com/wheelinpics/choptop/usdv2%20004.jpg

I used leftover sheet from the roof to make little "caps" for the roof edges and with some welding and bondo kinda sorta sealed it up and made it look kinda normal. With USD V2.0 I think the unibody is actually a little stiffer than stock.

The first non-RTI-ramp action the ZJ saw after the roof cutoff was out at CORE. www.coloradooffroadextreme.com Cool place east of Denver a bit, great area to go and test your junk out before heading to the hills.

http://www.mallcrawlin.com/wheelinpics/CORE03062005/CORE03062005%20001.jpg

The next "mod" I did was to get some tube doors. Nothing super fancy, but I LOVE having them on the trail. All the benefits of running without doors, but there's a still place to rest my leg and arm. And if I lay it on its side my hips are still kinda sorta protected. My head might hurt a bit though, LOL.

http://www.mallcrawlin.com/wheelinpics/toobdoors/toobdoors%20001.jpg

Then there was the Moab trip. Got the ZJ all loaded up on the trailer and ready to go, and this happened:

http://www.mallcrawlin.com/wheelinpics/fucksnow/fucksnow%20004.jpg

Luckily all the snow melted and dried off before we got to Moab so we didn't have wet asses the whole time.

Then we had this little mishap on Cliffhanger in Moab:

http://www.mallcrawlin.com/wheelinpics/moapapril05/gsw05prerun%20(20).jpg

http://www.mallcrawlin.com/wheelinpics/moapapril05/gsw05prerun%20(17).jpg

The piece you see sitting by Keith's ReadyWelder would be the frame side driver front UCA mount. Ooops. Welded it back up on the trail and went on our way.

Gotta get back to work, I'll post more later.

BigDaveZJ
04-14-2005, 04:52 PM
Playing around on Dump Bump:

http://www.mallcrawlin.com/wheelinpics/moapapril05/gsw05prerun35.jpg

That's one of the few pics I've seen that shows the steepness and height of Dump Bump.

Coming up Hell's Gate:

http://www.mallcrawlin.com/wheelinpics/moapapril05/GSWprerun05%20085.jpg

Strapping King Strapmaster:

http://www.mallcrawlin.com/wheelinpics/moapapril05/gsw05prerun%20(61).jpg

Not really sure what the future holds for the rig right now. Certainly need a cage, and will be doing some stuff to the ass end, either bobbing or dovetailing, and then a custom soft top so I can have a fully enclosed rig when i put the doors back on.

Bustin' Loose
04-14-2005, 11:27 PM
She still needs a name . . .

SuicideTireZJ
07-14-2005, 01:46 AM
I guess "The Wife" just won't cut it when you're married. Unless Pam's down with polygamy.....

Bustin' Loose
12-02-2005, 06:10 PM
Okay...we sooooo have to get her renamed. . . Maybe we can call her ho-bag. Wife just aint gonna cut in exactly 5 more weeks. We could call her Old Bag. . .

Then we can call mine New Bag of Tricks. :D

BigDaveZJ
04-03-2006, 10:54 PM
Wow, almost a year since I updated this . . . .

Anyways, spent some time out in the garage today farting around with the ZJ and playing with the new welder. For Christmas in 2004 my sister got me one of those 4xRac's for my Hi-Lift and I never got around to doing anything with it. So today I cut out one of the bars in the rear and moved it up about a foot and welded some plate on there to mount the 4xRac to. Looks like it's going to work pretty well. Also mounted up the CO2 tank today too, bolted it through the fender and welded it to the floor. No pics yet cuz I'm a lazy bastard, but they'll up sooner or later.

In 2 weeks I'm turning my ZJ over to T&T Customs (http://www.tntcustoms.com) so they can use my ZJ as a prototype for their new ZJ Y-Link kit. I'm totally stoked about this. I'll have to go up a little bit in lift, but oh well, it'll just look goofy for a while with 33's. They're also going to use my ZJ a prototype for a new bumper, which will end up looking very much like their super-sexy XJ bumper which can be seen here: http://www.tntcustoms.com/webV3/xjbumpers.asp

Oh, and I guess I need to come up with a new name for the ZJ since Pam now officially holds the title of Wife.

DCHZJ
04-03-2006, 11:32 PM
I like that bumper and i would ditch my ARB in a sec for that. Keep us posted on that and the Y-link

DJJordache
04-03-2006, 11:44 PM
In 2 weeks I'm turning my ZJ over to T&T Customs (http://www.tntcustoms.com) so they can use my ZJ as a prototype for their new ZJ Y-Link kit. I'm totally stoked about this. I'll have to go up a little bit in lift, but oh well, it'll just look goofy for a while with 33's. They're also going to use my ZJ a prototype for a new bumper, which will end up looking very much like their super-sexy XJ bumper which can be seen here: http://www.tntcustoms.com/webV3/xjbumpers.asp
freaking sweet! It must be nice to have he prototype and the FIRST one made LUCKY I always wanted a ZJ prerunner bumper maybe you can get some spy pics of it in the design/development stages:D

ILikeMud
04-04-2006, 01:06 AM
I can't wait to see the TNT y-link on your ZJ.

nate
04-04-2006, 02:26 AM
Ugly Sumabitch... would that be you or the Jeep? :D

JpRngr
04-04-2006, 02:39 AM
Soooo.....The Wife is now The Ugly Sumabitch?

Kraqa
04-06-2006, 12:38 AM
Soooo.....The Wife is now The Ugly Sumabitch?

uh ohhhhhhhh

JeepinHank
04-06-2006, 09:21 AM
Soooo.....The Wife is now The Ugly Sumabitch?

:smt044

Bustin' Loose
04-06-2006, 03:01 PM
Hmmm.....I'm not sure I like that transition . . .

Krash80
04-06-2006, 08:00 PM
At least your wife probably rides better than the jeep.

Krash80
04-06-2006, 08:15 PM
In 2 weeks I'm turning my ZJ over to T&T Customs (http://www.tntcustoms.com) so they can use my ZJ as a prototype for their new ZJ Y-Link kit. I'm totally stoked about this. I'll have to go up a little bit in lift, but oh well, it'll just look goofy for a while with 33's. They're also going to use my ZJ a prototype for a new bumper, which will end up looking very much like their super-sexy XJ bumper which can be seen here: http://www.tntcustoms.com/webV3/xjbumpers.asp

Oh, and I guess I need to come up with a new name for the ZJ since Pam now officially holds the title of Wife.

Turning it over to a shop!? You credit card jeeper! :gay:

And how bout calling your heep "The Mistress."

ELLLLLIOTTTTT
04-06-2006, 08:18 PM
Turning it over to a shop!? You credit card jeeper! :gay:



not as bad as Dirk. His toolbox consists of a checkbook and pen. :smt110

BigDaveZJ
04-06-2006, 10:14 PM
Turning it over to a shop!? You credit card jeeper! :gay:

And how bout calling your heep "The Mistress."


With the deal I'm getting on this setup for being the prototype, I'll take that!

And the Mistress could work, but I believe it's taken already by another member of this board.

jeepnzj1
04-07-2006, 06:46 PM
friend of mine just ordered shackles from tnt and he had to send them back they were out of square by about 3/8'' got the second pair and exact same prob. maybe bad jig or sompthing, good thing theres no shackle on a zj,

BigDaveZJ
04-09-2006, 11:16 PM
friend of mine just ordered shackles from tnt and he had to send them back they were out of square by about 3/8'' got the second pair and exact same prob. maybe bad jig or sompthing, good thing theres no shackle on a zj,

It might be a bad jig, I heard about another guy who had the same problem. I'm not too worried for stuff on my ZJ though since T&T will basically be using my ZJ to make the jig. Matt and Bob are both great guys though, I'm sure they'd get any problems you have taken care of.

BigDaveZJ
10-09-2006, 09:24 PM
Been a while since I've updated this!

Since the last post, I have installed Clayton's Long Arms, you can read about that here: http://www.mallcrawlin.com/forum/showthread.php?t=8165

The long arms have been working great, just need a bit more lift up front, with 3.5" it's a little low for the long arms and the front driver side arm makes contact with the frame rail during heavy baja action.

The PSC 621MR box that I installed has been VERY nice to have. Makes turning tons easier, my write up on that is here: http://www.mallcrawlin.com/forum/showthread.php?t=6912

I forgot to take pics when I built the steering brace, but I'm going to make one for Pam's ZJ over the winter so I'll get some pics then. It's pretty basic, ordered a steering box clamp from M.O.R.E., picked up some 1"x2" box and some misc. angle iron. Basically took a couple pieces of the angle iron and mounted them to where the front swaybar mounts and then cut a piece of the box to fit in between. Welded all of that together and then mocked up another piece of angle with the clamp on it and burned it all together. Been happy with it so, but it won't even come close to working on a 4.0 because of the radiator hoses.

Finally got around to putting some extended brake lines on it too. Factory ones were just too short with the LA's. Now I just need some longer shocks too to let it really flex up.

Haven't done as much wheeling this year as I would've liked, but still got some fun trails in. Hit GSW in June, did OCG and Wheeler Lake, couple easy trips up Bill Moore, and heading back to Moab Wednesday. Here's some highlights from this summer's wheeling:

Top of the World
http://www.mallcrawlin.com/wheelinpics/gsw06/gsw2006164.jpg

Poison Spider:
http://www.mallcrawlin.com/wheelinpics/gsw06/gsw2006218.jpg

http://www.mallcrawlin.com/wheelinpics/gsw06/gsw2006294.jpg

Old Chinaman's Gulch
http://www.mallcrawlin.com/wheelinpics/ocg62506/ocg62506009.jpg

http://www.mallcrawlin.com/wheelinpics/ocg62506/ocg62506065.jpg

Wheeler Lake
http://www.mallcrawlin.com/wheelinpics/wheelerlake070206/wheeler070206003.jpg

http://www.mallcrawlin.com/wheelinpics/wheelerlake070206/wheeler070206004.jpg

http://www.mallcrawlin.com/wheelinpics/wheelerlake070206/wheeler070206056.jpg

Got a little chilly at the top of Wheeler when it started to hail and almost snowed
http://www.mallcrawlin.com/wheelinpics/wheelerlake070206/wheeler070206062.jpg

Not sure if I'm gonna do much to the rig over the winter. Buying the truck kinda put a damper on any major mods, but I'd like to be able to fit 35's on it, just need a little more height and some tuning of the suspension and it'd be good.

