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OverkillZJ
03-06-2005, 12:28 PM
Alright, here we go. Many of you saw my insane post at NAGCA of elevinity billion views and such tracking the progress of my Jeeps rebuild. It started in 2003.

I'm pulling all of my old posts from NAGCA over into this thread, and then as the Jeep progresses I'll be adding to both threads :weedman:

OverkillZJ
03-06-2005, 12:28 PM
Many of you know of my plans for rebuilding a lot of my ZJ, making up for the stupid decisions I've made in the past. I'm going to use this thread as my "progress tracker pic posting thread" if nobody objects. :thumbsup:

Lets start with... where this is all being done: My own lil' tent garage. It kinda sucks to work on a wood platform, but it's nice and roomy for what I'm doing.


http://www.fccsonline.com/pic/garage1.jpg
http://www.fccsonline.com/pic/garage3.jpg
http://www.fccsonline.com/pic/garage4.jpg
http://www.fccsonline.com/pic/garage6.jpg

EDIT: Thought I'd add some picures of my "garage" workspace as well (the garage that came with the house that is, not the tent :))
http://www.fccsonline.com/pic/jeep/cleangarage.jpg
http://www.fccsonline.com/pic/jeep/aircompressor.jpg
http://www.fccsonline.com/pic/jeep/cleanworkbench.jpg

OverkillZJ
03-06-2005, 12:29 PM
Day one was getting the rear up on jack stands, that was a project in itself as I was nervous about the stability of my plywood platform on gravel holding up under the weight on a small area. 5 hours of being extremely careful later... it was up.

http://www.fccsonline.com/pic/d44a2.jpg

Day 2 was draining the cooling system to find my coolant leak... turned out to be the stupid radiator drain cock. It had no O-Ring left at all. I decided to replace the whole part all together, since the teeth that hold it in were worn.

Day 3, got new drain cock ($4.30 at Napa) and installed... I was afraid I needed a new radiator for awhile as the hole the "cock" (haha) went into was a bit out of shape. Bent it back with needle nose pliers and I think I can get a few more years out of it... Filled the system, started it, wohoo! no more leaks!!!

Then the fun part. Pulling the rear axle... Only took 2-3 hours with the help of a buddy who was nothing short of amused of my use with the BFH when things wouldn't move the way I wanted them to. He caught on quick. Took the skid plate off to get at the drive shaft, and was pissed to find that the drive shaft as seized itself and will no longer extend or compress. It's a good Tom Woods shaft that the boot ripped off of, so I'm going to need to invest some time rebuilding that... This meant that once the whole driveshaft was unbolted, I couldn't remove it since it was stuck between the yokes. I couldn’t get the springs out either since if I dropped the axle to remove them, the driveshaft would have all that pressure against it since it’s seized. Soooo, we removed all the control arms, and the shocks, and just yanked the jack holding the axle out. It was a very LOUD thump as the driveshaft fell to the floor first, followed by the springs going CLANG CLANG. It was midnight by the way. I’m sure the neighbors will want to have words with me after a few more nights of using my 625 ft lb impact gun at midnight.

http://www.fccsonline.com/pic/axleswap1.jpg
http://www.fccsonline.com/pic/axleswap2.jpg


I’m not entirely sure how, but I found one of my rear shocks to be quite busted up…. It’s actually got a bent thingy. No, I don’t have 3 hands, that’s my friend holding it for me 

http://www.fccsonline.com/pic/bentshock.jpg


I was a little disappointed to see that the road salt has eaten away at my axle end control arm mounts on my Claytons long arms, and I need to press in new ones. Guess it's time to finally invest in a good press.

OverkillZJ
03-06-2005, 12:30 PM
Second "big day" of working on it... Man, I'm tired, and I only worked on it for 5 hours or so :crazy

The first obsitcle was one of the tie rod ends that is completely busted... damn nut just spins along with the whole joint inside the thingy majigger. I began cutting it with the sawzall, but after eating a good blade in 2 seconds flat I decided that the next owner of the zxle can deal with it.
[img]http://www.fccsonline.com/pic/jeep/2.14.04.a.jpg
Disassembly continues...
http://www.fccsonline.com/pic/jeep/2.14.04.b.jpg
Here you can see the result of a good impact gun on it's lowest setting.. While trying to get off the disconnect bolts, I put in what I thought was a strong piece of metal into the whole to prevent it from spinning. Well, you can see the result for yourselves.
http://www.fccsonline.com/pic/jeep/2.14.04.c.jpg
http://www.fccsonline.com/pic/jeep/2.14.04.d.jpg
Now THAT's flex... the axles laying on the ground at this point, I wasn't really expecting that to happen so easily.

http://www.fccsonline.com/pic/jeep/2.14.04.e.jpg

Oops. That hurt... MFH (medium) on the hub bolts.
http://www.fccsonline.com/pic/jeep/2.14.04.f.jpg

I need to pull my Powertrax no-slip before selling the axle so I can use it in the HP30 I'm picking up, so the differential needed to come apart. MAN I forgot how bad gear oil smells...
http://www.fccsonline.com/pic/jeep/2.14.04.g.jpg
http://www.fccsonline.com/pic/jeep/2.14.04.h.jpg

My dad brought by a valentines day gift from him and my mom, haha, I felt it was appropriate to tie it to my date for the night, the ZJ! :thumbsup:
http://www.fccsonline.com/pic/jeep/2.14.04.i.jpg

OverkillZJ
03-06-2005, 12:32 PM
Nice little project you got there. You going to GSE?

Nope, GSW this year!

Probably back to GSE next year though, I chose west this year as I have friends getting married out there after the event, figured it works out well.

OverkillZJ
03-06-2005, 12:33 PM
I like the tent.
:thumbsup:

Do you own a grand Mark, I DIDN'T THINK SO! :spank:

glad you like the tent, the neighbors don't like your air compressor too much :lol:




Keep up the fire man.

How warm can you get the inside of that thing? How long does it take to set up/teardown?

How much does it cost? Thanks man.

How warm depends on the outside temp... At 28 degrees and above, that 220v heater I have hanging (17,000 BTU) seems to keep it about 55 which is good working temp for me. Costs a fortune to run. As it gets colder (since it's been 5 below here a couple times this year) I start turning on more heaters... have a 16,000 BTU propane heater, two 6,000 BTU electrics, and when all else fails, I have a 30,000 BTU propane heater.

I usually just run the big and a little electric, and only when I'm in there. Costs a small fortune to heat. I think you'd have big problems heating it in alaska when it's mega cold....

Setup takes the better part of a day, it's simple but time consuming. another day for the electrical wiring, and another day for the floor my dad and I built in there.

Tent = 700 + shipping
Parts for electrical = 220
Heater = 200
Flooring = 300
Look on the neighbors faces when the tent went up: Priceless :lol:

It's definately not a portable tent... it was 250 lbs or so shipped :thumbsup:

OverkillZJ
03-06-2005, 12:34 PM
I've also had my share of cold wrenching on gravel, got rather sick of it, so I built the tent. :thumbsup:

I'm afraid this weeks attention will be focused on my Audi...old 92 POS with a leaking head gasket and new tranny that I don't trust as far as I can throw it. Spent all day removing the speakers and subwoofers (to be put back in the jeep) - gonna take another few days getting it to a point were I can get a decent trade in value on it, have to replace yet another seized caliper.. I need reliable transportation to pick up Jeep parts! :smile: :D

OverkillZJ
03-06-2005, 12:42 PM
Heck a tent would be a luxury for me right now!

Matt - you just don't know how good you've got it! Useable space




Girl scout cookies taste funny :lol:

I love the tent, it's working out 100 times better than I expected it too. What sucks is my "real" one car garage that has a busted garage door and leaks water allover the floor, and freezes into an ice skating rink. Makes it hard to get to my tools sometimes when I'm busy falling allover the place.




So, you gonna reveal your plans or just keep us guessing?

You're assuming that I have plans ;)




Would of needed a hookup for the floor. My Dad is a maintenance mechanic at one of the mills that makes OSB, which is what you used for the floor.

$13.50 for 1/2" 8'x16' sheets. They cut those sheets into 4 pieces to make the standard 4'x8' sheets you get at the store.

No that's not a typo :D

You suck. I used 3/4" OSB and had to have it delivered (no truck) - I think I payed something more like $28 a 4x8 plus $35 or so for delivery...

OverkillZJ
03-06-2005, 12:44 PM
Well, have some used Borla headers on the way http://www.borla.com/graphics/img0026.jpg

So what to do with the rest of my exhaust.. 4 linking the rear, so the exhaust has to end in a turn down before the arms start... My first thought was 3" cat and muffler, but I wonder if that's too little backpressure. Maybe... 2.5" cat and muffler?

Wonder how well the magnaflow muffler would sound in this system, I want it to sound pretty damn agressive and throaty. At the moment I'm running stock exhaust with a magnaflow, and its deep, but kinda wimpy.

Turn downs aren't legal here at all, so to pass inspection I'll need to make a temporary side exit pipe, then put the turn down on.

Throughts? Ideas? Thin mints?

OverkillZJ
03-06-2005, 12:44 PM
I was looking at running a supertrapp when I 4-link the rear. looks like you can squeeze one in perfect back towards the rear. just another option. I've wondered why more ZJ's haven't looked at this option???

Also, if turn downs are legal are you sure side exit pipes are? I know they aren't here in WI. just thought I would mention it.

What the heck is a supertrapp? If I can get a tail pipe out the back, that would be my best option....

The PA inspection rules only state that the exhaust "must exit outside of the the vehicle chassis" - it never states rear, side, or anything of the like. Strange.

OverkillZJ
03-06-2005, 12:45 PM
Looks like I'll be putting the headers on, cat and muff and just leaving it until I can see what I can do about PA inspection. Perhaps I could get buddy buddy with someone who runs a station, it's only a sticker after all! :thumbsup:

OverkillZJ
03-06-2005, 12:46 PM
I added 3 pics to the first post of my work space... pics of the "real" garage with my small shop.


I need to stop these late night wrenching sessions. I finally took the no slip out of the carrier (to move to the HP30 I'm putting in) - but I killed 2 of the springs in the process. Need to get new ones. Was about to put the spider gears back in, and reassemble that axle, but I realized I'm missing one of the thrust washers... need to find the missing one... grrr...
http://www.fccsonline.com/pic/jeep/2.21.04.a.jpg

After that I decided to start rebuilding the rear drive shaft. Boy did it need it... First off let me say "How the hell did I ever do ujoints before getting the ujoint press"? Man does it make it easy. The ujoints themselves were pretty fried. I found a bigger problem though, the rubber boot has been missing on that axle for some time, and I never thought much of it since I don't drive the Jeep. The rear driveshaft is seized at the spines, and I can't for the life of me free it up. It's a Tom Woods shaft, so I'll give them a call to see what they suggest I do. Here you can see I sanded it down to bare metal and its all nice and shiny looking. It was turning into a rust popsicle. I have the urge to repaint it gray or some color other than black... anything, haha.
http://www.fccsonline.com/pic/jeep/2.21.04.b.jpg
I called it a night when I finished taking the shaft apart, realizing I need new ujionts as well as help un-seizing the shaft, and a new boot to boot! (yes, pun intended.)
When all was done I cleaned up nicely too!
http://www.fccsonline.com/pic/jeep/cleanworkbench.jpg

OverkillZJ
03-06-2005, 12:47 PM
Matt

Either a good amount of heat on the small portion of that DS, or soaking the whole section up to the splines in penetrating oil or kerosene should let you break it loose, possibly with the help of a BFH :D
John

I was hoping for a miracle fix, where I do some strange indian ritual and the driveshaft woule automatically be rebuilt and even repainted! :thumbsup:



U-joint press.......huh, what, where, how much?

Harbor Freight... $39... "3 in one service kit" - it does ball joints rather well too!

OverkillZJ
03-06-2005, 12:48 PM
Wohoo! new tools! Stubby wrenches and a decent bench vice. I had ratcheting stubby's, but I'm afraid of breaking them on the stuck stuff.

http://www.fccsonline.com/pic/jeep/2.27.04.a.jpg
LOOK! IT ROATES! Me likey...

http://www.fccsonline.com/pic/jeep/2.27.04.b.jpg

fun...
http://www.fccsonline.com/pic/jeep/2.27.04.c.jpg
http://www.fccsonline.com/pic/jeep/2.27.04.d.jpg

Here's the cleaned up armed next to the matching dirty arm. Improvement?
http://www.fccsonline.com/pic/jeep/2.27.04.e.jpg

Here you can see my stupidity at its finest... While I was trying to get the splines of the shaft apart, I knocked it off of the workbench onto the concrete floor (before I put the carpet down) and it landed on the yoke ear... Signifigantly bent. This is going to be interesting to fix...
http://www.fccsonline.com/pic/jeep/2.27.04.f.jpg

OverkillZJ
03-06-2005, 12:49 PM
I'd say today was one long freakin' day of Jeep wrenching. Got a good bit done though! :thumbsup:

Here's a pic of how I extended the steel brake lines to start below the frame rail, don't have to worry about maxing out my brake lines that way... They're rusting though, I HATE PA ROAD SALT!
http://www.fccsonline.com/pic/jeep/2.29.04.a.jpg

Here's a pic that shows why I decided to 4link the rear. At one point, before I knew how to change a tire, I had my first lift put on by a craphole called "Pro Trucks." They assured me the clunking noise was just the Johnny Joint in the rear track bar and it would go away over time. Well, it went away over time, but because the diff bolt that was hitting it had worn away enough metal so that it no longer hit... Lying SOB's.... It was then I decided to start learning this crap on my own... So now that I consider this track bar unusable, might as well 4 link the rear, right!?
http://www.fccsonline.com/pic/jeep/2.29.04.b.jpg

Front axle out...
http://www.fccsonline.com/pic/jeep/2.29.04.c.jpg

Started to chop off the exhaust since I'm redoing it all. Ok, so I just wanted to hear it without a muffler again. MAN does it sound sweet. I wonder if the neighbors thought so...???
http://www.fccsonline.com/pic/jeep/2.29.04.d.jpg

Rear axle out of the tent... lawn art.
http://www.fccsonline.com/pic/jeep/2.29.04.e.jpg

It’s starting to look kind of naked under there
http://www.fccsonline.com/pic/jeep/2.29.04.f.jpg

Hovercraft?
http://www.fccsonline.com/pic/jeep/2.29.04.g.jpg

Sparks are fun.
http://www.fccsonline.com/pic/jeep/2.29.04.h.jpg

Here I was torquing down the ring gear bolts to spec... Yes, any excuse to use the new vice...
http://www.fccsonline.com/pic/jeep/2.29.04.i.jpg

Here's the ring gear and carrier reinstalled to spec, shimmed, and ready for the cover to go back on.
http://www.fccsonline.com/pic/jeep/2.29.04.j.jpg

Front axle sanded down and repainted... I think I got rather high on the paint :pant:

Not putting these axles back in, just painting so I can sell the dag nam things.
http://www.fccsonline.com/pic/jeep/2.29.04.k.jpg

http://www.fccsonline.com/pic/jeep/2.29.04.l.jpg

Rear axle repainted....No more ugly yellow diff cover!!!
http://www.fccsonline.com/pic/jeep/2.29.04.m.jpg

OverkillZJ
03-06-2005, 12:50 PM
Started off the day by hosing down, lightly sanding, and painting the old axles again... first coat was with black primer, which looks just plain UGLY, so this time I went over it with high gloss black rustoleum... They look so good I don't want to sell them now... Someone buy the darn things ;)

http://www.fccsonline.com/pic/jeep/3.03.04.a.jpg
http://www.fccsonline.com/pic/jeep/3.03.04.b.jpg


Here you can see I removed the Claytons crossmember. MAN does that thing hold some mud. There's rocks the size of golfballs rolling around in it... I'm seriously done with mud, too hard to work on the rig even a full year later :crazy:

http://www.fccsonline.com/pic/jeep/3.03.04.c.jpg

Hmmm, what's missing here?

http://www.fccsonline.com/pic/jeep/3.03.04.d.jpg

I decided I wanted to do something more fun, so I started "unbolting" the exhaust from the manifold... Well, bolts wouldn't come off... and this was more fun anyway. Me vs. the bolts.

http://www.fccsonline.com/pic/jeep/3.03.04.e.jpg

I won.

http://www.fccsonline.com/pic/jeep/3.03.04.f.jpg

Man, PA road salt should be outlawed. Seriously, it's unreal the amount of rust I have on this Jeep.... Loooong way to go...
http://www.fccsonline.com/pic/jeep/3.03.04.g.jpg

But something good did come of the day, my new car came in! 2004 Toyota Carolla LE w/ fun options I won't bore you with here. Need a daytime pic, its really pretty... and there's something about driving 80 on back country roads with ease that the Jeep just doesn't do...

I think I'll call it "Jeep parts getter" :thumbsup:
http://www.fccsonline.com/pic/jeep/3.03.04.h.jpg

OverkillZJ
03-06-2005, 12:52 PM
Looks sweet Matt...keep up the good work!

BTW - That rust is INSANE!

I'm trying to keep up the work, but considering I'm a full time student and run my own little IT company, well, time is scarce :(

Jeep should come first, though, right!? :thumbsup:

And ya.... the rust sucks.... I think I'm going to do 2 coats of primer, and 2 coats of paint on everything aftermarket, since that's what seems to be rusting most...





Matt, your jeep looks almost as rusty as mine

Not for long if I can help it :jump:



lol @ jeep parts getter

maybe Part wagon.. I wish I could get a car.... I'm buying something new for a dd in aug, but I have to get a truck. I have to be able to tow. Plus then I can tow the zj back from telico too. I'd love to have a little car that'd get good gas.

I actually wanted a truck, since I'm constantly moving large things around... But the cars smarter for me now, since I'm commuting to school an hour a day. The thing gets 39 miles to the gallon, and is still rather peppy! Besides, the ride is just 10,000 times better than any truck I've ever been in. I'm turning into a pussy :pant:

Now I'll borrow my dads WJ constanly to move all the axles and stuff around I'm selling :angel:



Hoi your new car looks really nice and of course a handy partsgetter.
I really enjoy your dairi.
and keep up the good work
greets Wim :thumbsup:

Thanks for all the compliments guys. I should start taking bets, will this thing be done and tested before GSW? :eek:

I figure I have another full 2 weeks of taking things apart before ANYTHING even starts going back on it...

OverkillZJ
03-06-2005, 12:53 PM
My rig was in PA for a while before I bought it but it doesn't have a SPOT of rust on it which pleased me when I finally did the lift last weekend. No major problems with siezed bolts at all!


:D

You're just lucky :lol:


Did you even think about POR for the rusty stuff? I'm considering it for my hitch. It was the only rusty part under my ZJ. I lucked out mine lived it's first 10 years south of the Mason-Dixon line. It was still pretty clean when I put the lift on. I did try to spray the salt off a few times this winter.

This is a neat thread you got going on. You sure have advanced quite a bit from having somebody else put your first lift. You're even tackling a gear setup. :thumbsup:

Most of the rust seems to be on aftermarket components, such as the long arms and bumpers. The axle rust was from where I scraped them on rocks and didn't immediately repaint... and also, the last time I drove it before parking it for 8 months without touching it was a wet-salty-road day... Lets blame it on neglect :crazy:

Anyway, I looked into POR15, but it likes rusty surfaces to bond to, and i like grinding things down to fresh metal to paint from scratch. I think I'll just stay on top of the touch ups this time round to keep it under control.

And as far as moving up, I couldn't change a tire 3 years ago (no joke ;))

although it was my second lift I paid someone to put on.. first one was a Pro Comp 3", easy, though it seemed hardcore at the time... the second one that I paid for was adding 2" spacers and adjustible TB's blah blah blah, I couldn't get the arms in and I said "screw it" - I didn't understand the BFH concept just yet...

Biggest mistake I ever made.

:spam:

Headers just arrived, I'll post pics in a few. Tomorrow should be another big wrenching day with a big update (starting after work, blah)

OverkillZJ
03-06-2005, 12:54 PM
I lied. I never got to work on the Jeep yesterday, or today. Considering Mid Terms start next week, I don't see any major progress coming up soon either :(

Why do I have a feeling that nomatter how much time I put into this thing WELL before Moab, I'm still going to be wrenching on it just hours before I leave for the trip?

Oh well. I need to go to bed, I'm getting up at 5am to head to Krash80's to buy his old axles (TJ44 and HP30) that will hopefully suite my wheeling habbits for at least the next few years...

OverkillZJ
03-06-2005, 12:54 PM
Hmmmm… What could possibly be in the box?

http://www.fccsonline.com/pic/jeep/3.07.04.a.jpg

Oh, that’s right, noisemakers to piss my neighbors off! Picked these up for $150 shipped, couldn’t pass it up. Only thing that worries me, was that in the box they were shipped in, was a receipt from Kolak. The guy replaced them with Mike Leech headers and a full Kolak system. Just wish I knew why for sure, but they appear to be in perfect condition.
http://www.fccsonline.com/pic/jeep/3.07.04.b.jpg

They’re Borla, by the way

http://www.fccsonline.com/pic/jeep/3.07.04.c.jpg

Here you can see my growing collection of “lawn art” – my old ZJ axles, and the XJ axle I intended to build but never got around to. They’re all for sale! BUY THEM!

http://www.fccsonline.com/pic/jeep/3.07.04.d.jpg

So what am I replacing the old axles with? Krash80’s (Ron) old setup. He lives just south of Chicago, and I live in Pittsburgh, 450 or so miles away. Road trip! My dad, being the good guy he is, allowed me to drag him and his company WJ along. This way I got free gas and it only cost me the tolls, which were absurdly high I might add! Left at 6:30 am, and got to Ron’s at.. I don’t remember… 1pm his time? I knew he had a nice area to work on his rig in, but DAYUM! My house would fit in his garage maybe 6- 8 times, easily! My “tent” for that matter, well, it’d fit in there many more times than that ;)

http://www.fccsonline.com/pic/jeep/3.07.04.e.jpg

Ron might be the only guy I’ve met yet that has several vehicles just sitting around for parts, sale, fun, whatever. I only have room for my car and my Jeep. It’s depressing I tell you! I think I’m going to go live in his garage. He probably wouldn’t even notice.

http://www.fccsonline.com/pic/jeep/3.07.04.f.jpg

Now THAT’S a big@$$ axle… 14 bolt he’s putting in the rear-end of his Jeep. I thought I was moving up to a bigger axle, but he’s just going massive.

http://www.fccsonline.com/pic/jeep/3.07.04.g.jpg

Here’s a d30 diff cover sitting on top of (in side of) a 14 bolt cover. Which one do you think has a bigger ring gear?

http://www.fccsonline.com/pic/jeep/3.07.04.j.jpg


That’s a big freaking’ truck.

http://www.fccsonline.com/pic/jeep/3.07.04.h.jpg


Now I just KNEW that I didn’t own the only ZJ Hovercraft in the US! They’re multiplying!

http://www.fccsonline.com/pic/jeep/3.07.04.i.jpg


Yes dad, we’ll pose for the camera.

http://www.fccsonline.com/pic/jeep/3.07.04.k.jpg

Here are the axles on my back porch, no room in my garage or tent. I’m running out of room for this project fast, LOL. Front is an HP30 w/ 4.56 that I’ll be putting my no-slip in. Considering upgrading shafts, but I like the fact that standard shafts act like fuses and prevent me from tearing the ring and pinion up. It needs rebuilt due to pinion play, but Ron supplied me with the rebuild kit, project! I have to take the carrier out to put my No Slip locker in it anyway, might as well be redoing the rest!