MoonWorks
10-17-2006, 03:14 PM
I know you got your claytons on like 6 months ago but what ever happened to the T&T customs prototype?

ILikeMud
10-17-2006, 03:19 PM
It's been released.
Cehck T&T's site.

Matt on here has the kit as his ZJ was used for the proto typing.

MoonWorks
10-18-2006, 01:10 PM
I knew it was out but I was thinking they would let him keep the setup and wheel it. The thread went from T&T to claytons. Did they end up using matt's ZJ vs daves.

ILikeMud
10-18-2006, 01:28 PM
That's a story for Dave to tell.

BigDaveZJ
10-18-2006, 01:57 PM
After T&T got my ZJ up on the rack and got a good look at it, they decided it was too beat up to be a good prototype. Matt's rig that they ended up using was much in better condition. From what I've seen of the T&T kit it is still a solid kit, but I was in a time crunch and couldn't wait so I went with Clayton's, tried and true.

MoonWorks
10-18-2006, 07:54 PM
That's cool! I was just wondering since your thread went straight from test the T&T to installing claytons. I've run with quite a few guys with claytons and they've had the same response as you. I chose a different route...will update another day on the results. Finishing up the build now.

BigDaveZJ
04-24-2007, 12:31 AM
So it's been forever since I've updated this. Done some work over the last couple weeks, pushed the rear axle back a tad, reworked the hi-lift mount and made a spare tire mount today. No pics yet, but I'll get some eventually. We had to figure out a way to gain as much cargo room as possible so we could both ride in my ZJ AND get the dog in there somehow too. I really like the way it came out.

Matt
04-24-2007, 01:02 AM
You still going up to Slaughterhouse this weekend?

I'll drink one for you in Moab! :D

BigDaveZJ
04-24-2007, 01:07 AM
I'm still toying with the idea of going up somewhere this weekend. My Jeep is pretty much ready to go, Pam's still needs some work though before hers can go up. I also need to do some work to the CB, my antenna mount decided to self-destruct when we were in Moab last year. I need to clean the beads of my tires too, go leaks in all 4 that I'm guessing are the beads being dirty. Then I just need to change my ball joints and she'll be all set for summer. And maybe change some fluids too but that's easy stuff.

BigDaveZJ
10-02-2007, 08:54 PM
So once again I've gone forever without updating this damn thing.

FINALLY got around to getting some new shocks under there when I went to 35's. For those that have been around, well, forever, you may remember J's Jeep and his black 5.9. The shocks I took off the ZJ were his hand-me-downs, that he gave me in 2001 IIRC. Yeah, they were SHOT. So it rides a lot smoother now, the shocks are actually long enough for some good droop, and the 35's fit nicely.

It's done wheeling until Spring, just got back from Moab and have a few small things to work out. Need new bushings for at the very minimum the front uppers (axle side bushings are the ORIGINAL bushings, 170k, and LOTS of wheeling). I want to get around to some basic maintenence that I've been putting off for a while. The Jeep is working REALLY well right now though, only thing I'm missing is gearing and a front locker, but I just can't see spending money on a 30 . . .

fsjtrash
10-02-2007, 11:20 PM
That's it. I'm cutting the back off. Have you ever thought of doing something like all the older bronco's and blazers have? With the snap-on kevlar or whatever cover? Excuse me if you don't understand what the fuck I mean... They're kinda like a box cover....for an SUV?

BigDaveZJ
10-02-2007, 11:23 PM
Honestly, hacking off the back (for now) is one of the dumbest things I've done to my ZJ. Lost a bunch of cargo capacity, lost any hope of security in my Jeep, and it sucks balls when it's cold out. Now once I bob or dove the backend and put a cage on it, yes it will be worth it, but until I get to that point it's pretty much a dumb idea.

fsjtrash
10-04-2007, 08:52 PM
I suppose. It just looks so sweet? And I mean security isn't a big thing, its always in the garage or I'm in it. I see your point on the cargo though.. Why do you make me rethink things my friend?

BigDaveZJ
03-07-2008, 09:41 PM
Got 4.56 Yukon's on the way from Crazy Ed's Performance. Gotta get me an HP30 too. They're gonna reside under my Jeep for a while, then when I can get real axles we'll put them under Pam's. The 3.73's with 35's are just not cutting it.

Looks like I got some work to do with the pictures at the beginning of the thread, fawkin Imagestation going away.

BigDaveZJ
04-06-2008, 06:31 PM
Got the HP30 torn down today, ready for it's new gears. Changed the oil too. It was an exciting day.

SuicideTireZJ
04-06-2008, 06:48 PM
Changed the oil too. It was an exciting day.
I'm surprised you didn't do another full write-up on it

BigDaveZJ
04-14-2008, 06:51 PM
Old LP30 is out, HP30 is sitting on the bench ready for its gears. The spiders on my LP30 were getting kinda chewed up too, probably was pretty good timing to get this yanked out of there. Also yanking the PSC box and going with a Waggy box. Crunch time before GSW!

SirFuego
04-14-2008, 07:16 PM
I think I missed it earlier, but what's the HP30 going to be geared at? Beefed up axle shafts, too?

EDIT: Yeah, umm, I just saw the 4.56s a few posts prior. Disregard the first question then.

BigDaveZJ
04-14-2008, 07:17 PM
4.56 gears, stock shafts. I figure I can change a busted shaft quick enough where uber bling alloys just don't make sense. And I usually have two sets of spare shafts with me anyways.

ELLLLLIOTTTTT
04-15-2008, 01:50 AM
Why downgrade the steering box?

DansZJ
04-15-2008, 02:22 AM
Old LP30 is out, HP30 is sitting on the bench ready for its gears. The spiders on my LP30 were getting kinda chewed up too, probably was pretty good timing to get this yanked out of there. Also yanking the PSC box and going with a Waggy box. Crunch time before GSW!

Damn Dave, you're going to think I'm stocking you. Not only am I installing a waggy box too, but I also picked up an HP30 last Thursday dirt cheap. Both axles (HP30 and 8.8) are at the gear shop getting 4.56's installed. I hope to have them both back this week so I can install them this weekend. Then hit the trail and do a nice gentle break-in. Yeah right! Absolutely crunch time!!!

BigDaveZJ
04-15-2008, 10:18 AM
Why downgrade the steering box?

Cuz the PSC box has already worn out in 2 years of moderate use. The sector shaft has developed significant play, and adjusting the box doesn't tighten it up at all. PSC has even admitted they don't have the equipment to properly test that kind of stuff in their boxes. For twice the cost of a stock reman Waggy box I expected a lot more out of it.

BigDaveZJ
04-21-2008, 04:15 PM
PSC box is out, just waiting on NAPA to get me my Waggy box. Was going to tear apart the 8.8 today too to get it ready for the new gears, but the garage door's gotta be open for that and it's WAAAAY too fawkin windy out there today for that. Should have the box in by tonight, rip the 8.8 open some night this week, and then get the gears in Sunday. There's a chance the Jeep could be mobile by Monday, but I think that's pushing it. My goal is to have it rolling again by 5/5 so I can cruise with the homies for Cinco de Mayo. And I don't have any pictures cuz none of this shit is really all that groundbreaking.

BigDaveZJ
04-21-2008, 07:52 PM
Waggy box is in and the dead spot seems to be gone, won't know 100% until the road test. Started to rip apart the 8.8, definitely a good thing I did that. I must've submerged the diff at some point and the seal didn't hold up. Gear oil was an awesome goopy green color. Nice and thick too, took forever for that shit to get out of there. The mini-spool looks like it's seen better days too, not sure what I'm gonna do with that yet.

BigDaveZJ
07-22-2008, 07:30 PM
Gear swap went good, Jeep does MUCH better now with the 4.56's, and the Waggy box is doing a lot better too.

Thinking about going down a slightly different road now with the ZJ. I'm going to try and make it a bit more versatile, and something that can actually see some street time. Still going to tow it to most trails, but I want to get into more of the expedition style wheeling, and some of my past decisions have made that a very hard thing to do in my ZJ. The trailer I'm going to build to pull behind the ZJ will solve the storage space problems, but not the streetability problem. Will probably remove the rear spool in favor of an Aussie, put some light swaybars on, and come up with a "skin" for the front doors. Not super concerned with enclosing the rear right now since that'll really have to wait until a cage is done. Also need to address some areas I've neglected, like my windshield wipers that levitate off the glass at anything over 40mph making them pretty much useless, and some other little things. Hopefully going to get some new shoes over the winter too.

ajmorell
07-23-2008, 11:29 AM
Gear swap went good, Jeep does MUCH better now with the 4.56's, and the Waggy box is doing a lot better too.

Thinking about going down a slightly different road now with the ZJ. I'm going to try and make it a bit more versatile, and something that can actually see some street time. Still going to tow it to most trails, but I want to get into more of the expedition style wheeling, and some of my past decisions have made that a very hard thing to do in my ZJ. The trailer I'm going to build to pull behind the ZJ will solve the storage space problems, but not the streetability problem. Will probably remove the rear spool in favor of an Aussie, put some light swaybars on, and come up with a "skin" for the front doors. Not super concerned with enclosing the rear right now since that'll really have to wait until a cage is done. Also need to address some areas I've neglected, like my windshield wipers that levitate off the glass at anything over 40mph making them pretty much useless, and some other little things. Hopefully going to get some new shoes over the winter too.