Rear is a TJ44 w/ 4.56, Mosers, Rubi disc breaks, Detroit locker, and what Ron says is a stock track bar mount but I'm saying no way! If Jeep ever made a track bar mount out of 1/4" steel and reinforced it like this, I'd be rather impressed! Do they...?

I was origionally planning on 4linking it, but seeing as this TJ44 WILL BOLT UP with my long arms with no more modifications whatsoever, I see no need to. That solves my exhaust routing problems as well.

http://www.fccsonline.com/pic/jeep/3.07.04.l.jpg[/img]

OverkillZJ
03-06-2005, 12:55 PM
I love this thread! It's like my in-between, and after class Soap Opera that I follow dilligently every day :D

LOL, Jeep soap opera. I'd like to think my time put into the Jeep has a better outcome than a bunch of bitchy pregnant actors with no talent :lol: :angel: [/quote]

OverkillZJ
03-06-2005, 12:56 PM
I love this thread! It's like my in-between, and after class Soap Opera that I follow dilligently every day :D

LOL, Jeep soap opera. I'd like to think my time put into the Jeep has a better outcome than a bunch of bitchy pregnant actors with no talent :lol: :angel:

Hmm....
Soap opera's and Jeeps....this sounds familiar....
:friday:

Looks good Matt.
:)[/quote]

OverkillZJ
03-06-2005, 12:56 PM
Well, I decided it was time to pull the tcase. I’m going to be installing a “Tera 2 lo” in it, since I’m going to be locked front and rear, I have a feeling I’ll need it on the rocks @ Moab where there’s a lot more traction that I’m used to.

I did two stupid things… when replacing some of the studs when I installed the case over 2 years ago, I didn’t loctite them. So, when trying to unbolt the case from the tranny, I only got my ratcheting stubby wrench stuck there. It stayed there until the case was out. Since it’s ratcheting, I couldn’t just go the other direction… one way only… Derrrrr…..
http://www.fccsonline.com/pic/jeep/3.09.04.a.jpg

The second stupid thing was forgetting how much fluid spews when you break the seal between the tcase and the tranny. After seeing how much began to spew, I rushed for my drain pan. Of course, with the jack in the way it did nothing. So out came the peculiarly balanced funnel! That thing ended up being duct taped in place until it stopped dripping allover my wood garage floor.
http://www.fccsonline.com/pic/jeep/3.09.04.b.jpg


It’s out, and will sit there until I get the parts I need. It’s a JB conversions 231 HD w/ SYE for those that care.
http://www.fccsonline.com/pic/jeep/3.09.04.c.jpg


Next was chopping up the stock exhaust, to make unbolting the stock manifolds easier. I was beginning to think that I’d have to sell my new car just to pay for the amount of blades I was going through. There’s just nothing left on there….
http://www.fccsonline.com/pic/jeep/3.09.04.d.jpg

Yet, I’d say the saw won.

http://www.fccsonline.com/pic/jeep/3.09.04.e.jpg

I knew I’d get some good use out of this vice! I pulled the O2 sensors, since my budget is carefully planned yet tight, I might need to run these in the new exhaust temporarily until funds recover. We’ll see where I stand next month.

http://www.fccsonline.com/pic/jeep/3.09.04.f.jpg

Here I was killing power to the while ZJ for some work I’ll be doing soon… I rewired the Optima’s’ so they’re hard wired in parallel now, as I have them on a good gel cell specific float charger that should keep them at a perfect 13.56 volts while in storage. These will be coming out shortly for some repairs, and since I’m rewiring, well, everything.

http://www.fccsonline.com/pic/jeep/3.09.04.g.jpg

Man do I have my work cut out for me…

http://www.fccsonline.com/pic/jeep/3.09.04.h.jpg

Door panels would be nice too…

http://www.fccsonline.com/pic/jeep/3.09.04.i.jpg

Here’s something I wasn’t even planning on tackling just yet. It’s my Rubbermaid wiring box. Though it was a decent concept, I didn’t organize it as well as I should’ve, and the thing holds more mud and water in than it keeps out. As usual, me rushing into a solution without planning it out well enough first.

http://www.fccsonline.com/pic/jeep/3.09.04.j.jpg

Yet I did tackle it… all out… total rewiring time… The new wiring box will be water tight and where the stock air box used to be. Any guesses as to why?

http://www.fccsonline.com/pic/jeep/3.09.04.k.jpg

I didn't have as much time to work on the ZJ today as I'd planned. Customers kept breaking things. Oh well, the more they break the more money I have to spend on the project :thumbsup:

Ok. Bed time. Mid terms start tomorrow.

OverkillZJ
03-06-2005, 12:57 PM
And Matt you know it first get worse before its gets better.



Oh, it's about to start getting a HELL of a lot worse before it gets better... keep an eye on the updates ;)

OverkillZJ
03-06-2005, 12:58 PM
Matt-

When you put the TJ44 in, make sure post pics of how everything lines up and BOLTS IN for all the naysayers that claim TJ rears won't work under a ZJ.

BTW....when did you get carpet in your tent? :D

=Ron=

Ron, this is me. Do you really think that I'm going to put ANYTHING in that Jeep without taking lots of pics? :lol:

The axle installation might be delayed a little longer than I was expecting, I'm waiting on the 20 ton press I ordered, and still trying to hunt down a good price on a good dial gauge, as well as in. lb. dial type torque wrench.

I've had that carpet for awhile, just finally unrolled it :)
It was given to me and delivered for free, I had to use it somewhere! Makes it easier to neal than it is on concrete :cool:

OverkillZJ
03-06-2005, 12:58 PM
Sweeet… My jumbo wrenches came :D I put my size 10.5 shoe and a quarter in the pic as well for a size comparison. They’re freakin’ huge.
http://www.fccsonline.com/pic/jeep/3.13.04.a.jpg


I hate my rear bumper. Here’s me taking the tire carrier off. The shafts bent so I had to beat the hell out of it to remove it.
http://www.fccsonline.com/pic/jeep/3.13.04.b.jpg


It took a bit of pounding, almost tool carnage.
http://www.fccsonline.com/pic/jeep/3.13.04.c.jpg


This is how you remove a bumper when you don’t have anyone to help you. Let it fall!
http://www.fccsonline.com/pic/jeep/3.13.04.d.jpg


Time to take the doors off. I know the wires disconnect inside the b-pillar, but I decided to cut it here, and solder in some fancy harnesses that can be disconnected easily so I can take the doors off quickly whenever I want.
http://www.fccsonline.com/pic/jeep/3.13.04.e.jpg


Disassemble…
http://www.fccsonline.com/pic/jeep/3.13.04.f.jpg


…. Oh boy…..
http://www.fccsonline.com/pic/jeep/3.13.04.g.jpg


Well this one’s interesting. I’ve never wheeled anywhere illegal, let alone parked it anywhere for someone to leave me a note. This notes been in there for at least a year, hiding in the dirt under the seat among all of the old McDonalds fries I found.
http://www.fccsonline.com/pic/jeep/3.13.04.h.jpg


Ya, this thing needs some cleaning.
http://www.fccsonline.com/pic/jeep/3.13.04.i.jpg


Too many wires… All need to go. Don’t even ask what I was thinking. At one point in time I had different plans for the Jeep that involved LOTS of wires… no longer…
http://www.fccsonline.com/pic/jeep/3.13.04.j.jpg


Man was that tiring. Red Tops are out. The boxes will be coming out too, but I need to cut off the bolts since they’re all bent up.
http://www.fccsonline.com/pic/jeep/3.13.04.k.jpg


My hatch hasn’t been open in over a year, since like most ZJ’s it doesn’t work anymore! I popped the panel and stuck my hand down there and found the release rod, but ouch, I have cuts all over my arm. None the less, it’s open, and I’ll fix the latch.
http://www.fccsonline.com/pic/jeep/3.13.04.l.jpg
http://www.fccsonline.com/pic/jeep/3.13.04.m.jpg


Batteries happily floating on the charger…
http://www.fccsonline.com/pic/jeep/3.13.04.n.jpg


When I decided to have a music room, I wasn’t really planning on having 4 Jeep doors in it. The seat bottoms are under the bed along with a few door panels.
http://www.fccsonline.com/pic/jeep/3.13.04.o.jpg


I wasn’t really planning on having leather ZJ seats next to my couch either. Oh well, it works.
http://www.fccsonline.com/pic/jeep/3.13.04.p.jpg

Back at it tomorrow.

OverkillZJ
03-06-2005, 12:59 PM
What harnesses you use for the door quick disconnect?

Chad

I'll let you know as soon as I figure it out :thumbsup:

The only one's I have are 2 conductor, but I need to find a flat 6 conductor that's water resistent. I'll come up with one soon and post it

OverkillZJ
03-06-2005, 12:59 PM
http://www.msdignition.com/1protool.htm

Check the Deutsch Connectors

http://www.andersonpower.com/index.html


Chad

Those Deutsch connectors would be perfect, except that I can't find a source for them, and when I do I bet they're expensive. I might just do this:

http://www.allelectronics.com/cgi-bin/category.cgi?category=189&item=CON-60&type=store

Not really weatherproof, but they pull apart easily enough to clean the contacts, and are cheap enough to replace entirely when needed...





Looks like you're really getting into it. Maybe you should paint it yellow ;-)
Who made that rear bumper? Looks nice.

Is the carpet glued down, or does it come right out.

Yellow is something I first started thinking about 2 years ago... When the time comes for a new paint job, it's going to be yellow!

That rear bumper is Kennesaw Mountain. I can't advise against it enough... it looks nice, but that's all. It's a POS and it's nothing but trouble :pant:

There's no carpet, it has 2 layers of Cascade spray on sound dampaner, with 2 coats of herculiner over it. It's as quiet as stock, but I kind of miss carpet... I might put carpet in....

The stock carpet does come right out though, no glue. Just tucked under the panels.

OverkillZJ
03-06-2005, 01:00 PM
That rear bumper is Kennesaw Mountain. I can't advise against it enough... it looks nice, but that's all. It's a POS and it's nothing but trouble :pant:


A friend of mine has one on his 4 runner and it gave him nothing but trouble for over a year. The hinge got stuck and he wasn't able to open it. He took it back to Kyle at Kenn. Mtn and he replaced and lubricated the hinge properly. Now, the tire carrier will swing out to the end of its range of motion with the lightest push. I know you're a long way from Kennesaw, GA, but Kyle wants to keep his business and will fix it for free.

Good to know he'd fix it for free, but between paying freight to get it there, or driving it there myself... I'll eat the 8 hours of time to fix it myself. I'm planning on changing the mounting system and moving the tire location down 8" anyway. The welds on that thing are less than ideal as well...

Ok... eating some late lunch then back out to the POS.

OverkillZJ
03-06-2005, 01:01 PM
A local hot rod shop should be able to order you the msd connectors.

Chad
I need to find a local hotrod shop in that case. Need so get quotes on some custom exhaust bending anyway :smile:

OverkillZJ
03-06-2005, 01:01 PM
Lot’s and lots of griding rusted bolts away later, the batteries are out.
http://www.fccsonline.com/pic/jeep/3.14.04.a.jpg


Radio’s out, and what needs to be out of the dash is out…
http://www.fccsonline.com/pic/jeep/3.14.04.b.jpg


Still need to clean up all the ugly stinkin’ mud. I don’t even know how it got in there…. Right, that’s it.
http://www.fccsonline.com/pic/jeep/3.14.04.c.jpg


Drivers side exhaust manifold out, along with the steering hoses. I’m replacing the steering box and the steering pump. They’re both a year old and have lifetime warranties; I don’t know which ones busted so I’m just replacing them both. No cost to me anyway…
http://www.fccsonline.com/pic/jeep/3.14.04.d.jpg


Charcoal canister removed. I found out why I had gas smells from the front… when I removed it, I found a great big gash at the top, guess I slammed it on one too many rocks. I need a new one (junkyard) and will be placing it in the engine compartment this time.
http://www.fccsonline.com/pic/jeep/3.14.04.e.jpg


Alternators coming out for a bit of a check up (making bearing noises.)
http://www.fccsonline.com/pic/jeep/3.14.04.f.jpg


Taking off the filter for my tranny bypass-filter.
http://www.fccsonline.com/pic/jeep/3.14.04.g.jpg


I couldn’t end the night without breaking something. This header bolt sheered right off.
http://www.fccsonline.com/pic/jeep/3.14.04.h.jpg


Once again, I backed my ratchet into a corner I couldn’t get it out of. I really need to stop doing that…
http://www.fccsonline.com/pic/jeep/3.14.04.i.jpg


Now, I don’t know what the hell all of you are always bitching about as far as removing the passenger’s side manifold. It’s REALLY easy when there’s no axle under it… unbolt it, let it fall!!!
http://www.fccsonline.com/pic/jeep/3.14.04.j.jpg


I came across my first big problem in this build. I thought all 93-97 Borla headers were the same… meaning I thought they’d fit my 97 without a problem. I was wrong, seems to be happening a lot lately. See any differences in the pic below? I guess I have to make some kind of block-off plate for the new headers… this sucks.
http://www.fccsonline.com/pic/jeep/3.14.04.k.jpg


I found the worlds ugliest bug under the dash cowl, looks like it’s been there for a couple of years…
http://www.fccsonline.com/pic/jeep/3.14.04.l.jpg

OverkillZJ
03-06-2005, 01:03 PM
Looks like fun, I've got to get me a tent to work on the Jeep, but actually I don't have the land for it either :-(. Anyways I really enjoy reading the daily updates, it's just so real, I mean the stuck and broken parts etc. as well as the boneheaded moves that we all make that normaly you just don't hear about in most walk throughs. Keep up the good work.

The tents great, but kind of scary when it's windy. It'd be MUCH nicer to have concrete under it. The wood works for now, but I'm sure it won't last. I'm having trouble cleaning parts of the Jeep above the wood, not like I can just hose it all down like I want to. The biggest problem is that it scares the hell out of me having it up on stands on wood. It seems pretty stable, but everytime I'm under it I just think "what if this thing falls..." I'll be getting a house (no more renting) in August, we'll see the fate of the tent then... depends on the size of a garage I can find; if I have it my way I'll just live in a garage!
boneheaded moves in here... like the one where I was pulling wires through the conduit throught the firewall today, slipped, and ended up
Glad you enjoy the updates, but I must admit I don't put ALL of my nailing myself in the nuts. My friend Jeff was there and I'm afraid he'll never let me live it down. I didn't post the pics of me sitting in the shop stool while it was in the Jeep either, it was just too stupid ;)

OverkillZJ
03-06-2005, 01:03 PM
Seeing as my ZJ needed a better name than "POS" or "Project" I've been thinking about names for it. Genesis kept crossing my mind, but it's too freaking biblical. My mom came up with The Phoenix. For those of you who don't know what a Phoenix is, it's a mythical bird that is born out of it's own ashes. Never truly dies, is always reborn after burning. Seems fitting for this project. This is it's second birth, and I'm sure there will be a few more throughout my lifetime.

The name has much more deep meaning than that make it fitting, but I'll let you read up on it yourself if you're interested. http://www.mythicalrealm.com/creatures/phoenix.html

http://www.fccsonline.com/pic/jeep/phoenix.jpg

OverkillZJ
03-06-2005, 01:04 PM
Prolly a stupid question, but I love your detialed pics and I've been going through each one closely...... so.....what is this?
http://www.jeepcrew.com/uploads/whatsthis.jpg

OverkillZJ
03-06-2005, 01:04 PM
Appearently you don't read my thread CLOSELY ENOUGH, now do you? Sheesh. That's the hover lever. It's a hovercraft ZJ after all, you think you can still control it with a steering wheel? HA!

No, really, it's a laptop mount :grin: :thumbsup:

OverkillZJ
03-06-2005, 01:04 PM
When do you start putting stuff on as opposed to taking it off? ;) This looks like a MAJOR job!


Stuff starts going back on this weekend actually; as far as I'm concerned I'm WELL ahead of schedule! Most of the works going to be in May. School ends May 03rd, and I'm going to contract out a lot of my business work that month just so I can devote 30 days to nothing but working on the ZJ. If I can't do it in that timeframe, I don't deserve to own it!





BTW - Is your brother Pat still into wheeling? I'll never forget the day I found him by himself in Moab out of his jeep spotting himself down a 4+ obstacle. He would jump out of his XJ....get in front of it to check the tire placement and then jump back in and drive for 2ft then repeat as necessary....it was a funny sight :lol: Definitely a cool dude to wheel with :)

Yup, he's still wheeling! Actually, he moved to Westcliff Colorado last summer. When you saw him, he was taking a cross-country road trip to pick a place to live. He's got a good job teaching there now (4 days a week... lucky b@$sard...) and is looking at houses to buy with big garages... He'll be coming to Moab for a few days after GSW to get some Jeeping in if anyone's interested :thumbsup:

I'll also (hopefuly) be out there for a few days before GSW as well, wheeling with my buddy Mark who moved to CO when Pat did. They're both lucky b@$tards.

OverkillZJ
03-06-2005, 01:05 PM
but boneheads was so fitting... :lol:
Not quite as funny as draincock (with a space) coming out as drain cock. I was very confused at first.

OverkillZJ
03-06-2005, 01:05 PM
Yay... I've got a new steering box, steering pump (need to order a new pulley still) and all the stuff to get the headers on... various grade 8 bolts to replace the stock crap... etc....New plugs too.... yay...

Hopefully I'll actually get to the thing this weekend...

OverkillZJ
03-06-2005, 01:05 PM
If you don't mind me asking... how much money is this little project setting you back?

I cringe at the thought.

Not as much as you think (or maybe it is), since all the expensive stuff I got 2 years ago I'm reusing. Still adding up though. I'll post the weekend updates later.

OverkillZJ
03-06-2005, 01:06 PM
Prolly a stupid question, but I love your detialed pics and I've been going through each one closely...... so.....what is this?
http://www.jeepcrew.com/uploads/whatsthis.jpg

Better question..whats up with the Ghetto fabulous pedal covers that light up. I didn't notice them till tonight. Whats next?? Altezza Euro brake lights??? :lol: :lol: :lol:

Justs razzin ya. :thumbsup:

They're so I can find the pedals after a hard day of wheelin!

Actually those pedals are harder for muddy boots to slip off of. I suppose I didn't need to get the ones that actaully light up though to have that functionality....

Besides, when I have it all together with the good CB, laptop, radio, and gauge pod all on... It looks pretty ricer-sweet! :thumbsup:

OverkillZJ
03-06-2005, 01:06 PM
I didn’t get as much done this weekend as I wanted to, but when does anything with a ZJ ever go as planned?

Anyway, starting with the new arrivals…. What’s in the boxes?
http://www.fccsonline.com/pic/jeep/3.21.04.a.jpg

That’s right, CHEAP TOOLS!
http://www.fccsonline.com/pic/jeep/3.21.04.b.jpg

I love how at first glance; it looks as if they’re warning you that this tool is made in China, and therefore is like a time bomb.
http://www.fccsonline.com/pic/jeep/3.21.04.c.jpg

Now what….
http://www.fccsonline.com/pic/jeep/3.21.04.d.jpg

Finally, I got a radio that gets more than 1 station in this mini-valley I’m in. It’s an old Sansui from the late 70’s. Knowing my dad it was probably the first digital tuner on the market and cost him his soul. He likes his toys, sounds kinda familiar.
http://www.fccsonline.com/pic/jeep/3.21.04.e.jpg

It’s officially starting to look like a project. There’s new and old parts’ laying EVERYWHERE.
http://www.fccsonline.com/pic/jeep/3.21.04.f.jpg

New plugs gapped to stock spec. I had platinums in there, and they really ran well. I just can’t justify the price difference, and I’m the kind of guy who wants to change them more often than needed anyway. The Truck Plugs are pretty anyway!
http://www.fccsonline.com/pic/jeep/3.21.04.g.jpg

Drivers side header in. I used grade 8 bolts, amazingly it was CHEAPER than any header bolt set I could find. That includes the 4 extras I got.
http://www.fccsonline.com/pic/jeep/3.21.04.h.jpg
http://www.fccsonline.com/pic/jeep/3.21.04.i.jpg

Passenger side SUCKED. When I took the stock manifold off, I thought I was being all sneaky and stuff. With no axle under the jeep, it was relatively easy to unbolt and let of fall out. Not that simple with the new headers, they don't fit in that tight space... I had to do it the old school way justlike everyone else did. I thought I was special… I still hadn’t made the block off plate for that extra EGR port at this point, that’s the next day.
http://www.fccsonline.com/pic/jeep/3.21.04.j.jpg
http://www.fccsonline.com/pic/jeep/3.21.04.k.jpg

Continued in a few.....

OverkillZJ
03-06-2005, 01:07 PM
Last year, I blew up a steering hose. I realized that the wire harness was still SOAKED in the stuff a year later. I also realized that OH! PS FLUID EATS SOFT RUBBER! Like that on wires… I know this because I had a temp sensor on my old steering pump, and the wire was soaked in the fluid for the last year. There’s hardly any wire left on the wire, the fluid ate away at it. Interesting. Anyway, I decided to unravel the harness to inspect the wires, clean them, and re-wrap once the wire looming I ordered comes in.
http://www.fccsonline.com/pic/jeep/3.22.04.a.jpg

You can see how the fluid did a job on the outer part of the harness here.
http://www.fccsonline.com/pic/jeep/3.22.04.b.jpg

I had LOTS of crushed fins on the A/C condenser. I spent [i]hours[/] straightening lots of them out with a raiser blade. I figure about 10% of the fins were crushed.
http://www.fccsonline.com/pic/jeep/3.22.04.c.jpg

Better. The bottom was the worst, it was harder than the upper parts.
http://www.fccsonline.com/pic/jeep/3.22.04.d.jpg

Time to clean all the muck out….. I was AMAZED at how much mud came out of the radiator and engine compartment as a whole, considering I hosed it rather well before I put it in the tent.
http://www.fccsonline.com/pic/jeep/3.22.04.e.jpg

It’s here that I REALLY wish I had concrete in my tent. It was 20 degrees out. Yet I was washing my Jeep. The water ran down the tarp and outside, where it froze into one large puddle.
http://www.fccsonline.com/pic/jeep/3.22.04.f.jpg

Well here was my big blooper of the day. I’ll blame it on being distracted by those drinking who showed up for my little wrench fest. I was trying to get at that tranny cooler line you see there, to grind the end a bit flatter (can’t find my tubing cutter…) Obviously, I nicked the coolant hose. It could’ve been MUCH worse. Good thing came of it, one of the new guys that showed up, Dave, works at Advance Auto. I was at school today when I got a message on my phone that said “Hey Matt, this is Dave; your new radiator hoses are in, just come by and pick them up when you get the chance.”

That ruled.

I’m probably going to do heater, and bypass hoses while I’m at it. And as long as I’m in there, I think I’m putting in a FlowKooler water pump, and Robert Shaw t-stat. Debating between 180 and stock, too many arguments to make an educated decision. This is all just more work than I’d planned on. I’m 1/8 done with the project, and it’s over budget already. Typical.
http://www.fccsonline.com/pic/jeep/3.22.04.g.jpg


Is it me, or do the V8 ZJ’s have the worlds UGLIEST oil pans? It is supposed to be like that…. Right? (I hope.)
http://www.fccsonline.com/pic/jeep/3.22.04.h.jpg

I forgot how much fun oxy torches are…. Hence the $hit eating grin on my face. Time to make the block off plate for those headers!
http://www.fccsonline.com/pic/jeep/3.22.04.i.jpg
http://www.fccsonline.com/pic/jeep/3.22.04.j.jpg

First Jeff was introduced to the BFH. For a computer geek, he catches on to “pound and cut stuff” pretty quick!
http://www.fccsonline.com/pic/jeep/3.22.04.k.jpg


Oops.
http://www.fccsonline.com/pic/jeep/3.22.04.l.jpg
http://www.fccsonline.com/pic/jeep/3.22.04.m.jpg
http://www.fccsonline.com/pic/jeep/3.22.04.n.jpg
http://www.fccsonline.com/pic/jeep/3.22.04.o.jpg
http://www.fccsonline.com/pic/jeep/3.22.04.p.jpg

I’m rather proud of the finished product (before high temp paint anyway.) On the left is the gasket I used as a template, on the right is the plate I made. Props to Jeff for his first lil fabrication project!

Hopefully I’ll be able to just bolt it over that EGR plug and it’ll seal perfectly. I won’t know, won’t be firing that engine up for awhile.
http://www.fccsonline.com/pic/jeep/3.22.04.q.jpg

Did anyone ever tell you that playing with fire is dangerous? Well it’s also REALLY REALLY FUN. Good stress relief too! I bought a nice new hammer, so the old POS had to go!
http://www.fccsonline.com/pic/jeep/3.22.04.r.jpg
http://www.fccsonline.com/pic/jeep/3.22.04.s.jpg
http://www.fccsonline.com/pic/jeep/3.22.04.t.jpg
http://www.fccsonline.com/pic/jeep/3.22.04.u.jpg
http://www.fccsonline.com/pic/jeep/3.22.04.v.jpg
http://www.fccsonline.com/pic/jeep/3.22.04.w.jpg


I also got the new tranny cooler mounted, I forgot to take pics though. Not done with the plumbing just yet anyway.

OverkillZJ
03-06-2005, 01:08 PM
Open headers RULE!

Finished the EGR blockoff plate, got the ignition all tuned up and put back in... My brothers in town from CO, glad he could be there to hear the results of open Borla headers. Scared the hell out of me.... I posted two of the clips - 1.5MB each.

http://www.fccsonline.com/pic/jeep/headers3.wav
and
http://www.fccsonline.com/pic/jeep/headers4.wav


Also ordered the Tera 2-lo fork today, and some stuff from Kolak:

Flowkooler high flow water pump
Stant Superstat stainless steel 180 degree thermostat with gasket
Car Sound high flow 3" converter
Mopar upstream O2 sensor

I'm broke.

20 ton press is on it's way. Looks like all the stuff WILL be here in time for my full week of wrenching... Let's see if I can get some of this thing put back together!

OverkillZJ
03-06-2005, 01:08 PM
how much was the flow cooler water pump? I think my pump is on its way out so I guess its time to find a replacement.

It was about 3x the price of a rebuilt stock unit from Napa or Advance (not sure if I'm allowed to post prices here...) But seeing how many stock replacents fail people, and how few failures of flowkoolers I hear about, I feel that it's rather justified. I'm trying to build it for reliability and function, not cheap parts :thumbsup:

OverkillZJ
03-06-2005, 01:09 PM
Here’s another picture of the Jeep Parts Getter (daytime shot). I wonder how much trouble I’ll have switching between the ZJ-beast-thing and the Corolla?
http://www.fccsonline.com/pic/jeep/3.23.04.a.jpg

Here’s a picture of the block off plate installed… Painted the outside with 1200f+ exhaust paint, hoping to keep it from rusting out over time. Still like the way that little piece came out.
http://www.fccsonline.com/pic/jeep/3.23.04.b.jpg

Picture of the new auxiliary tranny cooler, stacked plate design as opposed to the fins that sucked so much on the stock one.
http://www.fccsonline.com/pic/jeep/3.23.04.c.jpg

That should be it ‘til spring break (starting Saturday).

OverkillZJ
03-06-2005, 01:10 PM
I gotta put in my 2 cents...

Matt,
That's an awesome job you are doing! I wish i had the stamina and guts to do what you are doing. My ZJ is sadly 2WD and I don't have the funds to lift or convert to 4WD. It looks like its coming along really well. Those headers sound good. Good luck with the project.... btw.... how's the Corolla? My friend wants one exactly like the one you have. My ZJ is in need of some suspension stuff. If you need poly. track bar bushings, I have them and have no need for them. They were for my old ZJ but i wrecked it. Good luck!!!

Carlo

Thanks, I like those 2 cents!!! It's always nice to get some positive feedback, especially when I'm at the point of "dear lord, what have I gotten myself into?"


My ZJ sat rusting for about a year and a half. I didn't have the heart to sell it (attachment issues ;)) and I didn't have the resources to work on it. I was living in a town house with a shared garage, from which I was banned from wrenching in, after cutting with my oxy setup scared one of the more elderly tenants :lol:

Then the decision was made to move to a house with a garage, so I could work on the Jeep, plus start playing my Drums, Piano, and Guitars whenever the hell I felt like it, and as loudly as I felt like it. I HATE having unfinished projects, such as the Jeep.

I Had a GREAT house lined up to rent; but the landlord decided they fixed it up so nicely that they were going to move into it themselves. I was pissed off, and had a month until my lease was up. I ended up where I am now, which obviously has a crappy one car garage and a gravel driveway. So along came the tent. Built the wood platform (help form my dad, he’s too good to me) and wired in some electrical, including the heater… Bought a crapload more tools, and started tearing it apart! I decided if I was going to fix it up, I was going to do it right and not skimp on anything.

So far everything is going as planned (except for the budget and several things I need to replace and hadn’t planned on…) In the end, I think it will be worth it to have a very reliable and well built ZJ that I can drive across the country for some good Moab wheelin’ every year :thumbsup:

Until it’s done, I’ll remain just as I am now… Stressed to all hell and worrying about what might go wrong during the next step. Most of the work on the ZJ will probably be during summer break (starting in May) – I’m off from school, and will hopefully be outsourcing some of my business so I can focus on finishing the project.



As far as the Corolla goes, I couldn’t possibly be happier with it. It’s quiet, it’s peppy, and it’s a comfortable ride; yet it handles like a sports car. Plus I’ve been getting 29MPG in the city (and the engine isn’t even broken in yet, only 800 miles on it). Best of all, IT HAS A WARRANTY AND I DON’T HAVE TO WORK ON IT! WHOOOHOOOOO!

I might end up taking you up on those bushings depending on what you want for them, I recently put poly in the front track bar, but I’m not sure about the rear, I need to check. I hate poly bushings in control arms, but I don’t think that it can be beat when it comes to track bars.

Ok. Time to study… Last big test before spring break is tomorrow morning (though my spring break will be nothing but a big Jeep wrenching week.)

:band:

OverkillZJ
03-06-2005, 01:10 PM
Thanks for all of the compliments, and the good lucks (I'm going to need it.)

Nate - You're right, that's WEIRD. I hadn't bought plugs in 2 years, and I remembered the Truck plugs being much cheaper, so I didn't even check on the Platinums. Oh well, I think I feel better running copper anyway.

OverkillZJ
03-06-2005, 01:11 PM
Dude...your giggling like a school girl in that wav file.....What a pack of idiots. You can come wrench with me anytime.

Ummmm, thanks?? :roll:

EDIT: Are you implying that you only wrench with packs of idiots? :spank: :pant:

OverkillZJ
03-06-2005, 01:11 PM
Matt,
I know you dont need my $.02 but here goes, Burn it to the ground and Collect the insurance on it.

Seriously now,
Thats a SHITLOAD of work, props to ya, Most any idiot can take it apart, but putting it back together is another story. :D

Good Job.
AW

OverkillZJ
03-06-2005, 01:12 PM
uhhh what was i saying? :thumbsup:


Well, I do believe that you were in the middle of calling yourself an "entire pack of idiots!" :thumbsup:


Matt,
I know you dont need my $.02 but here goes, Burn it to the ground and Collect the insurance on it.

Seriously now,
Thats a SHITLOAD of work, props to ya, Most any idiot can take it apart, but putting it back together is another story. :D

Good Job.
AW

Don't worry, I'll get it back together and better than new (seriously.) When I'm determined to do something, it becomes an obsession until I get it done.

Besides, the insurance on that thing wouldn't cover 1/3rd of the aftermarket stuff on there :cry:

And don't tell me good job until it IS back together :thumbsup: :lol: :eek:

OverkillZJ
03-06-2005, 01:12 PM
Dude...your giggling like a school girl in that wav file.....What a pack of idiots. You can come wrench with me anytime.

Ummmm, thanks?? :roll:

EDIT: Are you implying that you only wrench with packs of idiots? :spank: :pant:

If you knew me and my buds....you would not have to ask.

Examples:

I have......

Been Hit with a 12 pound sledghammer, TWICE.

Been Lit on Fire more than once.

been witness to a Scout we were bobbing the back off of flip off the overhead rack 6 feet off the ground and smash into a 15K Sanp On toolbox

Backed into and smashed, pressure washers, pickups, vans and countless other things all not in my Jeep or Pickup but was working on my Jeep.

Started an engine with the tranny cooler lines not hooked up (Sound familiar).

Been withness to a buddy buy a 60 dollar stanless steel latch and then Weld it on reuining the entire thing.

The list goes on forever

OverkillZJ
03-06-2005, 01:13 PM
Dude...your giggling like a school girl in that wav file.....What a pack of idiots. You can come wrench with me anytime.

Ummmm, thanks?? :roll:

EDIT: Are you implying that you only wrench with packs of idiots? :spank: :pant:

If you knew me and my buds....you would not have to ask.



The list goes on forever


I'd pay to see some of that :thumbsup:

OverkillZJ
03-06-2005, 01:13 PM
Dude...your giggling like a school girl in that wav file.....What a pack of idiots. You can come wrench with me anytime.

Ummmm, thanks?? :roll:

EDIT: Are you implying that you only wrench with packs of idiots? :spank: :pant:

:lol: :lol: :lol:

OverkillZJ
03-06-2005, 01:14 PM
Started an engine with the tranny cooler lines not hooked up (Sound familiar).




I just noticed that last one :lol:

It does sound familar. The good news is I couldn't remember which line was send and which was receive... I now know, since it shot a good 4 feet, and that was AFTER it flew through the radiator. I wonder how far it would shoot with no obstructions.....

I'm picking up my brothers GF at the airport shortly, whom I've never met. The first thing he wants me to do is let her hear the open headers. I'm thoroughly convinced that this is so she knows that I'm more insane than my brother when it comes to jeeps, so that she'll give him some slack on the subject.

OverkillZJ
03-06-2005, 01:14 PM
I'm picking up my brothers GF at the airport shortly, whom I've never met. The first thing he wants me to do is let her hear the open headers. I'm thoroughly convinced that this is so she knows that I'm more insane than my brother when it comes to jeeps, so that she'll give him some slack on the subject.

:lol: :lol: :lol: :lol: :lol: :lol:

Now that's some funnnnnnnny shiat.

Your project is looking great Matt!!

I'd have more done it Bill hadn't argued about how I wanted to mount the tranny cooler for a few hours ;)

I was wrong.. Spring break isn't this week.. it's NEXT week... so my huge daily updates will be next week... Works out well, more parts wiill be in by then.

OverkillZJ
03-06-2005, 01:15 PM
I'd have more done if Bill hadn't argued about how I wanted to mount the tranny cooler for a few hours ;)

Tell him to go play with his jetta.
:lol:
;)

Pulled the 44 apart last night. Gear pattern looks purdy.
:thumbsup:

:lol: :thumbsup: :pant:


I haven't even touched my axles yet, let alone decided what to do about steering :crazy

OverkillZJ
03-06-2005, 01:15 PM
The family came over, including my brother and his GF from Colorado and they wanted to hear the headers. How could I say no? This was the last time, however, as the backfires made my elderly neighbors think that I was shooting someone. Oops.

Sound clip: http://www.fccsonline.com/pic/jeep/headers5.wav


I started off the day by finishing the plumbing of the new tranny cooler. Since my stock lines were leaking like mad, I just cut them out and replaced them with rubber hose. I’d already cut them with my sawzall, but it made such a mess I did them again once I found my little pipe cutter.
http://www.fccsonline.com/pic/jeep/3.28.04.a.jpg
http://www.fccsonline.com/pic/jeep/3.28.04.b.jpg

Cleaning up the rusty cross member…
http://www.fccsonline.com/pic/jeep/3.28.04.b1.jpg

Getting there…..
http://www.fccsonline.com/pic/jeep/3.28.04.b2.jpg



If there’s any design flaw in Claytons long arms at all, it’s the lack of drainage in the cross member. Water sits in there until it dehydrates or swishes out… Decided to add some drain holes.
http://www.fccsonline.com/pic/jeep/3.28.04.c.jpg


Much better! IT DRAINS!
http://www.fccsonline.com/pic/jeep/3.28.04.d.jpg


I forgot what a mess removing the tranny plug makes. WOW taking that thing off just sucks. One reason I’m installing a drain plug ;)
http://www.fccsonline.com/pic/jeep/3.28.04.g.jpg


Randy showed up and wanted to use the torch. Why are all my friends obsessed with fire? I mean really, is cutting metal with fire really THAT cool?





You’re right… it is…
http://www.fccsonline.com/pic/jeep/3.28.04.h.jpg


Painting the cross member with a “hammered look” grey from Rustoleum. Home depot and Sears were both out of Hammerite.
http://www.fccsonline.com/pic/jeep/3.28.04.i.jpg


Drilling the 1/2" hole for drain plug… I wanted it on the side to avoid being hit by rocks, even though it won’t drain out as much fluid. The pan needs to be removed to change the filter anyway.
http://www.fccsonline.com/pic/jeep/3.28.04.j.jpg


Here’s my “to do” porch. Both axles need work, both bumpers need LOTS of work.
http://www.fccsonline.com/pic/jeep/3.28.04.k.jpg



http://www.fccsonline.com/pic/jeep/3.28.04.l.jpg

Yay…. Tedious time consuming crap…
http://www.fccsonline.com/pic/jeep/3.28.04.m.jpg


I was planning on reusing my old muffler and tailpipe since funds are REALLY tight, but, well. You can see the results for yourself.
http://www.fccsonline.com/pic/jeep/3.28.04.n.jpg
http://www.fccsonline.com/pic/jeep/3.28.04.o.jpg


I got the stuff for the shift linkage TSB 2 years ago and never installed it. In fact, I haven’t had working shift linkage since I installed my JB Conversions 231 w/ SYE over 2.5 years ago. I got part of it in when I realized that I can’t even do it all until the tcase is back in, so I can raise the driveline to the usual level.
http://www.fccsonline.com/pic/jeep/3.28.04.p.jpg


Nice weather +grill = LUNCH! MMMM… smoked sausage…..
http://www.fccsonline.com/pic/jeep/3.28.04.q.jpg


More tedious crap I didn’t allot time for…. Cleaning up the threads on bolts I’m reusing…
http://www.fccsonline.com/pic/jeep/3.28.04.r.jpg


Painting = tedious
http://www.fccsonline.com/pic/jeep/3.28.04.s.jpg
http://www.fccsonline.com/pic/jeep/3.28.04.t.jpg


Purdy tranny pan…
http://www.fccsonline.com/pic/jeep/3.28.04.u.jpg


Wait a tic, that’s not quite right… A vice and BF dead blow hammer later, all fixed. I learned that the BFH is your friend when doing exhaust work.
http://www.fccsonline.com/pic/jeep/3.28.04.v.jpg


In this one shot shows most of my efforts for the weekend. Exhaust done back to where the cat should be, painted tranny pan (was rusting) and installed drain plug + new filter, part of shifter TSB in place, and painted cross member thingy.
http://www.fccsonline.com/pic/jeep/3.28.04.w.jpg


What must the neighbors think?
http://www.fccsonline.com/pic/jeep/3.28.04.x.jpg

OverkillZJ
03-06-2005, 01:16 PM
IOP 10 :D Ah, my day is complete, now I can head to bed.

LOL. :lol:

You might want to keep some popcorn handy for next weeks updates ;) (I hope)

OverkillZJ
03-06-2005, 01:16 PM
Where'd you get the tranny plug at? Just drill a hole and it bolts together I'm guessing?

Pretty much, I picked up a B&M From Napa for about $5

OverkillZJ
03-06-2005, 01:17 PM
You might want to flair the ends if the tranny cooler lines to keep the rubber lines from comming off.

Chad

I was thinking the same thing. Double clamping wouldn't hurt either. Cheap insurance. It's one thing to dump tranny fluid all over the garage...er...tent. Different matter entirely on the trail or highway.

Man, I wish I had time to come out and wrench some with ya. That's what I call fun. And when you're done you can stand back and admire the result. Then you get to test drive it. Then you get to break something. Then you get to do some more and continue the cycle. Funny that some people don't get it.

crud. You're both right, I planned on flairing the ends, and for some reason I completely forgot when I was actually in there doing it.



This brings the suck.



Come wrench, I'm going to need the help and a miracle to finish this thing.

OverkillZJ
03-06-2005, 01:17 PM
There’s been some talk amongst friends that that there’s “no way in hell I’m going to get this done in time.” – care to put your money where your mouth is, anyone? Bueler? Bueler?

It’ll be done. I’m not guaranteeing I won’t be halfway through Kansas when it throws a rod, but it’ll be leaving Pittsburgh PA on time 


So on with the soap opera!
Every time Jeff comes over to help, it’s the same thing. We break something.
http://www.fccsonline.com/pic/jeep/4.01.04.a.jpg

Then we eat dinner. Rather predictable.
First night we hung out doing “geek stuff” I shocked myself on 120 “pretty good” – I think that set the precedence for our wrenching sessions as well.
http://www.fccsonline.com/pic/jeep/4.01.04.b.jpg

Tuesday was planned to be a full day of wrenching, but I never got to touch a tool (of the non-geek variety anyway.) When one of my more important clients’ hard drives crashed, and he hadn’t backed up to tape in months, it seemed more important than the ZJ. Good news is I now have more money towards tiers! I figure if it’s something that takes my time AWAY from the Jeep, then it’s part of the Jeep soap opera/saga.
http://www.fccsonline.com/pic/jeep/4.01.04.c.jpg

New arrivals (thanks mostly to Kolak) Flowkooler waterpump, Staunt Superstat w/ gasket, Mopar upstream o2 sensor (downstream is kinda newer, 20k or so) 3” car sound cat, 1” wiring loom, and TERA 2-LO! No, not TERA LOW, tera 2 low. For those of you that don’t know, this will allow me to use 2WD while in low range, a huge advantage since I run a locker in the front that made for some 5-point turns in the past.
http://www.fccsonline.com/pic/jeep/4.01.04.d.jpg

Just stocking up…
http://www.fccsonline.com/pic/jeep/4.01.04.e.jpg

Made a crappy tool out of some metal I had laying around, to hold the water pump pulley still while I turned the viscous fan’s nut. Did that sound perverted, or is it just me?
http://www.fccsonline.com/pic/jeep/4.01.04.f.jpg

Break from real wrenching… 20 ton press came. It arrived in an 18 wheeler that didn’t fit on my damn street, so I had to put it halfway in my poor corolla. Only 300 lbs, but that’s the most that car’s ever moved :)
http://www.fccsonline.com/pic/jeep/4.01.04.g.jpg

The idiots at Harbor Freight (I hate that place) forgot to include my free arbor plates. I’ll call to bitch about it later…. None the less, it’s assembled and it works quite well at bending weak metal. I know it’s Harbor Freight, but I was pleased with the welded frame construction. My local supplier of “good presses” failed to return my phone calls one too many times for me to give them my money.
http://www.fccsonline.com/pic/jeep/4.01.04.h.jpg

Moving that thing into place by myself kind of sucked.
http://www.fccsonline.com/pic/jeep/4.01.04.i.jpg

Anyway, back to the work at hand. Here’s my tool in action… Only one of the bolt holes ended up lining up like I wanted it to, but it worked like a charm anyway. That is… AFTER I started turning the nut in the correct direction. Seems there was some bad information in a thread I found on JU. Lefty still = loosy when doing this… when FACING the pump.
http://www.fccsonline.com/pic/jeep/4.01.04.j.jpg

Drained the engine blocks coolant, put it in my shiny new pep boys bucket, and taped it up w/ foil and saran wrap. It’s new, so I plan on reusing it.
http://www.fccsonline.com/pic/jeep/4.01.04.k.jpg

Who’se bright idea was it to put those tranny cooling lines right under the stupid drain plug anyway? Really, when the coolant hits them before a trickle, it splatters it everywhere. As usual, I made a mess and soaked my wood floor… again…
http://www.fccsonline.com/pic/jeep/4.01.04.k2.jpg

Once again I’m left asking myself “What have I done.”
http://www.fccsonline.com/pic/jeep/4.01.04.l.jpg

http://www.fccsonline.com/pic/jeep/4.01.04.m.jpg
http://www.fccsonline.com/pic/jeep/4.01.04.n.jpg
http://www.fccsonline.com/pic/jeep/4.01.04.o.jpg


First big blunder of the night… Crap that was just careless.
Stupid move #1.
http://www.fccsonline.com/pic/jeep/4.01.04.p1.jpg

Here was my second big “oops” of the night. After hearing the story of Risko doing the same thing when changing his heater hoses, I was EXTRA CAREFUL when removing them. I even used hose pliers. Guess what… CRUSH. I bent it out as best I could after taking the picture, and I think it’ll hold. If not, I’m going to just bypass the heater core for the summer, until I can get around to the repair. Stupid move #2.
http://www.fccsonline.com/pic/jeep/4.01.04.p.jpg

OverkillZJ
03-06-2005, 01:19 PM
Hey Matt, the TJ needs some new rubber (33's) which requires new gears (4.56's) ... When we gonna put that new press to work? I'll get the other gear goodies if you make the room :lol:

Oh.. Need to replace all 4 shocks (which is why all of the current TrXus's are cupped), lots of slack in the driveline (the rear gearset is probably way out of spec) and the U-Joints couldn't hurt to be replaced :) Oh, and replace the LCA's as well.