Dave let me know what you end up doing about the windshield wipers. Mine don't completely levitate but they are pretty much useless over 55mph.

BigDaveZJ
10-09-2008, 03:01 PM
Got the wipers fixed, just in time too with all the rain we had in Moab. Got some cheepies from Vato Zone since they won't see all that much use on my rig. Held up fine being on quite a bit over the weekend.

The Jeep's done for the year now too. Got a few things planned for the winter, but nothing major.

- New Tires. My $100 35's are pretty much done. I can't air down as much as I'd like because of the dry rot in the shoulders of the tires, they mostly hold at higher pressures, but at < 15 psi they lose a lot of air. Leaning towards BFG KM2 now that they make them for a 15" wheel in 35's. Always open to other ideas too, but the KM2's are definitely my top choice right now. Also will probably need to trim some more as brand new 35's are gonna be a bit bigger than worn out 35's.

- 8.8 repairs. My 8.8 is in need of some attention. Probably going to ditch the spool for an Aussie as mentioned in a previous post. Both wheel seals need to be replaced in a major way, and I'm probabloy going to swap out the Crane diff cover I've had for 4+ years for a Ruff Stuff Specialties unit. The Crane has served me well, but with the 8.8 I really like the option for the drain and fill plug in the cover that RSS offers.

- This is lowest on the priority list, but I'd really like to start the cage and do some work on the unibody. The floorboards are tearing apart underneath in a couple spots, and there's some other issues too that I need to address. For the time being I'll probably just do a hoop at the c-pillar with some runners to the back. Tie it in to the unibody in a few spots, add some gussets/triangulation, and call it good. It'll also require that I re-work my spare tire mount and CO2, but I've been wanting to do that anyways. I also kinda want to put the "tailgate" back on, so we'll see how that goes.

downtowncb
11-13-2008, 10:19 PM
Do you have some closer pictures of your tube doors?

Derek33
11-13-2008, 10:37 PM
I remember you saying you wanted to start directing your zj to be a DD. Are you still going in this direction?

I too am looking into the ruffstuff 8.8 cover, but Ill wait 'till i have a locker to put in at the same time.

piku303
11-13-2008, 11:12 PM
Honestly, hacking off the back (for now) is one of the dumbest things I've done to my ZJ. Lost a bunch of cargo capacity, lost any hope of security in my Jeep, and it sucks balls when it's cold out. Now once I bob or dove the backend and put a cage on it, yes it will be worth it, but until I get to that point it's pretty much a dumb idea.

you should go to a junk yard and chop the rear of a zj like you did to yours and bring it home, paint it black or something and build some latches to where you can snap it on and off, kinda like the chevy blazer trucks that you can pull the back off of. just an idea..

nierace
11-14-2008, 09:23 AM
What evers you do dont gets KM2's ! :D

Mine are skinny little bastads.

Jeeperoni91
11-14-2008, 05:19 PM
mine are correct width, 35x12.5 on 15x10s.

love mine, shits is mad nice yo:smt068

BigDaveZJ
11-24-2008, 11:25 AM
I think I got the ass end figured out finally. I've got a couple different ideas on how to exactly do it, one being WAAAAY over the top but super kickass, the other much more realistic. Basically tube will run along the roof line, c-pillar, and then on top of the quarter panels and across the back so I can put the tailgate back on. It will be done in two sections, one piece being the "hoop" so to speak along the roof and c-pillar and then horizontal section that runs around the back. They will join at the bottom front corner of where the rear windows would be. A piece of tube will run straight across connecting the two joints to each other. Then the horizontal section will be skinned with some sheet metal, and some tube run across to reinforce the spots where the spare tire and hi lift jack will be mounted. I'll hinge the tailgate somehow so it either folds down like a normal tailgate or swings up like a ZJ liftgage to access the cargo storage area.

Now there's a much smaller section to actually enclose, and this is where the two different methods come in. The super bling idea was to graft a 4-Runner liftgate into the opening with the power window, but I really doubt I could make that look good, and with the window going down, it would intrude on the cargo area, but it'd be kickass at least. So there'd be a vinyl window with canvas trim (think TJ soft windows) that would attach to the horizontal tube piece, and then zipper onto the hoop across the top. When not in use, it would just be rolled up against the crossbeam, and would be super fast to zip up if needed.

It still will not be a cage, but will still allow me to do a real cage in the future without any major mods to what I'm gonna do. It won't be hard at all to add some legs to the unibody rails from the c-hoop and crossbeam and tie in a minimal exo cage.

BigDaveZJ
11-24-2008, 02:25 PM
Here's a quick n' dirty MSPaint of the basic tube work.

ELLLLLIOTTTTT
11-24-2008, 09:48 PM
Reminds me of Trey's rig. See if you bug him for some detailed photos.

Let me know when you start on it and I'll swing by and lend a hand (or possibly just beer :D)

BigDaveZJ
11-24-2008, 09:59 PM
Trey?

northgazj
11-24-2008, 10:34 PM
Here's a quick n' dirty MSPaint of the basic tube work.

Reinforce the horizontal section and make a platform for one of the smaller rooftop tents that will fold out to the side of the Jeep. Underneath the platform could be storage and when the tent is up, you could have two poles on either end to attach an awning that extends over the back for additional shelter. Think about what alot of the Toyota guys fab on their expedition trucks. I'll try to find a picture of what I'm talking about.

BigDaveZJ
11-24-2008, 10:36 PM
At 6'5" 300lbs I ain't sleeping on the back of my Jeep, lol.

northgazj
11-24-2008, 10:51 PM
http://picasaweb.google.com/travelingtao/JeepForSaleAkaDragon#


like this, except the tent sits lower.

edit: just realized that is a hard shell tent and not a fold out, but you get the picture.

BigDaveZJ
11-24-2008, 11:01 PM
Yeah, not gonna do it. Don't have a problem setting up a tent when I go camping, and not gonna spend the $1,000+ for one of those tents.

piku303
11-25-2008, 02:45 AM
http://picasaweb.google.com/travelingtao/JeepForSaleAkaDragon#


like this, except the tent sits lower.

edit: just realized that is a hard shell tent and not a fold out, but you get the picture.

does anybody think this jeep/its people are a little interesting...?

dangerousdave
11-25-2008, 11:18 AM
that looks like a terrible way to camp. a tent on the ground would be so much easier than having to have a ladder with you in your trail supplies.

KDUB
11-25-2008, 02:02 PM
Dave, It sounds to me like you want to do something similar to Larry Trim, owner of TrailReady, did to his ZJ. I saw this in 4Wheel Drive & Sport Utility Mag. It might be worth looking into. Just a thought. Here's a link to some pictures from the article.

http://www.4wdandsportutility.com/adventures/west/0811_4wd_2008_idaho_trail_tour/photo_20.html (http://www.4wdandsportutility.com/adventures/west/0811_4wd_2008_idaho_trail_tour/photo_20.html)

BigDaveZJ
11-25-2008, 02:40 PM
Similar yea, just don't think I'll put the tire up that high though.

BigDaveZJ
11-28-2008, 01:32 AM
So I was talking to Putz (wannabe_offroad) today and he had a good idea that might work instead of the 4Runner rollup window. It would take away some of the open air-ness of the rig, but still could be cool. I could graft a sliding glass window in there from the back of a pickup cab, like an S10, maybe even bigger. Might have to make some measurements.

Derek33
11-28-2008, 01:34 AM
Ever think about taking the hatch off a zj from a junkyard and just attaching it to where you have cut? should be the same dimensions... roughly at least. It would be clutch to find a hatch with the opening glass.

BigDaveZJ
11-28-2008, 01:39 AM
I don't think the pop-up glass would clear the spare tire, and it would probably end up being too tall for the area anyways.

SuicideTireZJ
11-28-2008, 03:26 AM
So you mean you're doing something like swampy did to his rig back in the day?

BigDaveZJ
11-28-2008, 11:48 AM
Possibly yeah. My fab skills are at the level where I can make stuff work, but it's not always pretty, so we'll see what happens.

BigDaveZJ
12-08-2008, 02:48 PM
So the more I look at the rig I don't like the idea of the spare sitting on top of the "bed" area. I think it will make a lot of things trickier having it there. So then there is the dilemna of where to actually put it. I'm leaning towards a bare bones tire carrier/rear bumper. Nothing fancy, just some 2x4 with some clevis mounts and the swingout tire carrier. Should be pretty simple, and cheap, to make. Since that frees up the top of the bed area, I saw this from Tomken: http://www.tomken.com/catalog.php?search=terms%3D%26model%3Dall%26year%3 Dall%26cat%3DCARGO

Thinking something like that would be cool, give me a good place for fuel and water cans on long trips, as well as any other cargo that ends up there.

And if all goes as planned, the swingout tire carrier will also allow me to re-incorporate the rear hatch/tailgate and have it swing up exposing the drawer system I'm trying to figure out in the other thread.

And I said I wasn't gonna do anything to the ZJ over the winter . . .

BigClay
12-08-2008, 02:52 PM
Since that frees up the top of the bed area, I saw this from Tomken: http://www.tomken.com/catalog.php?search=terms%3D%26model%3Dall%26year%3 Dall%26cat%3DCARGO

Thinking something like that would be cool, give me a good place for fuel and water cans on long trips, as well as any other cargo that ends up there.




Is that the same rack they used on the ZJ build on trucks?

BigDaveZJ
12-08-2008, 03:23 PM
Dunno, don't recall seeing it. Is it the same Ryan?

JohnBoulderCO
12-08-2008, 03:29 PM
Swing out tire carrier? Are you welding the the part you cut off back on?

What happened to the "big rear bobbing" that you were going to do? That sounded pretty cool to me.

SuicideTireZJ
12-08-2008, 04:55 PM
Seriously, I agree with John. This is going down a road I am not cool with. Because my opinion totally matters.