Call me when you have time :lol: :lol:


I have an idea, BRANDON. Call me back when it's something that doesn't benefit you

well you're at it, get me the sat card I paid you for 6 months ago. Sign over the pghoffroad domain name, and pay John whatever it is that you owe him.

Ok, I think that about covers it! :spank:



ps, only if you get me the tools I need to set my gears in the front :thumbsup:

OverkillZJ
03-06-2005, 01:19 PM
Too funny Matt....too funny...
:lol: :lol: :lol:

Got the TIG all set up last night.
:thumbsup:

Project's looking good.

OverkillZJ
03-06-2005, 01:20 PM
Well, I didn't work on the Jeep tonight since I'm drunk off my @$$ - is that ok with all of you? :thumbsup: :thumbsup: :thumbsup:

OverkillZJ
03-06-2005, 01:20 PM
We'll let it slide for now... Now get back to work... lol I really enjoy watching this soap opera. I can't wait to see this project completed.

Lindley

OverkillZJ
03-06-2005, 01:20 PM
Well, I didn't work on the Jeep tonight since I'm drunk off my @$$ - is that ok with all of you? :thumbsup: :thumbsup: :thumbsup:

Just because you had 2 beers is no excuse.....
Now get back to work sally.
;)

OverkillZJ
03-06-2005, 01:21 PM
We'll let it slide for now... Now get back to work... lol I really enjoy watching this soap opera. I can't wait to see this project completed.

Lindley

Haha, hey Lindley. I wonder how many people I've caused to register on NAGCA from this thread...

I can't wait to see this project done too... I won't know what to do with myself!



Well, I didn't work on the Jeep tonight since I'm drunk off my @$$ - is that ok with all of you? :thumbsup: :thumbsup: :thumbsup:

Just because you had 2 beers is no excuse.....
Now get back to work sally.
;)

I wish I only had 2 beers... then when I woke up at 6am to tour a college campus, I wouldn't have fallen asleep :grin:
Oh, you don't have a grand, you can't use "Sally" on this forum :spam:

OverkillZJ
03-06-2005, 01:22 PM
Matt, I've been on JU since May 99 and saw this forum when it first began. I thought I was already registered but when I tried to do a post just a couple of days ago my user name was no good. Cool thing is I am able to use the same user name that I use on JU. I have a 96 ZJ with many modification with the latest edition, going on sometime between the middle to the end of April, being a Ford 9" being built by Sunray Engineering. I might have tried to do the biuld up myself but it is hard to do when I am in Germany, Air Force all the way, and the ZJ is in Virginia with my father-in-law.

Lindley

Awesome. Would you mind sending over that Sunray 9"? Those things are truly works of art.




Oh, you don't have a grand, you can't use "Sally" on this forum :spam:

Considering the quantity of time I have spent either working on your heep or winching it out of mud pits, I figure I have a little latitude.
:wacko:Mind you, you've only ever winched me out ONCE. But it was a hell of a stuck.... anyway...

Working on the heep, ya, ok, I'll give you that one :)

Any tips on installing my Tera 2lo later, other than a big set of snap ring pliers?



-------------------Jeep wrenching schedule----------------------
I'm not getting under the heep ‘til later tonight... Going to look at a house (w/ a real garage...)
Didn't get to work on it yesterday, was touring a college I'm trying to transfer to...

Can't work on it tomorrow, installing a closed circuit TV system for a Pittsburgh millionaire who will remain nameless... He wants to be able to control his Tivo (located 2 floors away) from his shower....

Tuesday and Wed = Jeep day...

Thursday = massive network rebuild I'm expecting to take 10 hours...

Friday night start ANOTHER massive network rebuild, that will take a total of 16 hours taking up my saturday as well...

Sunday will be spent catching up on the full 9 days of studying I've been putting of...

So, out of my 10 days I planned for "wrench fest" looks like I'll only be wrenching for 2.5 of them.... This causes a problem.

crud.

OverkillZJ
03-06-2005, 01:22 PM
New stuff… New heater hoses, radiator hoses (not in picture) Moroso “spiral” muffler, exhaust adapters to go from 2.5” headers to 3” cat and muffler, then to 2.25” tailpipe (for inspection, will be putting on a turndown as soon as it passes. I have bad luck with tailpipes and rocks.. NO COMMENTS MARK.)

I thought I’d give these Gojo gloves a try too. They’re great, I don’t know how I ever lived without them. You can feel through them great, but still have clean hands and no cuts after a day of wrenching.

Oh ya, the Moroso sticker must be worth another 10HP alone.
http://www.fccsonline.com/pic/jeep/4.04.04.a.jpg


Spirals surround a 1” pass-through core in the muffler. I’m dying to hear what it sounds like. Street legal, SMALL, and.. Ahem.. Cheap. I wanted another Magnaflow, but trying to save money where I can.
http://www.fccsonline.com/pic/jeep/4.04.04.b.jpg


Painting exhaust stuff. The clamps and muffler were raw steel, they’d rust like crazy. Trying to reduce the rust.
http://www.fccsonline.com/pic/jeep/4.04.04.c.jpg


Water pump and tstat time…
http://www.fccsonline.com/pic/jeep/4.04.04.d.jpg


http://www.fccsonline.com/pic/jeep/4.04.04.e.jpg

I truly can’t imagine cleaning that old gasket off without the right tools. I tried just scraping it at first with a brush, and a gasket scraper… Nothing… nada…. 20 minutes with the die grinder, done.
http://www.fccsonline.com/pic/jeep/4.04.04.f.jpg


It didn’t look like that much until the pic w/ the flash, haha.
http://www.fccsonline.com/pic/jeep/4.04.04.g.jpg


Finally…
http://www.fccsonline.com/pic/jeep/4.04.04.h.jpg

If you’ve ever wondered why I can’t hold a serious relationship for any time at all… The next three pictures sum it up quite nicely :lol:
http://www.fccsonline.com/pic/jeep/4.04.04.i.jpg
http://www.fccsonline.com/pic/jeep/4.04.04.j.jpg
….I really need a parts washer…
http://www.fccsonline.com/pic/jeep/4.04.04.k.jpg

Heater hoses done, upper hose on. I’m worried, the new hose seems to be shorter than the old one, I’m afraid it’ll rip off when the engine revs and moves around a lot.
http://www.fccsonline.com/pic/jeep/4.04.04.l.jpg


The bottom hose is also a different shape, I need to redo the way I tapped those tranny cooling lines tomorrow.
http://www.fccsonline.com/pic/jeep/4.04.04.m.jpg

Still so far to go…
http://www.fccsonline.com/pic/jeep/4.04.04.n.jpg


3:30am. Time for bed. Back at it tomorrow for a little while at least…


I’ll tell of the house I’m looking at with the massive garage later ;)

OverkillZJ
03-06-2005, 01:24 PM
Looks like tomorrows Jeep Wrenching day will be cancelled as well..

That 6 hour CC TV install has turned into a full blown re-cabling of a rather large house, I'm thinking 16 hours or so.

Wonder when I'm gonna get to study let alone wrench... :(

OverkillZJ
03-06-2005, 01:25 PM
I'm 4 major components short on this build....

1. No slip rebuild kit (hopefully being provided by Papromike)
2. ACOS (also being provided by Papromike)
3. 35" MTR's on rockcrawlers, any suggestions on where to purchase?
4. Currie steering and drop pitman arm (temporary solution that I'll resell after this year.) I just need to get this thing rolling, no time at all for anything over the knuckle like I'd like to do.... Again, any suggestions on purchase?

edit: also need air intake.. Want to fab a snorkel eventually, but for my quick solution I think I'll just go with a turbo city to save space... Anyone have one used for a good price?

OverkillZJ
03-06-2005, 01:25 PM
are you going to cross-over steering or inverted y?

In the long runnn... Undecided, but probably cross over.

For now, anything that I can bolt on and will work with 6" of lift and is stronger than stock.

OverkillZJ
03-06-2005, 01:26 PM
yea I'm in your boat.... I bent my tie rod and I was going to do the mini-con at Holister Hills but after watching a guy bend and BREAK his tie rod mid way down the trail, I decided against it. I'd really like cross-over as adding a red-neck ram would be really easy. Using cheby TREs and some dom tubing is one way to go. IV WHEELIN left me a list of places that could make me my steering. Do a search under his SN for that list. To bad the only real cross-over steering conversion on the net right now is rusty's.

Eventually, when I do whatever steering, it's going to be over the knuckle and have room for hydro assist... Thats next years project. Or one of. For now, I just need some kind of steering, haha.


Same here... hp30 with highsteer and a red neck ram....

OverkillZJ
03-06-2005, 01:26 PM
I got my Currie TJ setup through Summit Racing online. Had it 3 days later.
I got my MT/R's from Discount, but you don't have discounts out there. Check Wal Mart.
:D

OH, I see nothing abnormal with the parts cleaning pics :dunno: I also use my oven to heat up ring gears before installing them.

;)

OverkillZJ
03-06-2005, 01:27 PM
or you just use the camera with your hands dirty and wash the camera afterwards. :D

:thumbsup:

You got it.

I took that camera to my 5 jobs this week, clean computer type stuff... Everytime I saw the grip on camera, which used to be red but is now stained black with grease, I had to chuckle a little.


Sorry to tell everyone following the thread, but there will be very little, if any, jeep wrenching until May. Business is booming (60 hours on site this week, plus roughly 15 hours of administration time. this was a VERY tough week I never intend to repeat... 17 hours today just pushed me over the sanity limit. Anyway, school starts back up Monday, though I'll be skipping to wrap up a couple of jobs... The focus will now be on school until it's over in May. I don't know what's going on in any of my classes due to the time invested in the Jeep and work. I can't do both at once.

All I can do is be sure I have all parts in by May, I already know everything that needs work on the ZJ, so it should go smoothly once I get back to it. :cool: :spam: :pant:

OverkillZJ
03-06-2005, 01:27 PM
Alright.... I'm never working 76 hours in a week again. As soon as the paychecks come in I'll be ordering the Currie steering and my MTR's.

So who around Pittsburgh wants to rebuild my HP30 gears for free or a case of beer? I have a rebuild kit, but not the tools nor the skill. I have an offer from Karstmen to pass through his place in CO on the way to GSW with an empty case, and to set them there... But I'd really like to test this thing in 4WD before going to such an event.

I know there's someone around here.... Come on, help a Jeeper out :thumbsup:


3 weeks or so til the wrenching starts again. School and work are kicking my ass. 'Til then I just need to make sure I get all parts here on time for the project...


My head hurts. Ok. Back to studying.

OverkillZJ
03-06-2005, 01:28 PM
But I'd really like to test this thing in 4WD before going to such an event.

I know there's someone around here.... Come on, help a Jeeper out :thumbsup:




Do what?
Test?
Why?
:lol:

Call Bill and see if his buddy Jay can help you.

If not, you could always call Matt Peters. He may cut you a break since the housing is out of the jeep. I dunno, but worth a phone call. He does excellent work and it gives you a good excuse to drive out to 4wd Hardware. :D

If not, bring the junk here and we'll fix it.
:thumbsup:

OverkillZJ
03-06-2005, 01:28 PM
Do what?
Test?
Why?
:lol:



Would Jill be mad if I bought you a remote control Jeep as a wedding present? :spank: :pant: :angel:

OverkillZJ
03-06-2005, 01:28 PM
She bought me a remote control jeep for christmas a few years ago.
:lol:

And, no...she'd be mad if you bought her a remote controlled jeep for the wedding.
:pant:

OverkillZJ
03-06-2005, 01:29 PM
Today was a study for school day.. just like yesterday. But it being 79 and sunny, well, I needed a break for a few hours. My head hurt after all. I’d been pondering how to route hydraulic lines to the winch in such a way I didn’t kill them on the rocks again. Then it occurred to me… I don’t have to! I’m replacing the hydro winch with an electric, it just has less to go wrong. The hydro winch was custom mounted by a 4x4 fab guy and mounted in such a way that it couldn’t be removed without a little cutting. Out came the sawzall. It was scary how easy it was to cut through that ARB.


http://www.fccsonline.com/pic/jeep/4.17.04.a.jpg


http://www.fccsonline.com/pic/jeep/4.17.04.b.jpg



http://www.fccsonline.com/pic/jeep/4.17.04.c.jpg



http://www.fccsonline.com/pic/jeep/4.17.04.d.jpg


While I was in the mood for “destroy” I decided to start trimming the bar a bit to make room for the 35’s. Again, awesome how fast that saw cuts.
http://www.fccsonline.com/pic/jeep/4.17.04.e.jpg


With all the noise, the construction workers expanding the house next door stopped what they were doing for a few “what the hells” as I was saying things like “yeeaaaah you dirty whore, who’s your daddy!”

Hey, I’m moving. It’s fun freaking the neighbors out.
http://www.fccsonline.com/pic/jeep/4.17.04.f.jpg


Yep, 20 ton press works. It’s stupid fun.
http://www.fccsonline.com/pic/jeep/4.17.04.g.jpg


I discovered that the track bar bolt hole on the HP30 is out of round on both sides. Doesn’t look bad at all in the picture, but it’s something I might be concerned about a little down the road. Not for this build though, no time.
http://www.fccsonline.com/pic/jeep/4.17.04.h.jpg


I SHOULD be studying all day tomorrow… but it’s gonna be in the 80’s. Considering the electric line that should be going to the houses air conditioner, is currently routed to the tents heater, I think I’ll just have to get outside for some fresh air!

OverkillZJ
03-06-2005, 01:30 PM
Quick question for you. I have yet to take off the front bumper on my 1993 Grand but I will be replacing it with a ARB bumper or fab one up myself. In the picture above there are two pieces, one rustier then the other. Are they both supplied from ARB or is the one actually behind my stock bumper? Might be a stupid question.

From the pictures above it also appears that there is only two bolts holding the whole front bumper assembly in place? Is that true or is there more?

Not dumb questions :)

The rust part you see is 5/16" steel plate that was welded into my bull bar by someone on this forum with far more fab skills than I, which allows me to use any standard winch in it and not just a warn.

There are SIX bolts to hold the ARB bull bar on, though only two are visible in that picture. If you go back a few pages, and look at pics of the front end of my ZJ, you'll see the brackets that the bumper ligns up with. :cool:

OverkillZJ
03-06-2005, 01:30 PM
well if it makes you feel better it is 34 here today....might brake 40 for a high...... :lol:

It does make me feel better, thanks!

In preperation of next winters wrenching sessions, I spent the entire day looking at houses... Every "car guy garage" i find has a crappy house, and every beautiful house I find has a crappy garage.

The house I fell in love with today was 10k above what I wanted to pay, and I'd have to add a 2 car garage (8' doors) with a party deck above it... which brings my total cost to 30k more than I wanted.

Man, the things I'll do to keep this stupid hobby... I'm retarted.

OverkillZJ
03-06-2005, 01:31 PM
Any man that considers his shop/tool needs when looking for a house is far from retarded. Wise would be a better description. Hell the big reason I bought my house was because of the garages. :thumbsup:

And you'll find the Sweet garage/crappy house, crappy garage/sweet house thing to be the norm. Just find a happy medium, you can improve a garage easier than you can improve the house. Keep the faith man, you'll find "that" house, its just a matter of time.

Keep it up Matt!

Started Page 14!!

OverkillZJ
03-06-2005, 01:31 PM
IOP14, LOL!

At this point, I've realized you're right about a house being harder to improve on than a garage. I've found some beautiful houses with HUGE lots and no garage, which leaves me with the option of just building a garage from the ground up. I'm going to be living in this house a minimum of 7-8 years anyway, probably longer.

I'll just be happy to graduate from my tent!

Tomorrow should be a big Jeep day. I might get the tcase back in, exhaust on, steering pump and box on, and uh, start it?

Wonder if it'll explode?

OverkillZJ
03-06-2005, 01:32 PM
Just so you know - I went with what I thought was a happy medium - both house and shop needed some work, but I'm young, smart (OK that's debateable at times) and I got a pretty good deal. Anyway closed a year ago last Thursday (dang its been a year) - That night I gutted the kitchen and started my home improvement hobby/second full time job. I've about done it all now (carpet, laminate flooring, painting, sheetrock, cabinets), but to make a long story short - of the past year, I've spent 90% of my time on the house. In the other 10%, I've just about done everything I could imagine to the shop. New lighting, wiring, 220 for the welder, fridge for the weldor ;) , pegboard along one wall, workbench, shelves, driveway, drainage everything. The shop will take you a couple of months worth of weekends, a few cases of beer, and some buddies start to finish. The house will ALWAYS have something waiting for you. And when you think you're caught up - look at your yard.... :lol:

The moral of the story is the shop will take less time, effort, and overall headache. You've gotta live in the house. A shop is more - whenever I get around to it. IOW you can take your time a little more, and make sure you're doing things right.

OverkillZJ
03-06-2005, 01:33 PM
Having wireless internet on a laptop in the garage turned out to be a huge resource. Thanks so Stu-Offroad for being 10,000 times better than my factory service manual once again!

http://www.fccsonline.com/pic/jeep/4.18.04.a.jpg


Time to install my Tera 2-lo (low range in 2 wheel drive when desired).The install itself was much more straight forward and easier than I’d ever imagined. If I hadn’t been taking my time to admire the “simplistic beauty” and genius behind the 231HD, I really think it could be done in about 45 minutes.
http://www.fccsonline.com/pic/jeep/4.18.04.b.jpg

http://www.fccsonline.com/pic/jeep/4.18.04.c.jpg

http://www.fccsonline.com/pic/jeep/4.18.04.d.jpg

http://www.fccsonline.com/pic/jeep/4.18.04.e.jpg

Here’s where I proved that I’m a dumb@ss. I couldn’t, for the life of me, imagine why the chain was supposed to be resting on the range fork like that. After an hour of staring off into space and several phone calls to friends, I realized that the case was upside down and gravity was pulling on the chain… derrrrrr….
http://www.fccsonline.com/pic/jeep/4.18.04.f.jpg

OverkillZJ
03-06-2005, 01:34 PM
It’s Tuesday and I needed some wrenching time to take a little bit of the stress off. I always seem to forget just how stressful wrenching can be.

A friend of mine (hereafter Brandon, or Idiot, or Lord Athens in this thread, whichever your prefer!) needed to change all of the ujoints in his TJ. Stupid TJ guys always seem to assume things will go smoothly. He showed up at about noon and I told him sure he could use tools, but I had my own project to work on.

http://www.fccsonline.com/pic/jeep/4.20.04.a.jpg


Mind you, his jeep has 90,000 miles on it. Stock ujoints. What do you think is going to happen?
http://www.fccsonline.com/pic/jeep/4.20.04.b.jpg



During his first parts run, Jeff and I felt like being dicks, and flipped his smiley sign upside down. I’ve always wanted to do that ;)

Next time, I’ll swap the front and rear plates.
http://www.fccsonline.com/pic/jeep/4.20.04.c.jpg



Here’s a great shot of Jeffs large ass as he reinstalls my alternator. Hey Jeff, put the wires on BEFORE you bolt it down! I had to remove it later, retap the threads on the positive post, and reinstall it then wire it up; THEEEEEEENNNNN and ONLY THEN bolt it down :)
http://www.fccsonline.com/pic/jeep/4.20.04.d.jpg



Here is my “auxiliary” coolant temp sensor (to drive the digital gauge in my gauge pillar) that replaced the old pressure test-port (I think that’s what it was.)
http://www.fccsonline.com/pic/jeep/4.20.04.e.jpg



As suggested (and rightfully so) I removed all of the tranny lines and flared the ends. Peace of mind is a good thing. The harbor freight flare tool wasn’t perfect, but for $8, it did a damn good job.
http://www.fccsonline.com/pic/jeep/4.20.04.f.jpg



Lots of grinding, with the angle grinder and wire wheel later, THANKS JEFF, I painted the front half of my Claytons sub-frame. Looks damn good, “eh?”
http://www.fccsonline.com/pic/jeep/4.20.04.g.jpg


http://www.fccsonline.com/pic/jeep/4.20.04.h.jpg



Stubborn tcase bolt didn’t stay in the tcase when I removed it. I just cut it off. Little SOB got on my nerves. Besides, the sawzall is fun.
http://www.fccsonline.com/pic/jeep/4.20.04.i.jpg



When you have two entirely unrelated projects going on at once, with 4 people… it tends to get messy. I think by the end of the 2 day “wrench fest” every tool I own, was out and on the garage floor, or dirt, or road.
http://www.fccsonline.com/pic/jeep/4.20.04.j.jpg



Yet another laptop in the garage. This one not mine, but STILL showing Stu-offroad, love it :)
http://www.fccsonline.com/pic/jeep/4.20.04.k.jpg



Wow. I’d say Brandon found his driveline vibe/squeek.
http://www.fccsonline.com/pic/jeep/4.20.04.l.jpg



Maybe Brandon should’ve taken my advice to take OFF one shaft at a time, replace ujoints, and then reinstall back on the Jeep. Nope, he pulled both drive shafts, and both front axles. We called it a night at 4am… and started again at 11am the next day. Mind you, his TJ is on a public street… good thing it’s a dead end, with some very understanding neighbors.

http://www.fccsonline.com/pic/jeep/4.20.04.m.jpg



I decided to wake the TJ guys up by firing up my exhaust for the first time. That Moroso muffler ROCKS! It’s beefy, small, deep sounding, relatively loud, but NOT obnoxious. I HIGHLY recommend it to anyone who has limited space, due to long arms for example.

http://www.fccsonline.com/pic/jeep/4.20.04.n.jpg



Looking like a parking lot….
http://www.fccsonline.com/pic/jeep/4.20.04.o.jpg



I got ALL KINDS of stuff back on my ZJ. I don’t need to type it all, you can tell from the pics. Massive progress this week... I’m happy.
http://www.fccsonline.com/pic/jeep/4.20.04.p.jpg




http://www.fccsonline.com/pic/jeep/4.20.04.q.jpg




http://www.fccsonline.com/pic/jeep/4.20.04.r.jpg


My temporary air filter, mainly there to keep from sucking bees and wasps in (there are a lot here). I don’t know what to do for an air intake yet. I don’t like the turbo city (sucks in hot air, and with my headers, that’ll be REALLY hot air, no heat shield.) I can’t use a stock air box or K&N kit, because I need that space for a wiring box (you’ll see in a couple of weeks) – and I can’t afford a snorkel.

I might run a turbo city dual for now, and save up for a snorkel in the long run. Cold air = good.
http://www.fccsonline.com/pic/jeep/4.20.04.s.jpg


Exhaust is clamped together… I need to take an audio clip, it sounds exactly like I wanted it to. It’s… perfect. I can’t get the tailpipe on yet, I’m having trouble with adapting 3”OD to 2.25” OD. I truly hate exhaust fittings, gives me a headache.

Anyone know how much I should torque down those exhaust clamps?
http://www.fccsonline.com/pic/jeep/4.20.04.t.jpg




http://www.fccsonline.com/pic/jeep/4.20.04.u.jpg



Cross member is in, no more 5th jack stand needed at the moment…
http://www.fccsonline.com/pic/jeep/4.20.04.v.jpg


LOOK! IT RUNS! Well, kind of. It idles perfectly, but if you tape the gas and then let go, the engine dies. Something’s wrong. Any suggestions on what sensor to try replacing first? Upstream 02 is new, downstream has 20k on it but should be good. Ignition is new, but all the other sensors are stock at 65,000 miles on them.
http://www.fccsonline.com/pic/jeep/4.20.04.w.jpg


This picture amuses me. See, you can see the beer of yesterday, the coffee to help with the hangover this morning (and the whole 4 hours of sleep… thing…) and the coke of the current afternoon. Little did they know how late they’d still be there.
http://www.fccsonline.com/pic/jeep/4.20.04.x.jpg


WTF? I dunno. Most of us press out ujoints. After bending out one of his yoke years, he just started cutting. Hmmm. Hey, where’s my $$$ for some new cutting discs!?

http://www.fccsonline.com/pic/jeep/4.20.04.y.jpg



http://www.fccsonline.com/pic/jeep/4.20.04.z.jpg


Parts everywhere…
http://www.fccsonline.com/pic/jeep/4.20.04.a1.jpg

At this point it was 5:30pm (of day TWO) and I had to my logic class. I told them to clean and lock up before they left, assuming they’d be done (HAHAHAHA!)

I came home 5 HOURS LATER and saw this :D
http://www.fccsonline.com/pic/jeep/4.20.04.b2.jpg



After that, I decided I needed several glasses of wine…
http://www.fccsonline.com/pic/jeep/4.20.04.c3.jpg


Mostly cleaned up. Floor and workbench are still a mess, but at midnight I didn’t want to force them to use the vacuum.

http://www.fccsonline.com/pic/jeep/4.20.04.c4.jpg



For now on, use of my tools and shop will be an hourly fee or require more compensation than a couple of hot dogs and bottle of Pepsi.

OverkillZJ
03-06-2005, 01:35 PM
Loving the canadian beer.

hey your doing a ofull lot of work. have you thought about hydro assist while you got the whole thing apart?


Hydro assist crossed my mind, and maybe eventually sure... but at this point, I just want to get it back on the road. I'm going through withdrawl here. I haven't been offroad since GSMW, LAST YEAR!

I'd also be worried about that much steering power against the HP30 knuckles.

I'm debating between chevy 1 ton and Currie steering. I'm leaning towards Currie for the bolt on simplicity, which after this project, would be nice. Time is obviously a huge factor here...



... and ya, you crazy canadians have some good beer! :thumbsup:

OverkillZJ
03-06-2005, 01:35 PM
I have been following this thread since you started and man you are doing one hell of a job. I am the same way, its all or nothin. To bad im trying to do three rigs at one time. (boat, cutlass & jeep)

You said it will not stay running? Seems to me i saw somewhere where they said if your batrey is discoed for a long time the cpu needs to recal the idle speed. Dont know for sure but it sounds faamiliar. Think you just need to run it/keep it runnig a while and it will sort it self out.

Good luck, I will be watching.

Dave


I figure I've screwed it up enough in the past to require doing it right this time ;)

It's not a "low battery" or "ECU reboot" kind of stall. There's definately a sensor problem. It was occuring before I started this project as well. I was hoping it was ignition or O2 related, all of which is new. Guess I'll keep digging...

OverkillZJ
03-06-2005, 01:36 PM
What a vacuum leak? Just a thought as I know that will cause similar types of stalls.


That was one of the first things I thought (And good insight!)

I did have the "vacuum box" missing and that end wasn't capped. I thought I'd found it. I reinstalled it, tested for vacuum, and it holds at 20PSI perfectly....

OverkillZJ
03-06-2005, 01:36 PM
Anyone have a charcoal canister they want to send me? Mines got a huge crack in it....

also need a rear view mirror :angel:



If you can't duck it...

OverkillZJ
03-06-2005, 01:36 PM
Anyone have a charcoal canister they want to send me? Mines got a huge crack in it....

also need a rear view mirror :angel:



If you can't duck it...


:dunno: huh?

OverkillZJ
03-06-2005, 01:37 PM
I discovered that the track bar bolt hole on the HP30 is out of round on both sides. Doesn’t look bad at all in the picture, but it’s something I might be concerned about a little down the road. Not for this build though, no time.
http://www.fccsonline.com/pic/jeep/4.17.04.h.jpg


I'd be concerned about that crack thats forming at the bolt hole.

OverkillZJ
03-06-2005, 01:37 PM
Anyone have a charcoal canister they want to send me? Mines got a huge crack in it....

also need a rear view mirror :angel:



If you can't duck it...


:dunno: huh?

If you can't duck it... Fornicate it. To be more specific - insert synonym for fornicate that rhymes with duck.

I laughed Jim.

OverkillZJ
03-06-2005, 01:38 PM
Anyone have a charcoal canister they want to send me? Mines got a huge crack in it....

also need a rear view mirror :angel:



If you can't duck it...


:dunno: huh?

If you can't duck it... Fornicate it. To be more specific - insert synonym for fornicate that rhymes with duck.

I laughed Jim.


:lol:

I'm a little slow.

I didn't even notice that crack there, I'll have to take care of that.... Looks like the rear axle will be going in well before the front.

OverkillZJ
03-06-2005, 01:38 PM
You really need to introduce Brandon to the concept of......
Preventive Maintenance
:roll: :thumbsup:

I guess some things never do change, eh?
:grin:


Haha, at about 3am he muttered something like "now I know why Mark always does $hit on his Jeep before it breaks...

OverkillZJ
03-06-2005, 01:39 PM
Yup, i'm all about preventive maintainence now. NOW I understand your analness, Mark ;)

I'll have you know that while going back together, I did it by the book. Things that needed blue loctite got it and everything else got hitemp antisieze :)

We certainly do miss you around here Mark. Things definately suck now :(

On the other hand, I got my new compressor tonight :) Husky 27 gallon vertical, belt drive splash oiler. It moves some air and it's mmm.. quiet.

Pictures of my burnt #$! hand will be posted shortly when I can get back home. :)

Hey Matt, I'll be over this weekend to install Marks old DT3k's :lol:

OverkillZJ
03-06-2005, 01:39 PM
Yup, i'm all about preventive maintainence now. NOW I understand your analness, Mark ;)

I'll have you know that while going back together, I did it by the book. Things that needed blue loctite got it and everything else got hitemp antisieze :)


By the book my @$$!!! You're supposed to PRESS out the ujoints ya crazy bastad, not cut them out!

Not to mention you were planning on driving it home with 3 of 4 strap bolts holding the front driveshaft to the yoke. That could've been some good carnage. Man, I should've just let you leav like that to hear the CRUNCH CRACKLE POP from the end of the road :thumbsup:




We certainly do miss you around here Mark. Things definately suck now :(



No, we don't miss you Mark, STAY AWAY! I've lost 60 pounds without your home cooked wrenching session meals! :lol:



On the other hand, I got my new compressor tonight :) Husky 27 gallon vertical, belt drive splash oiler. It moves some air and it's mmm.. quiet.



Ya... I'll be glad to take that thing off of your burnt hands as payment for
Marks old shocks



Pictures of my burnt behind hand will be posted shortly when I can get back home. :)


I don't know if the internet is ready to see anything that nasy. You're not supposed to touch a Borla header while the Jeeps running nice and hot, by the way. Just thought I'd tell you incase that SIZZLE sound didn't give you the hint!



Hey Matt, I'll be over this weekend to install Marks old DT3k's :lol:

Fine with me, as long as you replace whatever tools you broke last time and VACUUM!

You might want to bake my elderly neighbors some cookies too. You probably gave them heart attacks.

OverkillZJ
03-06-2005, 01:40 PM
Is this flame fest really required Matthew? :-p




By the book my @$$!!! You're supposed to PRESS out the ujoints ya crazy bastad, not cut them out!

The one bearing cap got pressed to far in. Rather than risking driving it back through and bending the ears, I actually took a minute to think (I know, very unlike me) and figured it would be best to cut the cap off, rather than risk bending the ears out and totally FUBARing the axleshaft



Not to mention you were planning on driving it home with 3 of 4 strap bolts holding the front driveshaft to the yoke. That could've been some good carnage. Man, I should've just let you leav like that to hear the CRUNCH CRACKLE POP from the end of the road :thumbsup:


Agreed, that was poor thinking on my part. In my defense, we had been up for what, 13 hours after getting 4 hours of sleep from a prior 22 hour day? I wasn't exactly "all with it".



No, we don't miss you Mark, STAY AWAY! I've lost 60 pounds without your home cooked wrenching session meals! :lol:


++ I'd still rather be fat and happy with Mark and Jill around :) I'm sure it's the exact opposite for them though.



Ya... I'll be glad to take that thing off of your burnt hands as payment for Marks old shocks

No, that's quite alright. I'll hang on to it.



Pictures of my burnt behind hand will be posted shortly when I can get back home. :)




I don't know if the internet is ready to see anything that nasy. You're not supposed to touch a Borla header while the Jeeps running nice and hot, by the way. Just thought I'd tell you incase that SIZZLE sound didn't give you the hint!


The board turned my @$$ into a behind. I didn't touch it on purpose obviously. Of course, you also failed to mention to the rest of the board that you did the same exact thing 30 seconds later while I was inside dressing my wound, except you only did it to your fingernail :thumbsup:




Fine with me, as long as you replace whatever tools you broke last time and VACUUM!

You might want to bake my elderly neighbors some cookies too. You probably gave them heart attacks.

I know I owe you a scratch awl and a new grinding stone for the air grinder... Anything else?

Your neighbor is awesome.

OverkillZJ
03-06-2005, 01:40 PM
Your neighbor is awesome.

I wasn't talking about the "awesome" neighbors, they actually like me for some unknown reason. I was tlaking about the old ones your Jeep was parked in front of for 36+ hours while you made loud scary noises and listened to creepy music forever :lol:

Not to mention had Marks evil air compressor 20 feet from their door :lol:


Yes Mark and Jill, of course I miss you. Before you left, BRANDON WASN'T HERE BREAKING STUFF!


Brandon, you owe me PB blaster and brake cleaner :thumbsup:

OverkillZJ
03-06-2005, 01:41 PM
Rammstein is hardly creepy music.

I'll bring my new compressor over for you to use only on one condition, you put up a Matt CAM! :lol:

I brought a 3\4 full can of PB over for you on one of my many trips back home. And I suppose I can bring you a can of BRAKE cleaner.

When you're over 80, anything with lyrics is creepy music. Even though they sing a song that's a recipe for cookies.

Keep the compressor, THERE WILL BE NO MATT CAM.

OverkillZJ
03-06-2005, 01:42 PM
Painted the front bumper and tcase skid today... I'll upload those pics later. Here's a clip of the new exhaust system though http://www.fccsonline.com/pic/jeep/newexhaust.wav

I was sitting in it pretending I was offroading, like a little kid. I'm going through withdrawl to an extreme. You can hear how it's having trouble idling.

OverkillZJ
03-06-2005, 01:43 PM
I decided I didn’t need that chunk of bullbar either. It’ll now accept just about any standard winch, not just the Warns.

http://www.fccsonline.com/pic/jeep/4.24.04.a.jpg

I was going to prep it for painting with the wire wheel on the air spinny thingy, but looks like Brandon owes me more than a scratch awl and break cleaner *hint hint*

http://www.fccsonline.com/pic/jeep/4.24.04.b.jpg


gonna prep the tcase skid to paint…

http://www.fccsonline.com/pic/jeep/4.24.04.c.jpg


ALL DONE!!! About 4 coats on each. It should hold up well. Looks daaaaaaaaaaaamn good if I do say so myself.

http://www.fccsonline.com/pic/jeep/4.24.04.d.jpg



Stocking up (more.) Much much more to paint…. Axles, rear bumper, all control arms, and track bars.
http://www.fccsonline.com/pic/jeep/4.24.04.e.jpg
http://www.fccsonline.com/pic/jeep/4.24.04.f.jpg

OverkillZJ
03-06-2005, 01:44 PM
Rammstein is hardly creepy music.



Rammstein is EXTREMELY creepy music especially to anyone over the age of 50.

Matt I finally took your advice and registered for this forum so I can respond to any flames that take place at my expense :thumbsup: Not that I ever do anything to earn them :withstup: So anyway I'll be poking around and perhaps keep laughing at this thread and Matt I know why you don't want a MattCam and I'm not saying anything......yet :yes:

Alright, now that you're here, I get to flame you more :thumbsup:

Lets start with your username. I asssume it stands for "girlfriends ZJ?

There's a problem there Jeff, your girlfriend owns a WJ!!! :spank: :lol:


Now you DO get a :withstup:

OverkillZJ
03-06-2005, 01:45 PM
Alright, now that you're here, I get to flame you more :thumbsup:

Lets start with your username. I asssume it stands for "girlfriends ZJ?

There's a problem there Jeff, your girlfriend owns a WJ!!! :spank: :lol:


Now you DO get a :withstup:

There I fixed it..........a temporary lapse in exhaustion.........of course if we want to start in on the :withstup: quotes I'm sure you and I can go back and forth for hours so let's save both our dignities and not........anyway glad to be here none-the-less even though it only took me one post to get flamed.


ok now I really fixed it seriously I did.......


:roll: :eek:

OverkillZJ
03-06-2005, 01:45 PM
rofl.

Oh, and by the way, the wire wheel was already fuxored like that before I got my hands on it.

Infact, the only thing I used that for was to clean up the scaling on the front of the knuckles on the D30.


In payment for the electricity and consumables you used (including dinner) - it would be wise to keep me happy if you wish to use my tools again :spam:

OverkillZJ
03-06-2005, 01:46 PM
In payment for the electricity and consumables you used (including dinner) - it would be wise to keep me happy if you wish to use my tools again :spam:

He should also ALWAYS show up to wrench with BEER.
:thumbsup:

You're right... at the moment it's sunny / rainy / sleeting/ snowing and he's out on my street again changing out his shocks for my old SSV's :thumbsup:

I'll go tell him to walk for some beer before he touches another tool! :pant:

OverkillZJ
03-06-2005, 01:48 PM
It was 80 and sunny here all day. I had to go work in Rocky Mountain National Park all day today and tomorrow again. ;)

I've been too busy with yard/house work to touch the heep though.
Hopefully I can get some work done to it over the weekend.

As long as the heeps ready for some pre-wedding wheeling in June! :thumbsup:

Cause uh, mine will be :cool:

Speaking of... I'm emailing you and Pat my "possible" trip plans that I need both of your help on...

Look forward to pics of a soaking and freezing BK under his rig later tonight, it's funny as hell. His Jeeps turned out to be almost as bad as bills, some bolt always snaps off, even when he PB's it like he should. He's still out there!

OverkillZJ
03-06-2005, 01:48 PM
Thought I’d start off the day by seeing if the charcoal canister fixed my little “stalling out” problem.
http://www.fccsonline.com/pic/jeep/4.27.04.a.jpg



Checking voltage…
http://www.fccsonline.com/pic/jeep/4.27.04.b.jpg



I was planning on making a day out of sanding the rear bumper down and repainting, but the weather didn’t exactly agree with me… It’s probably rusting on the parts I ground down already. SOAB PITTSBURGH WEATHER!
http://www.fccsonline.com/pic/jeep/4.27.04.c.jpg


Taking care of all the open wiring with some wire looms… Wire porcupine!

http://www.fccsonline.com/pic/jeep/4.27.04.d.jpg

http://www.fccsonline.com/pic/jeep/4.27.04.e.jpg

http://www.fccsonline.com/pic/jeep/4.27.04.f.jpg



At this point, the infamous Brandon showed up to swap his TOTALLY shot DT shocks with my old Trailmaster SSV’s. I don’t think that the weather agreed with him very much… It was funny as hell.. I was nice and dry in the tent!
http://www.fccsonline.com/pic/jeep/4.27.04.g.jpg



Priceless…
http://www.fccsonline.com/pic/jeep/4.27.04.h.jpg



Battery boxes are now in.
http://www.fccsonline.com/pic/jeep/4.27.04.j.jpg


Now using larger grade 8 bolts and lots of RTV to try and keep more water out if I should ever.. ahemm… sink it again.

http://www.fccsonline.com/pic/jeep/4.27.04.k.jpg


The shift linkage has me ROYALLY PISSED OFF TO ALL HELL. I wanted to push my Jeep off of the jackstands at this point.

I haven’t had working shift linkage since I put my 231 in 2 years ago. I replaced my 249 with the 231. I can’t, for the life of me, get shift linkage that works. I think the silver part in the pic is a couple of inches to long. Anyone got the right part numbers for me? I’ll measure and post pics later of the problems…
http://www.fccsonline.com/pic/jeep/4.27.04.i.jpg



Anyone want to buy a project ZJ?

OverkillZJ
03-06-2005, 01:49 PM
long time thread watcher, first time poster. :smile: do you have the 231 shift bezel? i replaced my 249 bezel and shift gate with junkyard 231 parts made for a zj. no problems, works like it should. the case is a 1999 tj nv231, with the shift linkage out of a 93 or 94 zj. :eek:

kevin c.

I do have the 231 bezel, works like a charm. The linkkage I have was ordered by the dealer and "supposively" from a 94 w/ a 231. I call BS on them. Junkyards around here suck and I don't really trust a yard to send me what I'm asking for.... This sucks. Guess I'll leave it in 2WD while I patch it up and drive to a u-pull-it yard and try things til they fit.

Unless someone actually has part numbers, or measurments of how long the "long shaft" and "thing on the transfer case" should be...

:crazy

OverkillZJ
03-06-2005, 01:49 PM
Bah...
Just keep using the sledge hammer to shift it.
:eek:

:lol:

Sure, I'll just get under there with a sludge everytime I need to make a tight turn in moab with my locked F & R!

Everyone'd kill me before the end of the trail :pant:

I'll figure something out. Might cut what's too long and have it welded shorter. :cry:

OverkillZJ
03-06-2005, 01:50 PM
Hey Matt, long time ago I did the 231 swap too. I remember it was a pain to get the linkage right but I did win. I actually fabbed my own. Have patience, I will take pics and measurements and get them too you.

Dave


...Pics and measurements would be GREATLY appreciated... :smile:

OverkillZJ
03-06-2005, 01:51 PM
The ZJ has officially kicked my @$$ (or my arm, for that matter.) I spent the entire day yesterday sanding down and painting the 150 lb rear KM bumper.... Modified it a bit too, pics to follow. Anyway, it fell off of the horse's (that's the right word, right?) anyway, it landed on my arm.

Ouch.

Nothing broken (that I know of) but 30 hours later my arms still killing me :crazy :roll: :spank: :? :(

Killed my 4" angle grinder too. Bought a new one today. Oh yay. I'm bored and sitting in a coffee house so I thought I'd make a useless post.

OverkillZJ
03-06-2005, 01:51 PM
Well, I leave for my trip in just about a month from today, and truth be told, I’m not even half done yet. Getting down to the wire here.