I guess if it were my rig, I'd dovetail it, make a tailgate out of your liftgate, seal the seats in the back with something and make a plexi rear window and an easy simple steel frame for it. Then throw the spare right behind that, vertical in the bed, with some kind of rolling tuffy storage console or something. I know you plan on using this as an expedition rig, but most of your stuff will be in the trailer, right? I mean how much storage do you think you'll need in the rig itself?

BigDaveZJ
12-08-2008, 06:17 PM
I'm going to try and make it work without a trailer. I figured I'd be looking at 3-4 grand to make the trailer function the way I want it to. I can get my Jeep where I'd like it for expedition wheeling for under a grand and sacrifice VERY little in terms of crawling (only the departure angle from the rear tire being on back). We'll see how it goes, if things don't start to pick back up at the store, my Jeep is going to sit exactly like it is right now.

JohnBoulderCO
12-08-2008, 06:31 PM
Use Pam's for the expedition wheeling, it still has the roof.

Cut yours some more! Bob and dove it, that's free, except for the cut off wheels and blades. :D

Ted_Z
12-08-2008, 07:15 PM
You can fab that tomken rack yourself in an afternoon out of EMT conduit. I've got a couple large bolts & nuts (~1") you can have if you want to make a hinge for your rear carrier.

I like the idea of the drawer system, then a rack over them for bulky items like coolers and sleeping bags.

With regard to using a factory hatch, even with a pickup style window I think it would be worth using so the lines are a bit cleaner and you have a rounded edge and the back of the roof line. Then just fill in the lift glass area with sheet/strap as needed to fit the pickup type window. Less fab too.

BigDaveZJ
12-08-2008, 07:26 PM
Sleeping bags go inside where it's dry, or in an action packer on the basket maybe. WTF is EMT conduit? I know what an EMT is, and know what conduit is, but dunno WTF they have to do with each other!

John,
Some of the trips we hope to do are remote enough where there is no way in hell I'd take just one rig, so I want both to be as equipped as possible. Also, if I can store more stuff in my rig, that might leave the back of Pam's open so we could have room for the dog.

nate
12-08-2008, 07:35 PM
Less chance of critters attacking you. I usually keep a 12 guage by my sleeping bag in case a bear gets a little too friendly, but I'd sleep WAY better up there vs on the ground.


that looks like a terrible way to camp. a tent on the ground would be so much easier than having to have a ladder with you in your trail supplies.

Ted_Z
12-08-2008, 07:56 PM
EMT conduit = electrical conduit AKA thin walled tubing sold at home depot for a few bucks a 10' section.

This is what I'm visualizing based on your description:

http://img408.imageshack.us/img408/882/clipboard02eh0.jpg

BigDaveZJ
12-08-2008, 08:23 PM
That's pretty much what I'm goin for. Hi-Lift will be mounted on top of the bed as well, and the rack will probably be a bit smaller.

BigDaveZJ
12-29-2008, 05:15 PM
Tacked the tailgate back on today. Spare tire still fits where I had it before too which is nice, don't have to fawk with moving it until I get everything else figured out.

BigDaveZJ
03-19-2009, 04:36 PM
Did some work on the rear fenders yesterday. Didn't come out quite as good as I had hoped, but oh well. The fenders were originally trimmed with a sawzall, grinder, and BFH. My plan was to trim them up even with the door line, then drill a hole through the outer fender and plug weld it to the inner fender. It kinda worked. Hopefully I'll have better luck with the driver side. I might go back and hit it with some bondo too to try and smooth it out. The fenders were NOT thrilled about me tugging on them trying to get them close enough to weld.

Before and after pics:

jsteves
03-20-2009, 11:26 AM
I've seen much worse. Read: your front fenders.





















:finga: J/K they don't look too bad.

SirFuego
03-20-2009, 11:54 AM
Looks much better than when I trimmed mine :-D

chadjans
03-20-2009, 12:27 PM
I forgot how teany those OE brakes are.

BigDaveZJ
03-20-2009, 12:32 PM
Silly Chad, those aren't OE brakes. Well, not OE Jeep brakes anyways.

AgitatedPancake
03-20-2009, 12:57 PM
woooo go RE twin tubes! haha gotta love cheap shocks that work.

chadjans
03-20-2009, 01:03 PM
Silly Chad, those aren't OE brakes. Well, not OE Jeep brakes anyways.

None-the-less; they are small. :welcome:

BigDaveZJ
03-20-2009, 01:10 PM
Would you be happier if I swapped rotors and calipers from my truck over to my 8.8?? :flipoff2:

chadjans
03-20-2009, 01:53 PM
Would you be happier if I swapped rotors and calipers from my truck over to my 8.8?? :flipoff2:

Irregardless (lol) you have a ford axle attached to your jeep. Whatever floats your ship.:smt102

BigDaveZJ
03-20-2009, 05:03 PM
Sumbitch. Looks like the 35x12.50R15 KM2's are on backorder. Hopefully I can find some within the next 4-6 weeks.

Derek33
03-20-2009, 11:24 PM
Fender trim doesnt look bad, Dave. I like seeing updates on this rig. Gives me confidence since you still got that 30 up front like me.

How did your rear widow situation turn out? Any work on that?

Z
03-21-2009, 08:00 AM
Dave - instead of bondo, what about facing the mods with 3/16" plate? Would give you a finished look and provide protection. You could also use the plate as an anchor for support back to the inner fender if necessary.

BigDaveZJ
03-29-2009, 08:46 PM
Still haven't decided what to do on the fenders, but the driver side one came out a lot better IMO.

It looks like I will be making a trip to China Freight. I just got done reading this on PBB: http://www.pirate4x4.com/forum/showthread.php?t=737981&highlight=swag+roller

Looks like the perfect tool to help me get the lines right for the tube on the back of the ZJ. I figure do 4 bends with a regular bender, then slug 'em up with the sections done with the roller, and voila my Jeep doesn't suck so much anymore.

BigDaveZJ
03-31-2009, 06:31 PM
New tires!

Jeeperoni91
03-31-2009, 07:34 PM
Good deal, you'll love them Dave

Derek33
03-31-2009, 10:32 PM
Nice meats, Dave

ELLLLLIOTTTTT
03-31-2009, 11:59 PM
Nice meats, Dave

I bet Pam would agree.

BigDaveZJ
04-01-2009, 12:05 AM
Got the Jeep up to 70+ on the hwy and it did REAL nice. Real smooth, and surprised at how quiet they were.

dp96zj
04-01-2009, 01:05 AM
I bet Pam would agree.


:smt046

BigDaveZJ
04-07-2009, 11:36 AM
So Swag from PBB got the prototype of his 1.75" dies for the HF Roller and is looking to start production on them soon. I'm REALLY hoping I can at least get the tube work done by GSW. Won't really need the rear window or any of the stuff done to enclose it by then, but I'd really like to get the tube done so I can figure out my spare tire. With the tailgate on, my old spare BARELY fit, and now there's just enough more tread on my spare that it won't fit.

BigDaveZJ
05-03-2009, 02:49 PM
Roller dies are now available and have been ordered! There's a decent chance I could get this done before GSW now since with the addition of the M416 I'm much more comfortable just strapping the tire down to the floor of the Jeep.

BigDaveZJ
05-15-2009, 04:45 PM
Put it through its paces yesterday at Old Chinaman's Gulch. Tires fit pretty much perfectly, and everything is working quite well. The RSS diff cover is pretty huge, and has been clearancing my gas tank skid but it seems to be working itself out. The KM2's worked really well. They hooked up great on the rocks and did a very good job of wrapping around the rocks. Took a few good hits to the sidewalls as well with barely even a scuff mark on the tire.

At this point I doubt I'm going to get the tube work done before GSW, have to see what happens with a few other things first.

http://photos-g.ak.fbcdn.net/hphotos-ak-snc1/hs024.snc1/4264_104889568367_585188367_2567478_6030154_n.jpg

Derek33
05-15-2009, 06:16 PM
Nice pics! I just went through them all on facebook.

BigDaveZJ
01-16-2010, 09:53 PM
http://photos-g.ak.fbcdn.net/hphotos-ak-snc3/hs161.snc3/18848_296274713367_585188367_4668779_605793_n.jpg

chadjans
01-17-2010, 05:17 PM
Glad to see you are starting your cage work. :flipoff2:

BigDaveZJ
01-18-2010, 12:41 AM
http://hphotos-snc3.fbcdn.net/hs161.snc3/18848_298045648367_585188367_4678469_1820055_n.jpg

BigDaveZJ
01-18-2010, 12:49 AM
http://photos-d.ak.fbcdn.net/hphotos-ak-ash1/hs261.ash1/18848_298237558367_585188367_4680427_5328575_n.jpg

Elliott trying to work off his nickname:
http://photos-h.ak.fbcdn.net/hphotos-ak-ash1/hs261.ash1/18848_298236738367_585188367_4680425_509453_n.jpg

It's getting there:
http://photos-c.ak.fbcdn.net/hphotos-ak-snc3/hs161.snc3/18848_298235883367_585188367_4680423_6443060_n.jpg

Everything so far is lining up surprisingly well. We haven't tacked anything down yet or tried the liftgate, but I'm feeling pretty good about it all. I'm going to keep grinding away to get the fit better and then when I can get access to a bender I'll throw the tube together.

Chad, you will be happy to know too that I was contemplating doing a b-pillar hoop tonight too. We'll see how that all goes.

ajmorell
01-22-2010, 05:56 PM
lol, I love the thread title change Dave

ATL ZJ
01-22-2010, 06:19 PM
Loving the name.

What are you going to do to restrengthen the area behind the C pillar back to stock? Obviously it won't be possible to weld the innermost layer of the sides of the roof, and we all know how much a non-interrupted bead can weaken sheetmetal at the edge of the heat affected zone. What plans do you have for additional bracing? The one time I tried to drive mine after I hacked the back and didn't have support installed, the back end started wagging and hopping around like wild.