Started off trimming the rear bumber a bit.
http://www.fccsonline.com/pic/jeep/5.01.04.a.jpg


Groung down evently.
http://www.fccsonline.com/pic/jeep/5.01.04.b.jpg


Tried drilling a hole in the bumper to mount my new trailer wiring harness box thingy. The bumper defeated that nice titanium hole bit pretty fast.
http://www.fccsonline.com/pic/jeep/5.01.04.c.jpg


Out came the oxy.
http://www.fccsonline.com/pic/jeep/5.01.04.d.jpg


Nice and clean, eh?
http://www.fccsonline.com/pic/jeep/5.01.04.e.jpg


This thing has the 7 pole plug and the 4 post, so I can tow that future rock buggy I’ll probably never get around to building.
http://www.fccsonline.com/pic/jeep/5.01.04.f.jpg


At this point the mail man showed up with my press plates.. .FINALLY!!!
http://www.fccsonline.com/pic/jeep/5.01.04.g.jpg


Ok, this just pissed me off. Had the bumper up on stands, and was under it grinding old rust away….. When it fell on my arm. In a pissy fit of pain I killed the 4” angle grinder too. I hated that thing anyway, vibrated the hell out of my hand whenever I used it to the point that it was numb. 2 days later, and my arm still hurts.
http://www.fccsonline.com/pic/jeep/5.01.04.h.jpg


Pain or not, worked on. Bigger drain holes in the bottom.
http://www.fccsonline.com/pic/jeep/5.01.04.i.jpg


Bigger wiring plug to accommodate for the new harness. I want to keep all the wiring inside of the bumper.
http://www.fccsonline.com/pic/jeep/5.01.04.j.jpg


There, all pretty!
http://www.fccsonline.com/pic/jeep/5.01.04.k.jpg


Started taking the rear TJ 44 apart. Pretty darn rusty. Turns out the discs are exactly the same as my 44A though, which I have brand new ones for. I’ll measure these first to see if they’re worth cleaning up though.
http://www.fccsonline.com/pic/jeep/5.01.04.l.jpg


Playing with the press. To bad that was the only one that went that well.
http://www.fccsonline.com/pic/jeep/5.01.04.m.jpg


All I did Friday was order parts and pick up a new angle grinder… 4”, craftsman, some “special pack” that was marked wrongly at $29 (I say marked wrongly since the same grinder in a smaller kit was $59. Weird.) Definitely better than that 4” Ryobi POS I killed. Now I have 2 Craftsman angle grinders!
http://www.fccsonline.com/pic/jeep/5.01.04.n.jpg


Oops. That bushing didn’t quite come out as easily… I managed to wrap it around the press post, inside out.
http://www.fccsonline.com/pic/jeep/5.01.04.o.jpg


Fire, a solution! Ok it was just fun.
http://www.fccsonline.com/pic/jeep/5.01.04.p.jpg


Disassemble…
http://www.fccsonline.com/pic/jeep/5.01.04.q.jpg


Sweeeeeeeeeeet……… Detroit locker and Moser shafts, Rubi disc breaks… WOHOO!
http://www.fccsonline.com/pic/jeep/5.01.04.r.jpg


I was quite pleased to find that the old stock TJ shafts had already had the correct retaining plates put on them. I thought I’d have to order a couple of rubi parts so that my trail spares would work, but it’s already done!
http://www.fccsonline.com/pic/jeep/5.01.04.s.jpg

The night just went downhill from there. Looked at the 30HP rebuild kit that came with the axles, to find the ring gear bolts missing (no big deal) but more so… No crush sleeve, and no pinion seal. Uh, I need both. Damnit. Time for a trip to the dealer I suppose.
http://www.fccsonline.com/pic/jeep/5.01.04.t.jpg


What is it with me knocking heavy things off of my workbench? It landed on the good air compressor hose (which is pretty much new, by the way) and cutting a big gapping hole in it.
http://www.fccsonline.com/pic/jeep/5.01.04.u.jpg


AHHHHHHHHHHHHHHHHHHHHHHHHH.

Oh, it’s finals week by the way. I’m gonna be pissed off at the world for awhile here. Then rush to finish the ZJ. My sanity is gone.

OverkillZJ
03-06-2005, 01:52 PM
finals week coming up here too . . . i wanna kill myself over macroeconomics and my accounting class . . . what kind of rear bumper is that??

I'll get you a B+ on your accounting if you attempt my Logic class?




The rear bumper is a Kennesaw Mountain... I wouldn't reccomend it. A 12 year old could weld better than that :crazy

OverkillZJ
03-06-2005, 01:53 PM
Just a little control arm work… Finals week, not really spending much time on the rig. I leave for my trip in 3 weeks… Is anyone else wondering how I’m going to pull this off? I know that I am.

http://www.fccsonline.com/pic/jeep/5.04.04.b.jpg

http://www.fccsonline.com/pic/jeep/5.04.04.a.jpg

http://www.fccsonline.com/pic/jeep/5.04.04.c.jpg

http://www.fccsonline.com/pic/jeep/5.04.04.d.jpg

http://www.fccsonline.com/pic/jeep/5.04.04.e.jpg

http://www.fccsonline.com/pic/jeep/5.04.04.f.jpg

http://www.fccsonline.com/pic/jeep/5.04.04.g.jpg

OverkillZJ
03-06-2005, 01:54 PM
perfict timming.
but anywho, does the gold washer go on the snap ring side or the silver one?


Ah crap. I didn't notice a difference, I hope that's a trick of the light. I left the JJ in my track bar together so I can take it apart for reference...

OverkillZJ
03-06-2005, 01:54 PM
If you have a gold and silver, gold is on the snap ring side. Some all come with silvers and some all with gold.

Chad

OverkillZJ
03-06-2005, 01:55 PM
Looks like most parts will be in on time.

I still have 2 things I need NOW that I'm not sure about being in on time, due to the sender.

Does anyone know "Papromike" in person?

I was one of those he screwed 3 years ago for that "no slip group buy" back in the day. $260 deposit. After years of him not sending my money no matter how many unfulfilled promises, he offered parts. I told him I needed a Dana 30 NO-SLIP rebuild kit, and some front ACOS. This would pay off his debt to me and make him some $ in the process.

Just like his other promises, I've yet to get confirmation that he's sent anything. I’m not convinced he even plans on following through with any of his promises. I have promises of a “refund” going all the way back to March 12, 2002 (I’ve kept every email.)

If My 31 day road trip is screwed simply because he doesn’t get parts to me, I’ll be less than thrilled. Any one who knows him, PLEASE talk some sense into him giving me what is rightfully mine. Or beat him with a stick. An ugly stick. Big one.

OverkillZJ
03-06-2005, 01:55 PM
Dude throw some open spiders in the thing. When You get to moab I will weld them tight for you.....

If it is for a front diff just run it open. I am running completly open in the front as well. We can winch to eachother.

Papro if you are reading this stop being a pussy and just get this guy his part or his money......Your reputation sucks Pappy.

It is for a front diff, but I got the No-Slip for next to nothing and like it's street manners (even in 4wd) :)

Gonna use what I have :thumbsup:


That's assuming he gets me my parts... :roll:

OverkillZJ
03-06-2005, 01:56 PM
Dude throw some open spiders in the thing. When You get to moab I will weld them tight for you.....

If it is for a front diff just run it open. I am running completly open in the front as well. We can winch to eachother.

Papro if you are reading this stop being a pussy and just get this guy his part or his money......Your reputation sucks Pappy.

It is for a front diff, but I got the No-Slip for next to nothing and like it's street manners (even in 4wd) :)

Gonna use what I have :thumbsup:


That's assuming he gets me my parts... :roll:

Absolutly use it if you have it, but don't let it stop you from going on the trip. That POS dirtbag just isn't worth it. I can't believe this guy still has the nads to come around on the board....

OverkillZJ
03-06-2005, 01:56 PM
Well, it started today. 21 days to finish the Jeep. Most of my work has been outsourced, and schools done. Just me and the Jeep. I can do it as long as Papromike follows through on his promise. However, seeing he hasn’t responded to any of my emails, I guess we’ll see how that turns out. If you want to see me finish my Jeep in time and go on my 31 day excursion, send him an email, papromike@aol.com :) .

Pressed out the last 2 bushings…
http://www.fccsonline.com/pic/jeep/5.10.04.a.jpg



Burned out the remnants…
http://www.fccsonline.com/pic/jeep/5.10.04.b.jpg



Ground down all the control arms to bare fresh metal for painting. My wire wheel finally decided it’d had enough. It was throwing metal shards everywhere, including in my stomach. When I took one to the groin area, I decided it was time to replace the wire wheel.
http://www.fccsonline.com/pic/jeep/5.10.04.c.jpg



Those used to be an inch long.
http://www.fccsonline.com/pic/jeep/5.10.04.d.jpg



Ya know, this would be much easier if Brandon hadn’t killed my small wire wheel. The one I have left is too big to fit into tight spaces.
http://www.fccsonline.com/pic/jeep/5.10.04.e.jpg



Good as new…. It’s too bad metal rusts, because they look darn good bare like that.
http://www.fccsonline.com/pic/jeep/5.10.04.f.jpg



After 4+ hours non stop with the new 4” angle grinder, it burned my hand to the touch. Thought I’d let it cool for awhile.
http://www.fccsonline.com/pic/jeep/5.10.04.g.jpg



Rustolum Hammered Silver…. Same as the crossmember and sub-frame.
http://www.fccsonline.com/pic/jeep/5.10.04.h.jpg



This is how rusty the control arms were before grinding them down too.
http://www.fccsonline.com/pic/jeep/5.10.04.i.jpg



Purdy…
http://www.fccsonline.com/pic/jeep/5.10.04.j.jpg



That just looks…Silly…
http://www.fccsonline.com/pic/jeep/5.10.04.k.jpg




Not much Jeep work time tomorrow. Home inspection on the new house bright and early, ordering parts at the dealer, and arguing with a customer who’s 6 weeks late in payment. Fun day!

Ok. I guess I can squeeze the Jeep in there.

OverkillZJ
03-06-2005, 01:57 PM
Well, I'm out of school for the summer, so lately I have more time to wrench, especially since the girlfriend is in school and not always with me. I don't think she likes coming over to my house only to sit in my room watching TV while I spin wrenches outside. That's the biggest factor in me not being able to wrench. She complained once that I play on the computer too much, too. :roll:

but does she complain when you get airborne wheelin and her........ she puts on the "O" face. :spank: :thumbsup:

BWAHAHAHAHA :thumbsup: :thumbsup: :thumbsup:

OverkillZJ
03-06-2005, 01:58 PM
I just picked up my 35" MTR's from walmart.... Mounted and balanced, for 5, I only paid.. get this... $800...

they uh, forgot to charge me for the 5th tire :thumbsup:


and that was after I talked them into charging me last weeks price ($174) opposed to the present $198

OverkillZJ
03-06-2005, 01:58 PM
Good Score.

Now you can almost feel vindicated from the bung ramming Papro is giving you.

He says the no-slip rebuild kit will be on my doorstep on friday... I'll believe it when I see it. The ACOS he'll supposively be buying next week when his tax refund gets in.

Funny, I remember LAST YEAR when he said he'd pay me my $$$ after his tax return was in :roll:

OverkillZJ
03-06-2005, 01:58 PM
Currie steering arrived. Paint on it sucks, was nicked down to metal. The steering itself is crazy beefy. I think it'll be worth every penny...
http://www.fccsonline.com/pic/jeep/5.12.04.a.jpg


Now it’s Hammered gray. Purdy!
http://www.fccsonline.com/pic/jeep/5.12.04.b.jpg


Oh? A huge truck with parts? Just for me!? The neighbors are starting to wonder....
http://www.fccsonline.com/pic/jeep/5.12.04.c.jpg


Wheels and winch…
http://www.fccsonline.com/pic/jeep/5.12.04.d.jpg


BLING!
http://www.fccsonline.com/pic/jeep/5.12.04.e.jpg


Can’t wait to see how well this thing works… MileMarker 12,000 lbs.
http://www.fccsonline.com/pic/jeep/5.12.04.f.jpg


Off to wally world with my new wheels to pick up my 35” MTR’s and get them mounted. They had trouble balancing one.. it has weights almost the whole way around. I’ll see if it causes problems on the road. If so, I’ll take them somewhere where they know how to balance tires…
http://www.fccsonline.com/pic/jeep/5.12.04.g.jpg



http://www.fccsonline.com/pic/jeep/5.12.04.h.jpg

35” (34.whatever) against 30.4”
http://www.fccsonline.com/pic/jeep/5.12.04.i.jpg


I’m convinced that these would fit on a WJ with nothing but a BB. All you needs a sawzall!

http://www.fccsonline.com/pic/jeep/5.12.04.j.jpg


I don’t think they’ll fit on Jeffs Cougar though…
http://www.fccsonline.com/pic/jeep/5.12.04.k.jpg


This is more comfortable than it looks… I didn’t think I’d get away with the :flipoff2: version on here.
http://www.fccsonline.com/pic/jeep/5.12.04.l.jpg


Did some control arm bushings…. Bed time. Big day tomorrow… want to put the winch in the bull bar, trim the front fenders, and get the front end looking like a Jeep again.
http://www.fccsonline.com/pic/jeep/5.12.04.m.jpg


Also fixed my stalling problem. It was just the IAC. It runs PERFECTLY now.

I'm SO going to make my 30 day june road (off-road) trip!

OverkillZJ
03-06-2005, 02:00 PM
i dont know how much i can agree with your descision to mount them with the white letters out. i prefer them in.

That's nice, but frankly I couldn't care less what you think about which way I chose to mount the tires :lol:

I peronsonaly think that having a tire with white lettering and mounting that inward looks nothing short of retarded.... Key words i think

OverkillZJ
03-06-2005, 02:00 PM
Your Curtains are crooked.
:lol:
Ya, but I couldn't care less about this rental POS house any more. Closing on my NICE new house (that doesn't suck, unlike this place) in June (ya... well I'm on my trip. Parents are taking care of it :pant: )






Well, I'm out of school for the summer, so lately I have more time to wrench, especially since the girlfriend is in school and not always with me. I don't think she likes coming over to my house only to sit in my room watching TV while I spin wrenches outside. That's the biggest factor in me not being able to wrench. She complained once that I play on the computer too much, too. :roll:
I do know how that goes.. I put an engagement ring on mine to shut her up. She constantly says I have 3 g/f's, her, my Jeep and my computer. She says she gets the least attention. She's prolly right. But hell, if I can't do it now when IS the right time?


See, there are reasons I haven't had a serious relationship for years... oh, wait, ever since the Jeep started getting nuts! :thumbsup:




Back on topic, You'll have to let us know what you think of that winch. I'm mounting my new 8k warn and Protofab today. Just waiting on the freight truck. They called, should be here around lunch.

So far I'm impressed with the construction of the winch and fairlead itself. I'm really hating the solenoid, theres really no way to mount it other than in front of the radiator (dead center above the winch) in such a way it'll hinder air flow. I guess I'll do that for now and try to refab better later, perhaps.

OverkillZJ
03-06-2005, 02:01 PM
So far I'm impressed with the construction of the winch and fairlead itself. I'm really hating the solenoid, theres really no way to mount it other than in front of the radiator (dead center above the winch) in such a way it'll hinder air flow. I guess I'll do that for now and try to refab better later, perhaps.

Just cut a small circular hole to plug up the controller and mount it in the ARB if there's room. If cable length is the issue - welding cable works really well.

You could really mount the solenoid box anywhere. Knowing you Matt and your electrical skills. Just order another conroller/ remote (whatever you want to call it) and the female plug assembly that would normally be in the solenoid box. (Should be available on the replacement parts list in your winch manual) Cut off the cable on the remote and wire it directly to the female plug (as if you were connecting it to the solenoids). Then you've got an extension cord of sorts. Put the female plug in a little project box (a whole lot smaller than the solenoid box itself) to make it a little more water resistant and mount that anywhere you want. Plug the extension into the solenoid box and roll with it.

Maybe a little over simplified, but just an idea for you.

JH

OverkillZJ
03-06-2005, 02:02 PM
Where did you get the bushing for your control arms? Are they the new RE hourglass bushing?

Chad

I'm not going to say what they are since I know the opinion many on this board will have for me even trying them :pant:


Well I am not sure I agree swaping out the johny joint but they should work well for the rubber ends. I just want a bushing that is going to hearniate while driving on th street.

Chad

johny joints are only on the frame end; they're still there :spam:

OverkillZJ
03-06-2005, 02:03 PM
Had to cut the bulbar a bit more to fit the winch in… Still need to take care of the fairlead, no bolt holes on the front of the winch like the last one.
http://www.fccsonline.com/pic/jeep/5.13.04.a.jpg



Fender and “other stuff” trimming time… Not going to miss any of it!
http://www.fccsonline.com/pic/jeep/5.13.04.b.jpg



I started with the sawzall but found it too hard to control. Ended up using the air cut-off wheel, much easier to control. What a mess of metal everywhere. Thanks to the use of Brandon’s QUIET air compressor (and 100% duty cycle) it didn’t take all day.
http://www.fccsonline.com/pic/jeep/5.13.04.c.jpg



Mmmm…. I don’t want to give it back… (seriously…)
http://www.fccsonline.com/pic/jeep/5.13.04.i.jpg




http://www.fccsonline.com/pic/jeep/5.13.04.d.jpg



I just started cutting things that didn’t need to be there. Ended up being more than I expected to take off!
http://www.fccsonline.com/pic/jeep/5.13.04.e.jpg



Bull bar and winch on. Forgot what a PITA that bar is to mount and “relatively” align. Wheeled some wheels up, threw headlights and the front clip on to see how it’s going to look.. It’s starting to look like a Jeep again!
http://www.fccsonline.com/pic/jeep/5.13.04.f.jpg



Yup, they’ll fit.
http://www.fccsonline.com/pic/jeep/5.13.04.g.jpg



It’s getting there…
http://www.fccsonline.com/pic/jeep/5.13.04.h.jpg

OverkillZJ
03-06-2005, 02:04 PM
Where did you get the bushing for your control arms? Are they the new RE hourglass bushing?

Chad

I'm not going to say what they are since I know the opinion many on this board will have for me even trying them :pant:

Look like Daystar CJ spring bushings. Who cares what they are man....fill us in. Poly bushings are just fine.

Yup, they're poly. I hate the way Claytons LA's destroy bushings, especially with the 2 radius-style arms in the front. Planning on running all arms on the street, but pulling one upper at each end for offroad, since the poly doesn't have much give compared to rubber. I don't really want to rip and axle mount off or twist tubes by running both uppers.


Are you robbing 4 wheel parts stores on the weekends?


:lol:

Maybe ;)

OverkillZJ
03-06-2005, 02:05 PM
i fell kind of behind, i was only up to page 10

i sat down at 8:45, and i just finished catching up....1hr and 45 min


this is the coolest post ever. good luck, amazing devotion. nothing like knowing everything is done right. i guess you kind of know what the whole "real jeeps are built, not bought" thing is about, huh?

Paul

edit...woo! iop 21


This has got to be the longest NAGCA thread ever. :D




this is the coolest post ever.


i agree! tons of info, great picturs, what else do you need?!!?!?

OverkillZJ
03-06-2005, 02:06 PM
i bet you're getting tired of the "post reply" and "img" buttons, aren't ya?

OverkillZJ
03-06-2005, 02:06 PM
i bet you're getting tired of the "post reply" and "img" buttons, aren't ya?

I don't use the BBS image tags, atleast not the way you do ;)

Each image is the date (xx.xx.xx) and increments by a letter (so xx.xx.xx.b) - that way I just use a template in a text editor and do a FIND and REPLACE changing the date :D

What I am sick of is staring at an unfinished ZJ. I've been staring at it for 18 months thinking " I need to finish this thing right..." so along came this project...

OverkillZJ
03-06-2005, 02:06 PM
Stripped the front HP30 down. Empty case now, need to rebuild it. Oh so much fun! Thanks to Papromike for getting me my No-Slip rebuild kit! I might be throwing that in the carrier tomorrow. Still waiting to hear back from a couple local gear guys to see if they’ll be willing to help with the gear rebuild itself.
http://www.fccsonline.com/pic/jeep/5.14.04.a.jpg


Repainted the bottom side of the TJ-44 rear end, waiting til tomorrow to do the top. Primed it and used semi gloss black. I think I’m going to regret how many parts I painted with Hammered, without primer first. It chips easily. No primer needed my @$$...
http://www.fccsonline.com/pic/jeep/5.14.04.b.jpg


For example… had to grind down, prime, and repaint the currie steering.
http://www.fccsonline.com/pic/jeep/5.14.04.c.jpg


reassembling some of the control arms…
http://www.fccsonline.com/pic/jeep/5.14.04.d.jpg


Notice the dent on the left side of the light frame of the work bench. Spinning that nut on with one of my jumbo wenches, I was going to fast, slipped, and the wrench slammed into the light frame, knocking both bulbs out where the smashed and sent glass everywhere.
http://www.fccsonline.com/pic/jeep/5.14.04.e.jpg


Wasted half an hour cleaning that up…
http://www.fccsonline.com/pic/jeep/5.14.04.f.jpg


.Back to assembling Johnny Joints. What ingenious little things they are… Using Amsoil synthetic grease this time instead of the crap that solidified and clogged the grease hole last time.
http://www.fccsonline.com/pic/jeep/5.14.04.g.jpg


It was a day of breaking things, my neat “recording” measure tape my dad got me years ago decided to eat its own tape.
http://www.fccsonline.com/pic/jeep/5.14.04.h.jpg


I don’t now how the h3ll I did that… knocked the spray nozzle off in such a way that the can sat there with a 10 foot stream of parts cleaner shooting up into the air for a good ten minutes or so.
http://www.fccsonline.com/pic/jeep/5.14.04.i.jpg

Control arms are all back together… Don’t have length written down for the front lowers, I don’t know what I was thinking. Measured and wrote down all of the others…
http://www.fccsonline.com/pic/jeep/5.14.04.j.jpg


I had to get some wheelin’ in! Man, I forgot how much fun that little thing can be.
http://www.fccsonline.com/pic/jeep/5.14.04.k.jpg


Oops… Bad truck!
http://www.fccsonline.com/pic/jeep/5.14.04.l.jpg


Ya... hardcore!
http://www.fccsonline.com/pic/jeep/5.14.04.m.jpg


Never again will I let my jeep sit for 6 months with road salt allover the underside… Took the 20 ton press to get these out, and even then it took effort.
http://www.fccsonline.com/pic/jeep/5.14.04.n.jpg


Cleaned up. What do you think, should I paint them this time?
http://www.fccsonline.com/pic/jeep/5.14.04.o.jpg

Front and rear track bars sanded down, primed, and repainted. I bet that that hammered paint sticks a lot better with the primer under it...
Seems like I didn’t get enough done for 14 hours of work
http://www.fccsonline.com/pic/jeep/5.14.04.p.jpg

OverkillZJ
03-06-2005, 02:08 PM
Keep it up Matt.
Looks great!
:thumbsup:

OverkillZJ
03-06-2005, 02:08 PM
Do I get a cookie? A big one? Chocolate chip? :grin:



How about a Pirmani's the next time I am in town?? Thats better than any cookie I know of!! :yaba:

I could definately live with that!