AgitatedPancake
01-22-2010, 07:01 PM
he could take some thin(ish) sheetmetal and form it to the C-pillar from the inside, about 2" tall so he can butt weld the pillar to the new roof, then lay this over the seam and stitch weld it to the original body and new roof, dispersing the load and heat.

BigDaveZJ
01-22-2010, 11:43 PM
lol, I love the thread title change Dave

The name change was all Elliott, I guess that's what I get for giving him mod powers for some strange reason.


Loving the name.

What are you going to do to restrengthen the area behind the C pillar back to stock? Obviously it won't be possible to weld the innermost layer of the sides of the roof, and we all know how much a non-interrupted bead can weaken sheetmetal at the edge of the heat affected zone. What plans do you have for additional bracing? The one time I tried to drive mine after I hacked the back and didn't have support installed, the back end started wagging and hopping around like wild.

The support that I had previously with the 1x1's ghetto rigged into the back actually worked quite well. And I know exactly what you're talking about with the wagging. I actually had mine up to 65mph with NO reinforcement in the back. The unibody was basically getting death wobble. Interesting doesn't even come close to describing it. Keep reading for how I'm gonna do it.


he could take some thin(ish) sheetmetal and form it to the C-pillar from the inside, about 2" tall so he can butt weld the pillar to the new roof, then lay this over the seam and stitch weld it to the original body and new roof, dispersing the load and heat.

This pretty much nails it. The seam along the rear quarter panels will have some 16ga sheet backing it, stitch and plug welded. The actual seam along the outside of the fender will be mostly aesthetic. The roof section will utilize a similar technique, but I will start with rivets to avoid warping. I cut a section out of the donor roof that includes one of the roof cross members to use. It's about 8" wide and will span the roof seam. Stitch and plug welding, in addition to the rivets will be used for strength, and again an aesthetic weld on the outside (to be ground smooth-ish). On the multi-layer sections of the pillars I will use similar techniques, it will just be a little trickier. Also, the c-pillar will be tied in to the hoop I have bent up. Along the roof section I will use 2-3" sections of 1/8" plate, probably 4 or 5 of these. Just a small piece between the tube and the roof that will be just big enough to get a good weld.

Here's an example of what I'm planning on from Chad's rig:
http://imgur.com/nsQVG.jpg

http://imgur.com/V3pGO.jpg

I will also run a section of tube from the c-hoop to the c-pillar itself just below where the upper mount of the seat belt would be.

I feel this should be at least as strong, if not stronger, than what was previously in place that held up relatively okay for 5+ years.

I had planned to at least have the c-hoop and down bars tacked in place Wednesday, but had to push it back cuz of a damn cold. Hopefully we'll get some work done on it Sunday and I can post up some pics to give you guys a better idea.

BigDaveZJ
02-27-2010, 07:23 PM
http://photos-d.ak.fbcdn.net/hphotos-ak-ash1/hs444.ash1/24507_376130853367_585188367_5011773_7469196_n.jpg

paulkeith
02-28-2010, 12:39 AM
i knew this was do-able. good job....cool to see a tailgate hanging on 'er again.

CrawlerReady
02-28-2010, 12:42 AM
Looks damn good Dave! Can't wait see it all finished up GSW.

BigDaveZJ
02-28-2010, 12:50 AM
The gap across the roof is much bigger than I'd like, probably averages 1/2". In between the roof rack rails it's easy, riveted and tacked in another piece of that has a x-member in it, but filling that from the rails down to the door opening will be tough. Going to try cutting about 1/2" off the donor roof to fill it in.

MoonWorks
02-28-2010, 02:20 AM
Not bad...how's the hatch open/close? Is it pretty lined up?

BigDaveZJ
02-28-2010, 11:54 AM
Not bad...how's the hatch open/close? Is it pretty lined up?

The first time we tacked it on it was off just a touch. You could push the hatch to the pass side about 1/4" and it would work. We looked over everything and we could tell that the red roof was about 1/4" to the driver side in relation to the existing roof. There were also a couple issues on the seams below the windows too. So we took it back off to fix those issues and fully prep everything for welding. When we put it back on the top of the roof was still off just a touch. I kinda leaned against it while Pam pushed up on the backer plate from the bottom and tacked it in a couple places. Put the hatch back on and it worked like a charm.

The only hatch issue I have right now is that the struts are so shot that if you just drop the hatch closed it will slam so hard it will engage the lock mechanism. And since I haven't wired any of that up, it's kind of a PITA to climb through the back door and open it manually.

AgitatedPancake
02-28-2010, 12:29 PM
holy shitballs it's lookin good man, good work!

For welding the gaps, do you have a welding backing plate (like copper)? It would allow you to help fill a little without blowing through the sheetmetal.

Sudz
02-28-2010, 12:41 PM
The only hatch issue I have right now is that the struts are so shot that if you just drop the hatch closed it will slam so hard it will engage the lock mechanism.
my younger brother, being the cheap bastard that he is and refusing to replace the worn struts on his cherokee, came up with a fix that worked great.

he soldered a penny into the screwdriver slot on a small hose clamp.

you can figured out the rest :mrgreen:

progress looks good on the cargo area resurrection.

street legal again?

paulkeith
02-28-2010, 08:37 PM
vicegrips on the shock strut work too. the ghetto bastard that tried to sell me a 5.9 in alabama showed me that one.

BigDaveZJ
02-28-2010, 08:56 PM
It never really wasn't street legal in CO, pretty lax vehicle laws here.

I had thought about some of the "cheaper" solutions for the struts, but part of this whole process is to decrease the "ghetto-ness" of my ZJ so I will be getting new struts for it soon.

ajmorell
02-28-2010, 09:05 PM
For $20 or whatever you might as well just get new struts....you know your a cheap bastard when you'd rather use vice grips....hell I can't talk though for a long time I had a dowel I kept in the back to hold the gate up.

ELLLLLIOTTTTT
03-01-2010, 12:12 PM
Who's that handsome devil in the picture grinding?

Good to see a top back on this thing. First time it's had a roof since... 2003ish?

CrawlerReady
03-01-2010, 12:18 PM
Who's that handsome devil in the picture grinding?


It's not Jesus...that's for sure.

BigDaveZJ
03-02-2010, 10:44 PM
Spent some time working on the tack welds today. Going to have to touch up a few pin holes after I grind it down, but I was pretty happy with how easy it was. I tacked it every couple inches, and then built off of those tacks to fill it all in.

http://photos-g.ak.fbcdn.net/hphotos-ak-ash1/hs484.ash1/26502_383159933367_585188367_5040421_3830875_n.jpg

faststang1
03-02-2010, 11:52 PM
looks really good,when u putting the cage in?

BigDaveZJ
03-03-2010, 12:07 AM
You can see some of the tube in the window there. It's just a hoop at the c-pillar with down bars to the d-pillar area.

slim616
03-03-2010, 09:52 AM
looks good man, just out of curiosity how much time do you have wrapped up in it? I agree with you on not using the vice grips they had a tendency to loosen up over time when you don't adjust them and when you least expect it down comes the hatch. Another reason mines hatchless, That hurt bad enough the first time and figured there would be no second time:)

BigDaveZJ
03-03-2010, 10:21 AM
I've probably got a couple days of solid work into it. A lot of it has been a couple hours here, couple hours there.

BigDaveZJ
03-06-2010, 12:32 AM
Finished up the first round of exterior welding tonight. Still need to grind it all down and find the holes, as well as weld up the seam on the interior and plate them. I'm really starting to get sick of welding sheet metal, but overall the project is still going much better than I ever anticipated.

BigDaveZJ
03-30-2010, 10:27 PM
We set a record hi temp in Denver today and I spent a lot of the day out in the garage working on the ZJ. Got quite a bit done, and it's definitely more driveable than it was before. On a couple test drives that the Jeep wasn't really ready for yet there was a lot of movement and noise coming from the rear. I had only welded the outside of the unibody though, so I didn't expect perfection.

Here's some more detailed pics of how everything sat this morning:
http://photos-e.ak.fbcdn.net/hphotos-ak-ash1/hs478.ash1/26192_426747603367_585188367_5269303_3377384_n.jpg

Notice the pretty substantial gaps in the d-pillar, no big surprise that it wasn't really all that strong.
http://photos-b.ak.fbcdn.net/hphotos-ak-snc3/hs458.snc3/26192_426747613367_585188367_5269305_1296908_n.jpg

http://photos-f.ak.fbcdn.net/hphotos-ak-snc3/hs458.snc3/26192_426747638367_585188367_5269307_4954234_n.jpg

I've got pieces cut to fill the gap in the roof line, just haven't gotten to those yet.
http://photos-e.ak.fbcdn.net/hphotos-ak-snc3/hs458.snc3/26192_426747643367_585188367_5269308_1154400_n.jpg

Roof seam is welded and riveted, added more rivets today too.
http://photos-f.ak.fbcdn.net/hphotos-ak-snc3/hs478.snc3/26192_426747678367_585188367_5269313_4570916_n.jpg

These are the plates I cut out today to distribute the load on the interior seams on the unibody.
http://hphotos-snc3.fbcdn.net/hs478.snc3/26192_426747688367_585188367_5269314_5060111_n.jpg

And welded/riveted in place
http://hphotos-snc3.fbcdn.net/hs458.snc3/26192_426747703367_585188367_5269316_6005988_n.jpg

I figure the combination of the two should really help add some strength, distribute the load, and stay strong for a long time.

I grabbed some new hatch struts today too, and after putting them on I dove in to some of the wiring for the hatch. Here is where I noticed a mistake I had made. When I originally pulled the roof and hatch back in the day I left a lot of the wiring intact, and just had it kinda laying on the floor board. Well when I welded in the mini-cage I trapped the wire loom. So I had to cut it apart and connect it all back together. Wasn't really all that big of a deal, since only a few wires actually go from side to side. I got the license plate lights working, as well as the power locks mechanism for the hatch.

We took it on a test drive today too, and I have to say the improvement was significant. No squeaks from the back, and it felt much more solid. I still need to work on the roof line and reinforce that, as well as a metric shit-ton of body work left.

http://hphotos-snc3.fbcdn.net/hs458.snc3/26192_426747738367_585188367_5269322_165088_n.jpg

MoonWorks
03-30-2010, 10:43 PM
Pretty cool man. I've seen plenty of roofs come off but none of them go back on.

leeanderthal
03-30-2010, 11:32 PM
Progress looks good! Gotta fell better about the ability to lock stuff away! Does the hatch work good?

BigDaveZJ
03-30-2010, 11:37 PM
Hatch works perfectly. I thought getting the hatch to line up was going to be one of the biggest challenges but it honestly was pretty easy.

leeanderthal
03-30-2010, 11:42 PM
Glad to hear that. I think it looked pretty cool with the hatch cut off, I just like to lock my stuff up also.

BigDaveZJ
04-02-2010, 05:41 PM
Drove it on the washboarded gravel road this morning that exposed the major weaknesses a couple weeks ago and it did MUCH better. Very little noise and movement from the backend. I still need to do some additional reinforcements on that gap on the roof and tie the tube in a couple more places, but it should be plenty solid with all of that.

BigDaveZJ
04-10-2010, 06:34 PM
Laid down some bondo today.

http://sphotos.ak.fbcdn.net/hphotos-ak-snc3/hs511.snc3/26863_430728703367_585188367_5374327_1546507_n.jpg

http://hphotos-sjc1.fbcdn.net/hs491.snc3/26863_430728708367_585188367_5374328_2912212_n.jpg

After sanding it down I shot some primer.
http://hphotos-sjc1.fbcdn.net/hs511.snc3/26863_430702368367_585188367_5373514_700839_n.jpg

Sprayed some semi-gloss black too, but didn't get a pic of that.

In between bondo and paint I also finally got around to installing the radiator support that I got from KOR last fall. Looks like I was about do, lol.
http://hphotos-sjc1.fbcdn.net/hs511.snc3/26863_430728718367_585188367_5374330_7997640_n.jpg

Install was super easy even with my rig being wheeled for 10 years.

After I get some more flap discs I'm gonna move back to the roof line and finish that up.

dp96zj
04-10-2010, 06:40 PM
It's looking pretty good, the hard work's gonna make it look (almost) like a ZJ again! :flipoff2:

I remember when I put on my rad support, comparing the two supports was like night and day :eek:. That thing is pure beef.

Jeeptech01
04-10-2010, 07:12 PM
Lookin good. That is def a big undertaking to put the roof back on like that esp on a rig that has been wheeled hard with it off. God did that sound like ass kissing? Ugh not intentional LOL

BigDaveZJ
04-10-2010, 07:21 PM
Lookin good. That is def a big undertaking to put the roof back on like that esp on a rig that has been wheeled hard with it off. God did that sound like ass kissing? Ugh not intentional LOL

My biggest concern is will it still hold up after wheeling it hard, that'll be the true test of how well this all worked.

Jeeptech01
04-10-2010, 07:43 PM
You still have a cage in it right? If it didnt flex enough to prevent you from putting a straight roof on it after all that wheeling I doubt you will have issue with it. At this point your rig probably isnt counting on it for structural rigidity (since it has obviously done fine without it) so it may as well be an 85 pound roof ornament that you chose to weld on... To keep the neighborhood kids from stealing it? ed: the ornament not the Rig Heh

zj95maxx
04-10-2010, 08:49 PM
Show the interior "cage". I am interested in seeing how you mounted and designed it.

I know it is just the rear part, but still.

ajmorell
04-10-2010, 09:55 PM
Looks good Dave. Maybe I missed it but are you painting the hatch to match?

BigDaveZJ
04-10-2010, 11:51 PM
Show the interior "cage". I am interested in seeing how you mounted and designed it.

I know it is just the rear part, but still.

Last pic in post 153. Just a hoop and some down bars. More to strengthen the unibody than act like a cage. 1.75" .120 wall HREW. 1/8" plate tie in's to the floor in 4 places. Additional connections will most likely be added to the c and d pillar where the reinforcement plates are.

BigDaveZJ
04-10-2010, 11:52 PM
Looks good Dave. Maybe I missed it but are you painting the hatch to match?

The hatch was originally red, I did a crappy job prepping it the first time I painted it, so it will get another round of prep with more black. I'll also probably paint most of the red interior too.

zj95maxx
04-10-2010, 11:56 PM
Last pic in post 153. Just a hoop and some down bars. More to strengthen the unibody than act like a cage. 1.75" .120 wall HREW. 1/8" plate tie in's to the floor in 4 places. Additional connections will most likely be added to the c and d pillar where the reinforcement plates are.

Plates underneath? Tube going to "frame"?

BigDaveZJ
04-11-2010, 12:24 AM
Nope. If it were a roll cage, then yes I would have done those, but it is there to regain some of the structural rigidity of the unibody and distribute the load away from the welded seams in the body.

BigDaveZJ
04-11-2010, 01:36 PM
Couple shots with paint
http://sphotos.ak.fbcdn.net/hphotos-ak-snc3/hs491.snc3/26863_431001373367_585188367_5383589_521673_n.jpg

Both doors are cracked a bit so this one looks off a bit
http://sphotos.ak.fbcdn.net/hphotos-ak-snc3/hs511.snc3/26863_431001363367_585188367_5383587_7569092_n.jpg

http://sphotos.ak.fbcdn.net/hphotos-ak-snc3/hs491.snc3/26863_431001368367_585188367_5383588_256008_n.jpg

CrawlerReady
04-11-2010, 03:14 PM
Nice!!! I doubt anyone would even know that you had done this unless they saw your build. Looks good Dave!

Pitch
04-11-2010, 11:16 PM
Awesome work Dave!

You should have left the ZJ blue, red, and black and called it "Patches."

SirFuego
04-12-2010, 08:55 AM
That looks great, Dave!

BigDaveZJ
05-10-2010, 12:16 PM
I was working on welding some more on the roof line last week when my welding hood had an unfortunate run-in with floor and the headpiece shattered into a bazillion pieces. So while waiting for a new headpiece to show up I worked on some other stuff yesterday. I haven't put pics online yet, but we started work on a storage box/platform that will take the place of the rear seats.

We made it out of 3/4" plywood, and the top sits on the rear floor and goes to about 1/2" shy of my c-hoop, and then far enough forward to still allow the front seats to recline, about 33" total. We took more plywood and tried to contour to the floor as best as possible, and used 4 L-brackets to attach the front panel to the floorboard. The back section will be attached to the tube on the c-hoop somehow.

For access, we cut two doors into the top, a total of about 35" x 17". They're hinged with piano hinge on the back, so they are accessible from the front seats. We still need to carpet everything, and put it some tie downs and latches. The doors are held up by some 2" strips of plywood mounted to the bottom of the top panel that stick out into the opening about 5/8".

The cooler will sit on one side, with a spot for the dog on the other. I'm really happy with how it's turning out so far, and will try to get some pics up tonight.

Sudz
05-11-2010, 08:49 AM
Does the heater still work? if so, you're back in business. It's nice to be able to lock your shit up too

Looks good, welcome back :mrgreen:

BigDaveZJ
05-11-2010, 09:13 AM
Without doors
http://sphotos.ak.fbcdn.net/hphotos-ak-snc3/hs604.snc3/31804_442795138367_585188367_5649946_1130956_n.jpg

Doors in place, but not mounted to hinges
http://sphotos.ak.fbcdn.net/hphotos-ak-snc3/hs604.snc3/31804_442795143367_585188367_5649947_3569031_n.jpg


Ron,
The heater has always worked great. I salvaged the a/c a few years ago though in an attempt to fix the a/c on Pam's ZJ, so I will need to do something about that.

OverkillZJ
05-11-2010, 10:56 AM
Nice work...

ajmorell
05-11-2010, 11:32 AM
That's pretty sweet. What are you doing as far as latches go?

JohnBoulderCO
05-13-2010, 07:06 PM
Looking nice, good work.

BigDaveZJ
03-13-2012, 03:12 PM
Pulled the 8.8 out yesterday, need to go through it and do some things. First off is a new master install kit after the ring gear debacle last summer. Then I'm going to re-run the rear brake lines along the axle so they don't get caught on the gas tank skid again. Might also pull the t-case and do a rebuild kit there, and probably put some new bushings in the rear control arms and shocks. Once that's done a few more maintenence items in the front end and we'll be ready to go for the summer.

http://sphotos.xx.fbcdn.net/hphotos-ash4/426813_10150846553018368_585188367_12551277_212991 1885_n.jpg

BigDaveZJ
03-18-2012, 06:13 PM
Tore the 8.8 down today, I've got more work ahead of me than I anticipated. Looks like a couple of the threads on the ring gear are jacked, and the bolt holes in the carrier have ovaled out due the loose ring gear bolts.

http://a3.sphotos.ak.fbcdn.net/hphotos-ak-snc7/481391_10150861394593368_585188367_12601881_148173 6906_n.jpg

Brad S
03-19-2012, 10:23 AM
No good.

1ABrian
03-20-2012, 05:12 PM
[QUOTE=BigDaveZJ;330029]Tore the 8.8 down today, I've got more work ahead of me than I anticipated. Looks like a couple of the threads on the ring gear are jacked, and the bolt holes in the carrier have ovaled out due the loose ring gear bolts.

http://a3.sphotos.ak.fbcdn.net/hphotos-ak-snc7/481391_10150861394593368_585188367_12601881_148173 6906_n.jpg
THAT EQUALS THIS
http://i424.photobucket.com/albums/pp324/1989Mustang1989/kid20crying.jpg

BigDaveZJ
04-22-2013, 09:24 PM
I need to go through and fix some of these pics . . .