Come to town soon, I'm hungry :thumbsup:

OverkillZJ
03-06-2005, 02:09 PM
First I’d like to thank my parents… for endless patience for this insane project. They’ve stopped by to help and bring food on several occasions, not to mention picking things up I need constantly and lending me the WJ when needed. Not to mention lending me parts $ while I wait for some slow paying clients to pay up ;)

Now that that’s outa the way, on with the last 2 days of progress…

Parts painted and ready to go on…
http://www.fccsonline.com/pic/jeep/5.16.04.a.jpg


Discovered my Advance Auto lower radiator hose is entirely wrong, the bend isn’t near long enough to allow the sway bar to fit above it like it’s supposed to. Plus I forgot to put the spring in it. Trip to the dealer it is….
http://www.fccsonline.com/pic/jeep/5.16.04.b.jpg


My dad put the fairlead on, looks darn good.
http://www.fccsonline.com/pic/jeep/5.16.04.c.jpg


New rear wiper motor in, and this one works! The spare tire blocks the rear wiper anyway, but it’s legally needed to pass inspection here since it was OE…
http://www.fccsonline.com/pic/jeep/5.16.04.d.jpg


Anyone know to get a touch up paint color that’s even CLOSE to the factory color? I mean really… It’s red…
http://www.fccsonline.com/pic/jeep/5.16.04.e.jpg


The junk pile of stuff the garbage men won’t take grows…
http://www.fccsonline.com/pic/jeep/5.16.04.f.jpg


.Pinion rebuild time… once I get more parts in
http://www.fccsonline.com/pic/jeep/5.16.04.g.jpg


Need to put my no slip in the carrier.
http://www.fccsonline.com/pic/jeep/5.16.04.h.jpg


Ya, those score marks scare me. A lot. Guess it didn’t blow up in Krash’s rig, doubt it’ll blow up now.
http://www.fccsonline.com/pic/jeep/5.16.04.i.jpg

Finished the rear axles paint job. 2 layers of primer, several more of black.
http://www.fccsonline.com/pic/jeep/5.16.04.j.jpg


I dropped the can on the gravel, and it got a hole in the bottom. It was full. It sent paint everywhere, on me, my glasses, my nicely painted bumper (different color…) and on my new phone. I was pretty pissed.
http://www.fccsonline.com/pic/jeep/5.16.04.k.jpg



http://www.fccsonline.com/pic/jeep/5.16.04.l.jpg



http://www.fccsonline.com/pic/jeep/5.16.04.m.jpg


More painted parts…
http://www.fccsonline.com/pic/jeep/5.16.04.n.jpg


No more rust bucket ZJ!
http://www.fccsonline.com/pic/jeep/5.16.04.o.jpg


That’s so much more like it…
http://www.fccsonline.com/pic/jeep/5.16.04.p.jpg
http://www.fccsonline.com/pic/jeep/5.16.04.z2.jpg


This front axle pisses me off. One ball joint had a torn boot and all kinds of dirt got in there, and another ball joint had tons of play. New joints are in order…
http://www.fccsonline.com/pic/jeep/5.16.04.q.jpg


Hours of my dad playing with his new Dremel later, the trimmed fenders are pretty much cleaned up. Need to find some weather strip that looks good along it.
http://www.fccsonline.com/pic/jeep/5.16.04.r.jpg


Burning out the old bushings since I need to use their old sleeves for the poly bushings. Ended up moving a sleve over from my old axle. That HP30 is getting on my nerves.
http://www.fccsonline.com/pic/jeep/5.16.04.s.jpg


I was amused that when I heated it that hot that fast, first the bolt sleve shot out 6 feet and melted the carpet, followed by the bushing fireball itself.
http://www.fccsonline.com/pic/jeep/5.16.04.t.jpg


One completely and 100% empty HP30. It’s so light you can move it around with one hand holding it. Kinda nice!
http://www.fccsonline.com/pic/jeep/5.16.04.u.jpg


This is a shot of the rear e-brake mounting bracket. Looks like whoever built the axle had it on something with a different style of ebrakes. I might use my 44A brackets (I bet they fit) or cut off what they welded on and re-notch it. Just another one of the 10,000 things I hadn’t expected.
http://www.fccsonline.com/pic/jeep/5.16.04.v.jpg


Thanks for the paint run Dad! http://www.fccsonline.com/pic/jeep/5.16.04.w.jpg



I asked him to get me “some” playground sand for the sandblaster to sand down that axle tomorrow for painting, he brought some back… 120 pounds some…
http://www.fccsonline.com/pic/jeep/5.16.04.z.jpg



The JKS Quick Disconnects and I just couldn’t reach a mutual understanding where it decided to un-seize itself. After hours of PB blaster and liberal amounts of heat, I called it quits. No project $ left, I guess I’ll just use dog-bone style links and unbolt them when I go off-road.
http://www.fccsonline.com/pic/jeep/5.16.04.x.jpg


Laptop screen support came in. Hoping I can off-road without ripping another laptop screen off of it’s hinges.
http://www.fccsonline.com/pic/jeep/5.16.04.y.jpg

OverkillZJ
03-06-2005, 02:12 PM
Matt,

how are you going to follow me to all the GSs if your Jeep is up on stands?

Hunter :ZJ:

I'll hover :thumbsup:

OverkillZJ
03-06-2005, 02:13 PM
A little sandblasting and parts washing, prepping to paint.
http://www.fccsonline.com/pic/jeep/5.18.04.a.jpg



http://www.fccsonline.com/pic/jeep/5.18.04.b.jpg



http://www.fccsonline.com/pic/jeep/5.18.04.c.jpg


Hung axle :D
http://www.fccsonline.com/pic/jeep/5.18.04.d.jpg


Big freaking dent in the new rear 44’s diff cover. Ron, what the heck did you do to these poor axles!?
http://www.fccsonline.com/pic/jeep/5.18.04.e.jpg


took the cover off of the old axle… apparently I forgot to put oil in there after putting it back together. Guess it’s a parts axle now!
http://www.fccsonline.com/pic/jeep/5.18.04.f.jpg


.
http://www.fccsonline.com/pic/jeep/5.18.04.g.jpg



http://www.fccsonline.com/pic/jeep/5.18.04.h.jpg



http://www.fccsonline.com/pic/jeep/5.18.04.i.jpg


http://www.fccsonline.com/pic/jeep/5.18.04.j.jpg



http://www.fccsonline.com/pic/jeep/5.18.04.k.jpg



http://www.fccsonline.com/pic/jeep/5.18.04.l.jpg



http://www.fccsonline.com/pic/jeep/5.18.04.m.jpg


Whoops, I had the fan on to vent the garage while painting. I guess I painted the fan.
http://www.fccsonline.com/pic/jeep/5.18.04.n.jpg




I don’t know how I ever lived with this trigger thing.
http://www.fccsonline.com/pic/jeep/5.18.04.o.jpg

OverkillZJ
03-06-2005, 02:13 PM
Cleaned the inside
http://www.fccsonline.com/pic/jeep/5.20.04.a.jpg



http://www.fccsonline.com/pic/jeep/5.20.04.b.jpg


started using a heat gun on the cascade (sound stuff) I slapped in the doors years ago and forgot to heat. Then slapping in speakers and door panels on.
http://www.fccsonline.com/pic/jeep/5.20.04.c.jpg


Cleaned up rear control arm bolts
http://www.fccsonline.com/pic/jeep/5.20.04.d.jpg


setting control arms
http://www.fccsonline.com/pic/jeep/5.20.04.e.jpg


UPS brought my repaired TomWoods driveshafts, still waiting on all of my other parts.
http://www.fccsonline.com/pic/jeep/5.20.04.f.jpg


.Oh ya… progress!
http://www.fccsonline.com/pic/jeep/5.20.04.g.jpg


I learned that the upper control arm mounts on the TJ axle are forward almost TWO INCHES of that on a ZJ axle. My upper arms are as short as can go after I was done adjusting, and the pinion is still too high. Will have to lengthen the lowers.
http://www.fccsonline.com/pic/jeep/5.20.04.h.jpg


I tried to put it up on the springs, but there’s not enough weight in the vehicle. The thing has about 14” of lift at the moment with an empty body in the back.
http://www.fccsonline.com/pic/jeep/5.20.04.i.jpg


http://www.fccsonline.com/pic/jeep/5.20.04.j.jpg


Put in an optima…
http://www.fccsonline.com/pic/jeep/5.20.04.k.jpg

Ok. Off to the junkyards, need to get parts...

OverkillZJ
03-06-2005, 02:15 PM
Nice axle droop!


:lol:


It's a shame you can't go for a nice custom paint job while you got the body all cleaned out. No better time to change colors completely....

OverkillZJ
03-06-2005, 02:15 PM
I ended up spending most of the day at a u-pull-it-yard with Brandon. This place had 7 THOUSAND vehicles, but not one single right side ZJ tail light and auto dimming rear view mirror. Ended up getting a regular XJ mirror. Also found shift linkage, brought it home and still seems to long. Screw it. Who needs to shift their tcase anyway? Also got 2 good D30 shafts from an XJ I’ll put 760’s into w/ full circle clips and tacked caps…. That should hold me over until I snap the shafts ;)
http://www.fccsonline.com/pic/jeep/5.21.04.b.jpg


Came home only for another wrench fest to begin. Didn’t really get that much done on the ZJ, after the junkyard, my body just hurts. I did get the Mopar lower radiator hose on though, which means now I can get that sway bar on there.
http://www.fccsonline.com/pic/jeep/5.21.04.c.jpg


Auto tap arrived (Thanks Risko!) – we thought we’d try it on the Rubi… Can you believe those things have an advanced timing of 9 freakin’ degrees? No wonder they drive like lil’ Honda engines…
http://www.fccsonline.com/pic/jeep/5.21.04.d.jpg


Thanks for dinner Bill!
http://www.fccsonline.com/pic/jeep/5.21.04.e.jpg


Some of Bill and Dave’s bike buddies stopped by. I don’t think they knew what the hell to make of all this...
http://www.fccsonline.com/pic/jeep/5.21.04.f.jpg

OverkillZJ
03-06-2005, 02:17 PM
How do you like the Auto Tap? I was thinking of getting one myself.

I dig it



How do you like the Auto Tap? I was thinking of getting one myself.

It rocks!


i used to run auto tap in the civic- its nice- if your tuning- but if theres not alot done aftermarket wise to the motor- its not super useful- imo

tony



....it really has nothing to do with anything aftermarket. Having a stalling problem? Want to see what position the IAC stepper motor is in? Track RPM's versus shift points? Check for DTC's and reset them without resetting the whole ECU?

I could go on and on about why the AT is one of the most useful tools I have, and my engine is not modded for power.

OverkillZJ
03-06-2005, 02:17 PM
Jeff stopped by for business stuff. We were only in the house 3 minutes, but by the time we came out we found that his 20 pound dog ate his half pound angus beef burger… I just had to post it… Where’d it all go!?
http://www.fccsonline.com/pic/jeep/5.21b.a.jpg


To the Jeep. Got the bumper mounting brackets and skid up.
http://www.fccsonline.com/pic/jeep/5.21b.b.jpg


Needless to say this didn’t work. Walter and Jeff stopped by to help during a crazy short storm.
http://www.fccsonline.com/pic/jeep/5.21b.c.jpg


That’s more like it.
http://www.fccsonline.com/pic/jeep/5.21b.d.jpg


Cleaned up front control arm bolts.
http://www.fccsonline.com/pic/jeep/5.21b.e.jpg


Putting it in place.
http://www.fccsonline.com/pic/jeep/5.21b.f.jpg


Yup.
http://www.fccsonline.com/pic/jeep/5.21b.g.jpg



http://www.fccsonline.com/pic/jeep/5.21b.h.jpg


I called it a night after I put together the drivers side door w/ speakers and all that fun stuff.
http://www.fccsonline.com/pic/jeep/5.21b.i.jpg

OverkillZJ
03-06-2005, 02:18 PM
Daytime shot of the bumper. Need to put in the truck lights, hitch wiring, and wire it all up.

http://www.fccsonline.com/pic/jeep/5.22.04.a.jpg


New Spicer ball joints.
http://www.fccsonline.com/pic/jeep/5.22.04.b.jpg


New Spicer ball joints installed and knuckles bolted on.
http://www.fccsonline.com/pic/jeep/5.22.04.c.jpg


They’re like moths to the flame. Jeeps just seem to appear wherever the tools are.
http://www.fccsonline.com/pic/jeep/5.22.04.d.jpg



http://www.fccsonline.com/pic/jeep/5.22.04.e.jpg


How’s that for progress? I’m still amazed by the beefiness of the Currie steering.
http://www.fccsonline.com/pic/jeep/5.22.04.f.jpg


Everyone who was supposed to set my gears around here has fallen through… Ugh. Put the pinion gear in the case to keep stuff out, and only running outer shafts for the hub-bearings. I’ll drive it to a shop in 2WD, or show up at Marks door in CO with gears in a box on the way to GSW :D
http://www.fccsonline.com/pic/jeep/5.22.04.g.jpg



http://www.fccsonline.com/pic/jeep/5.22.04.h.jpg



http://www.fccsonline.com/pic/jeep/5.22.04.i.jpg


http://www.fccsonline.com/pic/jeep/5.22.04.j.jpg


Calipers needed to be cleaned and lubed up.
http://www.fccsonline.com/pic/jeep/5.22.04.k.jpg


I’ve had good luck with this “disc brake quiet” stuff. Never have brake squeal.
http://www.fccsonline.com/pic/jeep/5.22.04.l.jpg



http://www.fccsonline.com/pic/jeep/5.22.04.m.jpg



http://www.fccsonline.com/pic/jeep/5.22.04.n.jpg


Mmmm… Shiny new rotors…
http://www.fccsonline.com/pic/jeep/5.22.04.o.jpg


Front tires on. I’d have it on the springs if Papromike would get me my ACOS. I can’t really center the axle or align it without it sitting on the springs. Need them now….
http://www.fccsonline.com/pic/jeep/5.22.04.p.jpg


Tires stick out further than I expected, though the axle isn’t close to centered. I think it’ll be about 1” per side. Need a Jeep friendly inspection station…
http://www.fccsonline.com/pic/jeep/5.22.04.q.jpg


Not bad for a days work…
http://www.fccsonline.com/pic/jeep/5.22.04.r.jpg


http://www.fccsonline.com/pic/jeep/5.22.04.s.jpg


My washing machines gonna hate me.

http://www.fccsonline.com/pic/jeep/5.22.04.t.jpg

EDIT: Thanks to my dad for fixing the rear latch (jammed)

OverkillZJ
03-06-2005, 02:21 PM
nice hand print, you should name that rag wilson. :D


WOW! Moving right along. That's alot of work!


Looking good Matt!

BTW - Gear set-up will cost you 2, yes TWO, cases of Yuengling Lager.
:thumbsup:

Consider it done!

As long as you point me to the beer distro near you, because that weight across the US would probably add another $100 to my gas bill :lol:




:thumbsup:

OverkillZJ
03-06-2005, 02:22 PM
Looking darn good. By the way.. where'd you get the Currie steering setup? Did it come with everything you needed for installation? Like the ball joint do-dad at the pitman arm, drag link, and tie rods? I saw the kit for like 400 and wasn't sure whether to go with Currie or Poison Spyder.. you obviously prefered the Currie, is there any particular reason why?

I got it shipped for 350 from summit, I think they sold their souls to the devil to get that price. It's the first product I've ever purchased that my man Kolak couldn't beat the price on.

The Poison Spyder setup rocks, don't get me wrong. I feel that the problem with it is that it uses your stock pitman arm. I bent my ZJ V8 tie rod a year ago and had been temporarily running an XJ pitman arm, which I also utterly destroyed. Even if I were to get a new ZJ pitman arm, I'd have to weld on the gusset that Poison Spyder provides. I don't have a welder, and I feel that that's "polishing a turd" anyway.

The Currie setup came with every nut, bolt, grease zerk, cotter pin, etc. Haven't put on the steering stablizer bracket yet.

OverkillZJ
03-06-2005, 02:22 PM
Looking darn good. By the way.. where'd you get the Currie steering setup? Did it come with everything you needed for installation? Like the ball joint do-dad at the pitman arm, drag link, and tie rods? I saw the kit for like 400 and wasn't sure whether to go with Currie or Poison Spyder.. you obviously prefered the Currie, is there any particular reason why?

I got it shipped for 350 from summit, I think they sold their souls to the devil to get that price. It's the first product I've ever purchased that my man Kolak couldn't beat the price on.

The Poison Spyder setup rocks, don't get me wrong. I feel that the problem with it is that it uses your stock pitman arm. I bent my ZJ V8 tie rod a year ago and had been temporarily running an XJ pitman arm, which I also utterly destroyed. Even if I were to get a new ZJ pitman arm, I'd have to weld on the gusset that Poison Spyder provides. I don't have a welder, and I feel that that's "polishing a turd" anyway.

The Currie setup came with every nut, bolt, grease zerk, cotter pin, etc. Haven't put on the steering stablizer bracket yet.


Summit? I don't suppose you can get me a link to that website or a phone number if they don't have one? 350 bones is pretty sweet. I suspect that my tie rod may have been slightly bent and that all the grease zerks are old and loose which is what is causing my vague steering, so I'd like to just replace the steering setup with something that's going to last. Thanks for the info. Also, is the whole steering installation a difficult task? I'll need a pitman arm puller if I'm replacing that, correct?

OverkillZJ
03-06-2005, 02:23 PM
www.summitracing.com


Matt - the point of the Yuengling is that you can't buy it here. :spank:

You have to bring it from PA.

:thumbsup:






Matt - the point of the Yuengling is that you can't buy it here. :spank:

:thumbsup:


LOL, ok, I get it now. I'll make room for it :thumbsup:


But if I get thirsty on the way there... ;)

OverkillZJ
03-06-2005, 02:24 PM
Hey, if Mark gets Yuenling, I get a case of Woodchuck!!! That's the price if you want to help me put power in my garage.

Let me get this straight, to save you a few grand by wiring 220 into your new garage, I need to give YOU a case of Woodchucks!? WHAT THE!?

Besides, UGLY brothers aren't allowed to post in my thread.

Man, they need to make me a Moderator of my own thread :pant:


Actually, if Mark doesn't mind a case of Woodchucks sitting in his garage until you can get it, that could be an option. I don't want to take it to GSW with me though.

Than again I could keep it in the hotel room since you're probably meeting me there anyway... hmmm.....


I have a feeling half the ZJ will be beer...

OverkillZJ
03-06-2005, 02:24 PM
I’d have it on the springs if Papromike would get me my ACOS

Nice. You might want to just count yourself lucky that he owned up the half of what he really owes....

You better get your behind in gear and stop talking on the Internet. We are like 2 weeks out.....

OverkillZJ
03-06-2005, 02:26 PM
I’d have it on the springs if Papromike would get me my ACOS

Nice. You might want to just count yourself lucky that he owned up the half of what he really owes....

You better get your behind in gear and stop talking on the Internet. We are like 2 weeks out.....

Not 2 weeks.. I have 10 days before I want to leave. I'll get it done.





---------------------------------------------------
Ok. Now I'm kind of annoyed. I've been on the job since 8am, freakin' client called yesterday saying "is it bad if our office server says operating system not found?"

Needless to say I've been here for 15 hours including a few breaks while scans ran. I hate this $hit.

One less day of wrenching :crazy

Back at it tomorrow, even if I have to close the company.

---------------------------------------------

Ok... I'm going on 22 hours here now.... Even if I finish now, that kinda takes most of todays wrenching away due to lack of sleep...

stupid computers...

OverkillZJ
03-06-2005, 02:28 PM
RedBull is your friend......


...just got home... job from 8am yesterday til 11am today.


Never, ever again :roll:

Time for bed.



RedBull is your friend......

it gives you wings!!


...and heart problems, haha

OverkillZJ
03-06-2005, 02:28 PM
So what was that you were saying about bets Matt?

We need some people runnin' numbers on this thing... #2, who am I kidding? Someone's probably already got you on a book-makers list in Vegas. :lol:

Keep it up man!

OverkillZJ
03-06-2005, 02:29 PM
Picked up a wiring box at radio-shaft, installed a wire bushing thingy in itl
http://www.fccsonline.com/pic/jeep/5.24.04.a.jpg


Mounted, but not wired up. I’ll do that last if I have time before the trip.
http://www.fccsonline.com/pic/jeep/5.24.04.b.jpg



http://www.fccsonline.com/pic/jeep/5.24.04.c.jpg


I’m hungry at the moment, and the picture of dinner looks so good I just had to post it.
http://www.fccsonline.com/pic/jeep/5.24.04.d.jpg


cleaned up the center console
http://www.fccsonline.com/pic/jeep/5.24.04.e.jpg


Started wiring the switches to a wiring harness, but got so sick of it I haven’t touched it since.
http://www.fccsonline.com/pic/jeep/5.24.04.f.jpg


Worked on one of the rear doors for awhile.
http://www.fccsonline.com/pic/jeep/5.24.04.g.jpg


Guess I didn’t really get that much done. Oh well, at least the shocks came in.
http://www.fccsonline.com/pic/jeep/5.24.04.h.jpg

OverkillZJ
03-06-2005, 02:29 PM
Time to change the bearings and seals on the Moser D44 shafts. It wasn’t as bad as I’d expected, except for packing the bearings which HA Brandon did anyway…

http://www.fccsonline.com/pic/jeep/5.25.04.a.jpg


http://www.fccsonline.com/pic/jeep/5.25.04.b.jpg



http://www.fccsonline.com/pic/jeep/5.25.04.c.jpg


http://www.fccsonline.com/pic/jeep/5.25.04.d.jpg



http://www.fccsonline.com/pic/jeep/5.25.04.e.jpg

Brandon was using my cheapie brake cleaner to clean up one of the retaining plates, and I had the urge to light it on fire…. http://www.fccsonline.com/pic/jeep/5.25.04.f.jpg

Want to do it again…

http://www.fccsonline.com/pic/jeep/5.25.04.g.jpg

Jeff taking off parts of the old AL44 (POS) axle so I can throw the rest of it in the trash pile.
http://www.fccsonline.com/pic/jeep/5.25.04.h.jpg

I don’t think Snoopy wants to be up there.
http://www.fccsonline.com/pic/jeep/5.25.04.i.jpg

Discovered that ZJ disc brake backing plages have a 1/8” smaller whole than Rubi plates. We ended up moving all of my ZJ brake parts except calipers and pads over to the Rubi backing plates that came on the TJ44 axle I bought.