Anyways, got an ARB and Warm M8000 a couple months ago off another ZJ that I picked up. Definitely a different look than what I'm used to.

https://sphotos-a.xx.fbcdn.net/hphotos-ash3/598552_10151530257268368_1860988877_n.jpg

Have some LED strips coming for rock lights to replace the Harbor Freight cheapo fogs I had been running as rock lights for about the last 10 years. Also have some switches on the way from OTTRATW for a custom switch panel that will go in place of the VIC in the dash. Going to add a dual USB outlet in the panel too for charging the GoPro and phones.

Managed to blow up some of the t-case innards last fall too. Apparently one of the planetary gears was missing some of its bearings, and in turn took out the thrust washers in the t-case. The teeth on the input gear were actually slightly chipped from chewing up some of the shards. Got that all fixed up with another case from the yard. Not much else needs to be done right now since the case broke about an hour into a weeklong trip, so I had just finished up a bunch of maintenance work at that point.

biggoofy
04-22-2013, 10:10 PM
Looks good man.

BigDaveZJ
04-22-2013, 10:16 PM
Some of the t-case damage. If you look closely right in the middle of the gear you can see the damage. The first time I had the case apart Jim and I completely missed it, but it made an awful noise. I'm assuming the sun gear has similar damage.

6847

Ken L
04-22-2013, 11:11 PM
Dave's ZJ with a front bumper that's not just the sheetmetal crossmember. Who would have ever thunk it!

redneckrollercoaster
04-22-2013, 11:50 PM
Looks nice, Dave. Thought I had you pegged as more of a minimalist, though lol

BigDaveZJ
04-23-2013, 12:18 AM
Yeah the ARB wasn't my first choice, but with the price I paid for the ZJ that it was on I couldn't really pass it up.

BigClay
04-23-2013, 08:23 AM
My ARB wasn't bad, it took a lot of hard licks and still kept going. My biggest compaint was the poor approach angle.

BigDaveZJ
04-23-2013, 10:49 AM
Yeah I know they're plenty beefy, but I always enjoyed the approach angle of not having a front bumper. But it was a lot easier than fabbing up a custom bumper and recessing the winch into the factory x-member area.

BigDaveZJ
04-30-2013, 07:36 PM
Got a little bit of work done over the last few days. Made the switch panel to go in place of the VIC and started in on the new rock lights. I got a roll of 600 LEDs for $25 on Amazon and have mounted them to driver side so far, and they're bright as shit. Hopefully they hold up for a while. Currently there's a 10" strip facing the rear on the rearward side of the rear rocker leg, same thing on the front facing forward, and then 32" on the bar that bolts to the pinch seam. On my old ass RRO sliders the pinch seam bar sits up above the main slider by quite a bit so they should be safe. I'm going to put a strip on the steering box brace and bumper for some forward light as well.

Crappy cell phone pic of the switch panel. Made from lexan and mounted with RTV because that was what I had on hand. The upper light on the switches comes on with the dash lights, and the lower light comes on when the switch is turned on. The HCS is a momentary for the misters, the other 2 are in the on position. Replaced the factory 12v outlet with a "marine-grade" one, and added another 12v outlet to my dash panel, as well as 2 USB ports for charging cameras and such.

http://img.tapatalk.com/d/13/05/01/ugu5ubu4.jpg

BigDaveZJ
05-03-2013, 10:26 PM
New rock lights.

6854

Jeep Whore
05-03-2013, 11:25 PM
i'm doing the same set up for rock lights but the front is different. from pictures i saw posted, the front strip doesn't seem like it gives enough light off to the side/ in front of the tires. do the pictures just not do it justice for the front corner area?

BigDaveZJ
05-04-2013, 11:06 AM
My old rock lights that I had been running for about 10 years only lit up under the rocker panels and I never had much of a problem with them. There's also not really a spot on my rig to light up the corners any better without destroying the lights everytime I go wheeling. But there should be plenty of light to see anything I need to with this setup.

Mtn WJ
05-04-2013, 01:11 PM
I was surprised to see how much light he was getting with those strips. Pretty even coverage too.

Jeep Whore
05-04-2013, 10:39 PM
My old rock lights that I had been running for about 10 years only lit up under the rocker panels and I never had much of a problem with them. There's also not really a spot on my rig to light up the corners any better without destroying the lights everytime I go wheeling. But there should be plenty of light to see anything I need to with this setup.

Ok, once I do my bumper trim then I can get my 48 led panels in there I will post pictures of the light out put of those installed maybe see if thats something you would be intrested in doing

BigDaveZJ
07-10-2013, 11:19 PM
So Pam and I have been discussing what we'll do when the unibody starts to fall apart around the rest of the Jeep as that is bound to happen sooner or later. Our thought is to find another ZJ, gut it, build a good internal/exo cage similar to the one Ryan did in his 5.9 and go for a solid combo expo/crawler rig. And tonight I'm perusing CL and find this: http://denver.craigslist.org/cto/3926429941.html Anybody wanna buy my green ZJ so I can go get this one?!?

BigClay
07-11-2013, 10:57 AM
Are you dead set on another ZJ, or have you considered something with a frame?

BigDaveZJ
07-11-2013, 11:09 AM
It'll be another ZJ. If I found this other ZJ 2 years from now I'd likely be all over it, but at this point my unibody is still holding up relatively okay and I don't have the room to complete this scale of project. Nothing with a frame really intrigues me and fits what I want without a ton of work.

Ken L
07-11-2013, 12:13 PM
Simple solution for you, Dave. Don't look at ZJs on Craigslist.

FortCollinsZJ
07-16-2013, 01:52 AM
BUY THIS!!!! http://denver.craigslist.org/cto/3936069924.html

BigDaveZJ
08-10-2015, 05:45 PM
So we're going to bring this POS back to life. Have a list of things that need to be done to it to get it ready to go, but nothing too major considering it's just sat since GSW a couple months ago.

- fix DW. in 15+ years of owning a ZJ I've gotten DW twice, one of them was last week when I tried to drive the ZJ, need to figure out what's causing it and fix it
- there's a charging/battery issue. not sure if it's not charging right, or just not holding the charge. Got a CEL that leads me to think it may be the computer
- need taller rear springs. with the tire carrier in the back we added a LOT of weight back there
- I broke something in the front axle at GSW, thinking the hub, has a nice rotational speed dependent noise going on
- I'm going to get the a/c working again
- still haven't fixed my speedometer
- need to get the smog test done and plates renewed
- going to patch and reinforce the areas of the unibody that are cracked or bending
- replace suspension bushings

All in all not too bad, and should get us pretty close to where we would have been on building a new rig, especially given how little we've actually been wheeling lately.

Kraqa
08-12-2015, 04:11 PM
well now that you have a shop.....get to work man.

BigDaveZJ
08-12-2015, 04:16 PM
I just gotta finish the shop! Got one work bench done, 3 more to go, run the airlines, mount the compressor, and I'm sure some other stuff that will come up too.

BigDaveZJ
11-14-2015, 02:50 PM
Pulled the ZJ into the shop, going to do a little work on her today. Got some new seats for it out of a 96 to 98 Laredo and need to tear the front end apart to find a new noise. Also hoping to start planning out the cage work.

http://images.tapatalk-cdn.com/15/11/14/c4738e462972c0aa4b43d102954cee73.jpg

Sent from my Nexus 6 using Tapatalk

BigDaveZJ
11-14-2015, 03:46 PM
Old seats are out, cleaning up 15 years of gnarliness that was under the seats. Running with no doors and in the rain can certainly take its toll on an interior.

http://images.tapatalk-cdn.com/15/11/14/5994b159fe0f82f4337dbebc4391ce83.jpg

And I found the noise from the front end. Was hoping it was a hub or something and not the gears. 2nd ring gear in the last few years.

http://images.tapatalk-cdn.com/15/11/14/e6366e36ba1c5ab457f3166985cd48ab.jpg

Need to figure out if I'm going to put new gears in the 30 or get a real axle.

Sent from my Nexus 6 using Tapatalk

BigDaveZJ
11-14-2015, 04:31 PM
Seats are in.

http://images.tapatalk-cdn.com/15/11/14/6b144b8429c98501111fadd770f1057f.jpg

Sent from my Nexus 6 using Tapatalk

JohnBoulderCO
11-14-2015, 07:13 PM
What would the new front axle choices be?

Edit: I just saw your CO4x4 wanted post.

BigDaveZJ
11-14-2015, 07:27 PM
Yeah it's basically fix the 30 for $300 or drop a few grand on real axles, likely a 44/9 combo. Don't want more than 35s so hard to justify 60s.

fluxcap
11-14-2015, 07:39 PM
The 8.8 is stronger then a factory 9 unless you like spitting out pinions

Stealth Crawler ZJ
11-14-2015, 09:36 PM
I have a good 8.8 with welded tubes a good truss, 4:10 gears, iron rock mounting kit and a ballistic 3/8 steel diff cover!
Give you a good price on it! 😉

BigDaveZJ
11-14-2015, 11:23 PM
Already have an 8.8

Stealth Crawler ZJ
11-15-2015, 01:39 AM
Well just sayin if you wanted to refresh you know just in case haha!

ELLLLLIOTTTTT
11-15-2015, 01:12 PM
Since you know how to set up gears, I'd just replace them. 35's shouldn't be grinding teeth off like that, but we all know you don't take the easy lines.

Ted_Z
11-16-2015, 01:01 PM
Nice thing about the d44 route is that you can convert to over the knuckle steering (among other things). Makes a huge difference on the street. If you pick up a some flat top knuckles, I can machine them for you probono (since you're such a nice guy and all) now that I know how to do it (http://mallcrawlin.com/forum/showthread.php?26511-Knuckle-up&p=349272).

Ted_Z
11-16-2015, 01:47 PM
https://denver.craigslist.org/pts/5311506605.html

BigDaveZJ
11-16-2015, 02:50 PM
So if I did the HP44 . . .

Housing
Brackets $500 (only looked at Clayton so far really)
Gears $250
Install Kit $100
Locker $1000
Shafts $300-$1400
Steering? Currently have the Chevy 1-ton TRE setup, UTK, would imagine that I could adapt some of that to the 44 pretty easily.
Knuckles?
Hubs?
Wheels?
Brakes?

Just trying to put together what this would actually cost me so I can make a solid decision.

Ted_Z
11-16-2015, 05:22 PM
If you use a HP D44, you can run all Ford stuff as is, but if you want high steer you'll need to do the hybrid outers (Chevy/early waggy outer knuckle and spindle). Also you can narrow the HP44 to waggy width reasonably simply which allows you to correct your caster.

Also since you have the 8.8 built already, you can just toss on some 5x4.5 to 5x5.5 adapters and be done.

Add all the brackets to your list.

K2
11-16-2015, 06:14 PM
Also since you have the 8.8 built already, you can just toss on some 5x4.5 to 5x5.5 adapters and be done.

I am about to sell my set of 4 Spidertrax adapters, let me know if you are interested.

BigDaveZJ
11-24-2015, 05:01 PM
Keeping the HP30 for the time being, ordered up the gears today. Will probably start building a HP44/9 combo at some point, but for now that's money that can go towards a Typhoon!

BigDaveZJ
05-18-2016, 03:00 PM
Turns out my axle money did go towards a Typhoon, lol. Now that the shop is mostly done I've had the opportunity to go through the Jeep a bit more and take care of some things I had been neglecting. R&P replaced in the front axle, all new bushings in the suspension, new front trackbar, general maintenance stuff mostly. Put some taller spacers in the back to make up for the weight of the rear bumper. Also put a/c back on the Jeep. Picked up the Harbor Freight gauges and pump and replaced the accumulator. Blowing ICE cold now, just need to monitor it as I'm sure there's a leak or two somewhere.

Only things that are really left right now are pretty minor. I need to change out the front diff fluid after gear break in, replace the axle seals in the front diff, and still need to fix the speedo. More long term items are reinforcing the rear unibody and re-working a couple things on the rear bumper. Other than that, I might work up a better storage system in the back that can fit an ARB fridge and some storage drawers, but that really depends on how much we end up wheeling the JK as the JK could be the recipient of that stuff.

ELLLLLIOTTTTT
05-19-2016, 01:32 PM
You have a rear bumper now?

BigDaveZJ
05-19-2016, 02:12 PM
You have a rear bumper now?

I bought K2's rear bumper last year when he was parting out his ZJ.

http://uploads.tapatalk-cdn.com/20160519/5878450d344b46469d2cc7012ecac688.jpg

BigDaveZJ
06-14-2016, 03:46 PM
Some of you probably saw that I had some cooling issues and likely smoked a head gasket at GSW. Going to use this thread to chronicle some of those repairs as well as the other items that I plan on replacing/repairing while I'm in there.

So far I'll be doing:

-head gasket
-port/polish???
-intake plenum gasket (maybe the Hughes kit)
-water pump (Flowkooler?)
-radiator (may do OE replacement, may upgrade, $$ is the big factor)
-radiator hoses
-bypass hose
-thermostat
-header panel
-new headlights
-repair the a/c line that assploded
-full ignition system
-Taurus fan? Or maybe just an electric pusher on the front?
-clean the crap out of everything

If I pull the motor completely out of the Jeep I'll do more, like the rear main and oil pan gasket. For now though I'm going to try and keep it in.

Ted_Z
06-14-2016, 04:05 PM
I guess before you tear it down, maybe do a leak down test to be sure it truly is a head gasket. I have a compression tester set up if you'd like to borrow it. Also you could try one of the chemical testers that can tell if combustion byproducts are in the cooling system.

Oh, don't put an electric pusher fan in, blocks more airflow then it adds at highway speeds.

jsteves
06-14-2016, 04:37 PM
Some of you probably saw that I had some cooling issues and likely smoked a head gasket at GSW. Going to use this thread to chronicle some of those repairs as well as the other items that I plan on replacing/repairing while I'm in there.

So far I'll be doing:

-head gasket
-port/polish???
-intake plenum gasket (maybe the Hughes kit)
-water pump (Flowkooler?)
-radiator (may do OE replacement, may upgrade, $$ is the big factor)
-radiator hoses
-bypass hose
-thermostat
-header panel
-new headlights
-repair the a/c line that assploded
-full ignition system
-Taurus fan? Or maybe just an electric pusher on the front?
-clean the crap out of everything

If I pull the motor completely out of the Jeep I'll do more, like the rear main and oil pan gasket. For now though I'm going to try and keep it in.

Flow cooler is shit. Just a Chinese pump with extra find on it. Just get an OE one.

BigDaveZJ
06-14-2016, 06:05 PM
I guess before you tear it down, maybe do a leak down test to be sure it truly is a head gasket. I have a compression tester set up if you'd like to borrow it. Also you could try one of the chemical testers that can tell if combustion byproducts are in the cooling system.

Oh, don't put an electric pusher fan in, blocks more airflow then it adds at highway speeds.

I'm planning on testing it to make sure, I'll let you know if I need to borrow your setup.

And the only time my ZJ really sees highway speeds for any period of time is on my trailer, lol.

fpkites
06-14-2016, 10:02 PM
Pusher could block airflow for even a short amount of time. I convinced Scott to cut them off this year.

JohnBoulderCO
06-14-2016, 11:07 PM
I told Scott to take them off for years. I'm glad you were able too.

BigDaveZJ
06-15-2016, 12:01 AM
Ordered a block tester today, hope to have confirmation on the head gasket this weekend.

BigDaveZJ
06-17-2016, 08:37 PM
Good news and bad news . . . . it's not the head gasket. No f'ing clue where the leak could be now.

Stealth Crawler ZJ
06-18-2016, 12:14 AM
How did you test To reach that result? The reason I ask is because mine tested ok too but I kept having coolant blowouts that after 6-7 blowouts and overheating issues when I took it apart the end result was a small gap in the gasket that would only leak through when under great pressure for extended amounts of time. Hopefully it's something waayyy easier and cheaper but I would say don't rule this out yet..



Because Jeep.

BigDaveZJ
06-18-2016, 10:25 AM
I used one of the 2 chamber block test kits that tests for exhaust gas in the air in the radiator. Basically it's a turkey baster you hook up to the rad neck and suck air through a chemical. If it changes colors you've got exhaust gas in the cooling system. Colors didn't change.

Sent from my Nexus 6 using Tapatalk

BigDaveZJ
06-19-2016, 11:53 AM
Going to dump some uv dye in the coolant and get one of those pressure test kits, hopefully nail down a spot that's leaking.

MoonyJohn
06-20-2016, 07:37 PM
Your jeep down from moab too?

Im tracking down some wobble wobble wobble

BigDaveZJ
06-20-2016, 09:23 PM
Your jeep down from moab too?

Im tracking down some wobble wobble wobble

I thought it was the trackbar johnny joint and bushing? Figured that would've nipped it in the bud.

BigDaveZJ
06-21-2016, 10:49 PM
Coolant system holds pressure just fine. Only thing I can think of at this point is some type of temperature dependent leak. I.E. it gets hot enough that air starts getting pulled in but can't replicate it in the shop.

Kraqa
06-22-2016, 12:47 AM
ever considered a cracked head?

i've had a 5.2 with one. would run fine till it got hot then over the period of about 30 min it would pressurize the coolant system.

BigDaveZJ
06-22-2016, 08:35 AM
I did, but the block tester should have tested positive if it was the head.

Stealth Crawler ZJ
06-23-2016, 01:35 AM
Coolant system holds pressure just fine. Only thing I can think of at this point is some type of temperature dependent leak. I.E. it gets hot enough that air starts getting pulled in but can't replicate it in the shop.

Exactly what mine did..



Because Jeep.

BigDaveZJ
06-23-2016, 09:39 PM
Started tearing it down tonight, got the accessory bracket off and now the front of the motor is soaking in degreaser, shit was NAAAAAASTY.

BigDaveZJ
06-24-2016, 12:29 AM
http://uploads.tapatalk-cdn.com/20160624/f37519a4c714dbcfe0f962c8e6f60a59.jpg

Stealth Crawler ZJ
06-25-2016, 10:13 PM
The suspense is killing me!...



Because Jeep.

BigDaveZJ
06-26-2016, 12:39 PM
Then come over and help!! Lol!

http://uploads.tapatalk-cdn.com/20160626/60b0d9782767e97798d3d7ee11dbb98d.jpg

http://uploads.tapatalk-cdn.com/20160626/447890a06e6f5cabbaf89efcd0f0bd8f.jpg

http://uploads.tapatalk-cdn.com/20160626/42c346e7597d66d5b5be9bf971cd12d3.jpg

Sent from my Nexus 6 using Tapatalk

K2
06-26-2016, 01:46 PM
Amazon needs to work on their packaging!

BigDaveZJ
06-26-2016, 03:01 PM
Gaskets appear to be in decent condition. Time to take the heads to get tested.

http://uploads.tapatalk-cdn.com/20160626/a0d4ece10d4fc01b8fb2da49220e727b.jpg

http://uploads.tapatalk-cdn.com/20160626/d8edfd60fac0a27db9dd8e6143546351.jpg

Sent from my Nexus 6 using Tapatalk

Ted_Z
06-27-2016, 02:38 PM
You should just move all your running gear over to another ZJ ;)

ELLLLLIOTTTTT
06-29-2016, 01:50 PM
This looks much more doable than the 4.7L in WJ's. Such a PITA.

BigDaveZJ
07-07-2016, 01:55 PM
Well, my UPS guy is about to hate me. Local engine shop wanted $170 to clean and test both heads, which is certainly fair. But given the probability of it being the heads, and the price I found for a reman'd set I'm just going to get the remans: http://www.ebay.com/itm/272218404105?_trksid=p2055119.m1438.l2649&ssPageName=STRK%3AMEBIDX%3AIT

Also going to order new head bolts, all the gaskets, water pump, radiator, hoses, etc etc etc.