OverkillZJ
03-06-2005, 02:31 PM
Obviously the Turbo City air intake arrived from Kolak… What it’s doing on Jeffs head, well, I don’t know.
http://www.fccsonline.com/pic/jeep/5.26.04.a.jpg

I invested way too much time organizing the ignition wires perfectly. Looks sweet though.
http://www.fccsonline.com/pic/jeep/5.26.04.b.jpg

The only thing that looks cooler than this intake, is it’s sound. It’s rare that the intake sounds cooler than the intake.

Yes, I know it sucks hot air. I don’t really care, it solves my problem.
http://www.fccsonline.com/pic/jeep/5.26.04.c.jpg

Rear shafts and backing plates in.
http://www.fccsonline.com/pic/jeep/5.26.04.d.jpg

Rotors and calipers on, e-brake connected and adjusted.
http://www.fccsonline.com/pic/jeep/5.26.04.e.jpg

I broke my fan shroud last week in such a way that it got sucked into the fan whenever you rev it (air sucks it in) – Brandon did a darn good job of fixing it with a metal brace riveted in.
http://www.fccsonline.com/pic/jeep/5.26.04.f.jpg

Rear drive shaft is in. Rebuilt by Tom Woods for a very fair price and great service as always. The splines were so seized that the unit had to be cut out and replaced. Half of the shaft is now new.
http://www.fccsonline.com/pic/jeep/5.26.04.g.jpg

His new special joints have grease zerks on the outside of the caps. I think it rocks, SO easy to grease it while the shaft is installed now.
http://www.fccsonline.com/pic/jeep/5.26.04.h.jpg

OverkillZJ
03-06-2005, 02:35 PM
nice shaft


Are you hitting on me? :pant:


:oops: i didnt mean to give you the wrong impression. i mean your a nice guy and all but i just don't feel that way abotu ya. I was talking to the jeep. do you think she likes me? :thumbsup:


:oops: i didnt mean to give you the wrong impression. i mean your a nice guy and all but i just don't feel that way abotu ya. I was talking to the jeep. do you think she likes me? :thumbsup:

:lol:


I don't care if she likes ya, I'm kind of possesive of her :spam:



ya well. one of these days. man i wana come out there and wheel with some of the guys on this board. when is the next GSNW? i'm be rollin on 1 tons in 2 weeks and i wana go out and try to brake #2 with some real grands not the stockers out here.


GSNW might be the only grand slam I never make it to, I'm entirely on the other coast. Get to GSW though ;)

I think there's actually openings now...




hmm. do you knwo where thats held? i might make the effort to go out there.


GSW is held in Moab.

I am going to make every effort to go to GSNW as well. I am kinda hoping they have it in Elensburg or Enchilium (sp). The Dry side of the cascades has some nifty rock formations and lots of big tight tree's.

Matt- Keep up the fire man...you only have like 7-8 days!!

They chuggy is ready. Only thing I am missing is a pair of front shafts for the 30. darn movers lost them when they moved us from Alaska. None in the JY around here but I am hoping to get a set in Pocatello.

If anyone reading this has a set and they wanna get rid of them....I am buying.....lol


I've been asking around for ya.

My junk is almost ready. The atlas goes out for its trial run this weekend. Just need to come back, fix what I break, and finish up a few little things befor GSW. I wish I had the time and money to do the airshox befor GSW, but I don't think it's in the cards.

Cody

OverkillZJ
03-06-2005, 02:36 PM
GSW is held in Moab.



If anyone reading this has a set and they wanna get rid of them....I am buying.....lol

I'll have an extra set of CV-style axle shafts that need new boots, but i don't see those lasting very long with you :lol:


if I had the time I'd pull some from a junker around here for you, you can get a set here for $15 each and slap some 760's in them :D

OverkillZJ
03-06-2005, 02:37 PM
I guess that cutoff disc is done with then? It was almost impossible to get it off when that much was gone.
http://www.fccsonline.com/pic/jeep/5.27.04.a.jpg

Trimmed more in the fender wells. There’s not much left…
http://www.fccsonline.com/pic/jeep/5.27.04.b.jpg

I found that I missed the bottom nut to the transfercase/tranny mounting surface. I managed to get it in there without dropping the crossmember, but it really sucked doing so.
http://www.fccsonline.com/pic/jeep/5.27.04.c.jpg

Tcase skid is in
http://www.fccsonline.com/pic/jeep/5.27.04.d.jpg


Of course the TJ clown crew had to come by to lose more of my tools and aggravate me just a little more and take more of my project time away ;)
http://www.fccsonline.com/pic/jeep/5.27.04.e.jpg

Guess it was time for Bills Rubi to grow up just a little.
http://www.fccsonline.com/pic/jeep/5.27.04.f.jpg

Daves is next
http://www.fccsonline.com/pic/jeep/5.27.04.g.jpg

I wish I took a picture when my dads grand was there too, jeep parking log. Neighbors hate me. I get glared at, it’s amusing.
http://www.fccsonline.com/pic/jeep/5.27.04.h.jpg


http://www.fccsonline.com/pic/jeep/5.27.04.i.jpg

Yes.. His Jeep is apart in the middle of a public street.
http://www.fccsonline.com/pic/jeep/5.27.04.j.jpg


Back to mine. I don’t even know what this pics of. I don’t care anymore.

My head hurts.

I want a cookie, can I have a cookie before bed?
http://www.fccsonline.com/pic/jeep/5.27.04.k.jpg



Instead of Brandon helping me as he said he would, he found it more productive to link the air compressors together and add a 3 way manifold… IT’s neat and all, but it doesn’t get me any closer to being ready for my trip. At least he put the darn rear diff skid plate on.
http://www.fccsonline.com/pic/jeep/5.27.04.l.jpg


Brake lines are in on the front. Need new copper washers though.
http://www.fccsonline.com/pic/jeep/5.27.04.m.jpg



http://www.fccsonline.com/pic/jeep/5.27.04.n.jpg


Of course they’re not done before midnight……
http://www.fccsonline.com/pic/jeep/5.27.04.o.jpg



http://www.fccsonline.com/pic/jeep/5.27.04.p.jpg


I need friends with real Jeeps!
http://www.fccsonline.com/pic/jeep/5.27.04.q.jpg

OverkillZJ
03-06-2005, 02:38 PM
I didn’t have a dead-blow hammer that’s heavy enough to pound the control arms into place, so I made one. Of course I ended up scratching the nice new paint up anyway.
http://www.fccsonline.com/pic/jeep/5.28.04.a.jpg

I spent the next several hours just lining up control arms and setting pinion… I think I got it right after, well, hours. I love Claytons arms when they’re on, but what a PITA it is to adjust them when your tabs are bent up.
http://www.fccsonline.com/pic/jeep/5.28.04.b.jpg



http://www.fccsonline.com/pic/jeep/5.28.04.c.jpg


http://www.fccsonline.com/pic/jeep/5.28.04.d.jpg



http://www.fccsonline.com/pic/jeep/5.28.04.e.jpg


http://www.fccsonline.com/pic/jeep/5.28.04.f.jpg


http://www.fccsonline.com/pic/jeep/5.28.04.g.jpg

OH! WHAT’S THAT!? SHOCKS AND SPRINGS!
http://www.fccsonline.com/pic/jeep/5.28.04.i.jpg

My dad putting on my new rear tail light. At least some of it will pass inspection!
http://www.fccsonline.com/pic/jeep/5.28.04.j.jpg


After a long hard days work, most of which I didn’t take any pictures of, the Jeep is NO LONGER ON JACKSTANDS!!! WOHOO!

I still have a lot of work, but today was a huge accomplishment. How the heck to I get the springs to settle? These are the same springs I had on before, which netted 6”… but at the moment, I think it’s sitting at 10”. I tried bouncing the heck out of it, didn’t seem to make them budge.

Also have to figure out the rear brake line plumbing. No idea just what I’m going to do yet.
http://www.fccsonline.com/pic/jeep/5.28.04.k.jpg

http://www.fccsonline.com/pic/jeep/5.28.04.o.jpg

OverkillZJ
03-06-2005, 02:39 PM
ummm.........
just curious.......
but ummmm.......
The rubi is BRAND NEW.
What the heck took so long to put in a budget boost?
Last jeep Bill had was rusted together, so he had an excuse then.
:lol:

Super shorty is done. TCase goes back in tomorrow AM, then we're off to Carnage on Sunday for a shakedown run.
:thumbsup:

Gonna go play on Storm Mountain tomorrow for shits and giggles.

Who knows, it is Bill after all!

And hey, my Jeep WAS rusted together :thumbsup:

This things coming together... kinda

OverkillZJ
03-06-2005, 02:42 PM
oh man, youll make it, your off jacks and you know thats a good feeling. things will fly right as rain. :thumbsup:


Matt- If you for some reason find it in your heart to go get me a set of shaft I will be eternally grateful....lol. But will you bring those dang CV shafts if you don't? They would only be in a emergency situation most likely anyway, and I would just pull strap on anything that required big power.

But if you could get a set out of the junkyard....You would ROCK. There just are not any in the yards here in North Dakota, well within 100 miles anyway.

I just hate not having those spares, darn movers. And darn me for not checking on them sooner than a week before I leave....



ummm.........
just curious.......
but ummmm.......
The rubi is BRAND NEW.
What the heck took so long to put in a budget boost?
Last jeep Bill had was rusted together, so he had an excuse then.
:lol:

Super shorty is done. TCase goes back in tomorrow AM, then we're off to Carnage on Sunday for a shakedown run.
:thumbsup:


It didn't take long to do the budget boost, the first time.. It's because we did it twice :-D What it really came down to is noone bothered to read the directions, thus we put the short bump stop spacers up front with the long bolts.. Got everything bolted back together hella quick. Get to the rear. Hrmm.. Bolts are entirely to short.. Had to put the rear back together, take fhe front apart again, swap the bolts and then reassemble and redo the rear. It was a clusterfuck.

Oh, and Bill lost a number of bolts to the airbox. So we spent a while looking for things. The lack of daylight didn't help any of the above.



What it really came down to is noone bothered to read the directions

:spank:

I'm off to Carnage for some long-deserved wheelin. First run on the 4.88's, ARB, and a host of other new items.

:greet:

OverkillZJ
03-06-2005, 02:43 PM
Matt- If you for some reason find it in your heart to go get me a set of shaft I will be eternally grateful....lol. But will you bring those dang CV shafts if you don't? They would only be in a emergency situation most likely anyway, and I would just pull strap on anything that required big power.



Getting to go to a junkyard is looking bleak, unless I find time while visiting Mark. I really want to pull a TJ sway bar anyway, I hate not having a sway bar on this Jeep...

OverkillZJ
03-06-2005, 02:44 PM
I have a few more days of updates... I find my Jeep being almost done yet having several large (almost no-go) problems... But I seem to have a solution for each one only if I get some serious help from both friends and vendors.

At t his point, you could drop an a-bomb on my Jeep and I might not mind. I'm so sick of working on it I wish I never had to again. Only thing that's driving me is the thought of going on my 35 day excursion itself.... Just wouldn't be the same in my econo-car.


I'm not going to update tonight, I cant' even function. Up and at them bright and early tomorrow, two days left...

OverkillZJ
03-06-2005, 02:44 PM
I say you just steal Brandon's swaybar... :lol:

I'm close to doing it... along with stealing my dads rear brake line setup.

Or I could just take yours...

Heck, I'll take your whole Jeep. I'm sick of this.


BTW, for the record, no projects here until I'm done with this, seriously. I'm having enough trouble dealing with my own :eek:

OverkillZJ
03-06-2005, 02:45 PM
I'm sure we can track down a sway bar and shafts here. It may cost you more $$ though, some of the local yards think thier #2 is gold plated. :roll:

Ran Carnage yesterday. Beautiful day, ended up with 7 jeeps. ARB, gears, HP30, everything worked great. :thumbsup:

OverkillZJ
03-06-2005, 02:45 PM
I say you just steal Brandon's swaybar... :lol:

I'm close to doing it... along with stealing my dads rear brake line setup.

Or I could just take yours...

Heck, I'll take your whole Jeep. I'm sick of this.


BTW, for the record, no projects here until I'm done with this, seriously. I'm having enough trouble dealing with my own :eek:

Don't worry about me... I am done for now with mine. Only wrenching I plan on doing at your place is on your Jeep. :smiley22:

OverkillZJ
03-06-2005, 02:47 PM
Matt, if you call Novak's up in New Brighton and tell them what you want I will run up after work tomorrow and pick the parts up. They always have a few TJs in the yard.


Matt, what swaybar do you need? I have the rear one off my ZJ I could send you temporarily since my ZJ isn't going anywhere for awhile. Shoot me a PM w/ anything else you need that I may have.


Matt, what swaybar do you need? I have the rear one off my ZJ I could send you temporarily since my ZJ isn't going anywhere for awhile. Shoot me a PM w/ anything else you need that I may have.

Thanks Risko, ZJ sway won't come close to working on that TJ axle though; I tried with mine, and my brothrs XJ sway. Brandon (Pittsburgh Brandon) located one at Novak though, need to call them tomorrow.... Bill, if you're not working tomorrow and they have it, any chance you could swing up there? :crazy


Anyway, I just lost 3 hours due to breaking my glasses working on the Jeep. I spilled a bottle of paint that went into my eyes and I swiped the glasses off. After 5 minutes of flushing out my eyes, had to have my mom drive me for new glasses.

More money down the drain.


En den???

3 of us are out there working our @$$es off to get it rolling here shortly :thumbsup: (tonight)

Nothing like midnight wrenching...

OverkillZJ
03-06-2005, 02:47 PM
Well it rolls, but not under it's own power yet :lol:

So close. All that's left to really test drive (and get the springs to settle) is lowering the front pinion angle to help with the claytons LA's hitting the HP30, and tightening things up. Not to mention a backyard-alignment.

OverkillZJ
03-06-2005, 02:47 PM
ahh fun fun :lol: :ZJ:
You TJ guys :roll:





;)

OverkillZJ
03-06-2005, 02:48 PM
I took this picture to my local napa for parts to make brake lines that will work well. Of course they looked at me like “huh?”

http://www.fccsonline.com/pic/jeep/5.29.04.a.jpg

Dad soldering in the new rear door harnesses
http://www.fccsonline.com/pic/jeep/5.29.04.b.jpg


Bill and Dave throwing most of the interior together
http://www.fccsonline.com/pic/jeep/5.29.04.c.jpg


http://www.fccsonline.com/pic/jeep/5.29.04.d.jpg



http://www.fccsonline.com/pic/jeep/5.29.04.e.jpg


http://www.fccsonline.com/pic/jeep/5.29.04.f.jpg

That was scary, never had a wheel destroy itself like that before
http://www.fccsonline.com/pic/jeep/5.29.04.g.jpg

Trimming the rear spring perches to get the schocks by
http://www.fccsonline.com/pic/jeep/5.29.04.h.jpg

All the neighbors see is a bunch of people working on one vehicle in a tent and it getting bigger and louder
http://www.fccsonline.com/pic/jeep/5.29.04.i.jpg

Looking good :thumbsup:
http://www.fccsonline.com/pic/jeep/5.29.04.j.jpg



http://www.fccsonline.com/pic/jeep/5.29.04.k.jpg


The rear springs were sliding into the shock tubes, so we made some “ghetto” retainers. They don’t need to prevent the spring from lifting up, considering the springs flex through the entire suspension cycle.

I did the other side much better, this will have to do for now.
http://www.fccsonline.com/pic/jeep/5.29.04.l.jpg



http://www.fccsonline.com/pic/jeep/5.29.04.m.jpg



http://www.fccsonline.com/pic/jeep/5.29.04.n.jpg


Checking for shock clearance.
http://www.fccsonline.com/pic/jeep/5.29.04.o.jpg

OverkillZJ
03-06-2005, 02:50 PM
My spring retainers
http://www.fccsonline.com/pic/jeep/5.30.04.a.jpg


http://www.fccsonline.com/pic/jeep/5.30.04.b.jpg


Door wiring continues
http://www.fccsonline.com/pic/jeep/5.30.04.c.jpg


http://www.fccsonline.com/pic/jeep/5.30.04.d.jpg



http://www.fccsonline.com/pic/jeep/5.30.04.e.jpg


http://www.fccsonline.com/pic/jeep/5.30.04.f.jpg

I didn’t take any pictures the whole day after that. Brandon and I had been busy racking our brains over the crazy brake connector this axle came with. I have no idea where it came from, but after hours and hours, we simply couldn’t get it to work.
http://www.fccsonline.com/pic/jeep/5.30.04.g.jpg

For one last hurrah we got in Brandons TJ to go to his house and see if his old YJ had some brake parts that would work. It did, but were on a welded plate that just wasn’t worth removing. I want his GPS unit though… Neato…
http://www.fccsonline.com/pic/jeep/5.30.04.h.jpg


http://www.fccsonline.com/pic/jeep/5.30.04.i.jpg


http://www.fccsonline.com/pic/jeep/5.30.04.j.jpg


That left us with brakes not done.
http://www.fccsonline.com/pic/jeep/5.30.04.k.jpg


Next problem. HP30 and Claytons Long Arms really don’t get along. Not at all. Arm hits the diff in a baaaad way.
http://www.fccsonline.com/pic/jeep/5.30.04.l.jpg


Here’s a picture of that crazy little brake thing we couldn’t find the correct connector for.
http://www.fccsonline.com/pic/jeep/5.30.04.m.jpg



http://www.fccsonline.com/pic/jeep/5.30.04.n.jpg


Shot of that door harness. Easy to remove those doors now!
http://www.fccsonline.com/pic/jeep/5.30.04.o.jpg


Underside shot
http://www.fccsonline.com/pic/jeep/5.30.04.p.jpg


This is not the kind of Corona that you want to drink…
http://www.fccsonline.com/pic/jeep/5.30.04.q.jpg



http://www.fccsonline.com/pic/jeep/5.30.04.r.jpg


Breakfast… lunch…dinner… it doesn’t matter anymore. It’s pizza or something cheap.
http://www.fccsonline.com/pic/jeep/5.30.04.s.jpg

OverkillZJ
03-06-2005, 02:51 PM
I don’t feel like typing stuff… Here’s pictures….
http://www.fccsonline.com/pic/jeep/5.31.04.a.jpg


http://www.fccsonline.com/pic/jeep/5.31.04.b.jpg



http://www.fccsonline.com/pic/jeep/5.31.04.c.jpg


http://www.fccsonline.com/pic/jeep/5.31.04.d.jpg



http://www.fccsonline.com/pic/jeep/5.31.04.e.jpg


http://www.fccsonline.com/pic/jeep/5.31.04.f.jpg


http://www.fccsonline.com/pic/jeep/5.31.04.g.jpg


http://www.fccsonline.com/pic/jeep/5.31.04.h.jpg


http://www.fccsonline.com/pic/jeep/5.31.04.i.jpg


http://www.fccsonline.com/pic/jeep/5.31.04.j.jpg



http://www.fccsonline.com/pic/jeep/5.31.04.k.jpg



http://www.fccsonline.com/pic/jeep/5.31.04.l.jpg



http://www.fccsonline.com/pic/jeep/5.31.04.m.jpg



http://www.fccsonline.com/pic/jeep/5.31.04.n.jpg



http://www.fccsonline.com/pic/jeep/5.31.04.o.jpg



http://www.fccsonline.com/pic/jeep/5.31.04.p.jpg



http://www.fccsonline.com/pic/jeep/5.31.04.q.jpg



http://www.fccsonline.com/pic/jeep/5.31.04.r.jpg

OverkillZJ
03-06-2005, 02:53 PM
fantastic progress! this project has been a blast to watch... congrats dude


we goin' to fill that beast up at sunoco tonight or what!? :smiley22:


You know what.....I have the brakeline that attaches to your stock line and that crazy fitting in my trail box...lol....figures. Looks like you got it figured out anyway.

Oh and I think Cody found me some shafts. But still bring your spare cv's just incase.

Looks like your about done!

OverkillZJ
03-06-2005, 02:53 PM
we goin' to fill that beast up at sunoco tonight or what!? :smiley22:

only if somone gets over here to help me set that pinion angle :lol:


You know what.....I have the brakeline that attaches to your stock line and that crazy fitting in my trail box...lol....figures. Looks like you got it figured out anyway.

Oh and I think Cody found me some shafts. But still bring your spare cv's just incase.

Looks like your about done!

The local shops looked at it and said "what the h3ll is that?"
Oh well. Works now, I like using common parts anyway incase I need to replace at some point.

Looks done, but really not close :-/

OverkillZJ
03-06-2005, 02:54 PM
super smart way to do the rear doors. I'm going to do that. where did you get that little connector?

:)

www.allelectronics.com


Ok.. .Time to go set my pinion angle and dial a few things in so I can uh, DRIVE IT!

OverkillZJ
03-06-2005, 02:55 PM
My spring retainers
http://www.fccsonline.com/pic/jeep/5.30.04.a.jpg





at least its not just a bolt sittin there when i first peeped it NACE! :thumbsup:

OverkillZJ
03-06-2005, 02:56 PM
Claytons LA's version 2.0 are HP30 compliant. Otherwise let the grinding begin.

Already ground down, but out of curiosity, did he move the mounting point on the lower arm further back, or do something different with the bracketry with the upper arm?

I'm about to go test drive, if I die, hope you enjoyed the read :thumbsup:


He welded the axle end of the UCA at an angle to provide the offset needed to clear the pumpkin. Good luck on the test drive!


Finally seeing someone else doing wiring the "right" way- soldering, shinkwrap and the whole bit.

Looking good. can't wait till it's done

OverkillZJ
03-06-2005, 02:57 PM
IT'S ALIVE!!! IT'S ALIVE!!! IT WORKS!!!![/color]

OverkillZJ
03-06-2005, 02:58 PM
In 30 minutes, there will be more pics.. and.. VIDEO of the maiden voyage!!!



He welded the axle end of the UCA at an angle to provide the offset needed to clear the pumpkin. Good luck on the test drive!

I just Called Clayt to order that angled arm and a 4-link rear :lol:

My grinding job seems to have worked, but it's still closer than I'd like it to be. Plus I still have some caster adjustment to make.

OverkillZJ
03-06-2005, 02:59 PM
No pictures needed.

Leaving for a 35 day road trip Thursday morning... In the Jeep of course :thumbsup:

I've been building the Jeep just for it.


http://www.fccsonline.com/pic/jeep/6.1.04.a.jpg

http://www.fccsonline.com/pic/jeep/6.1.04.b.jpg

http://www.fccsonline.com/pic/jeep/6.1.04.c.jpg

http://www.fccsonline.com/pic/jeep/6.1.04.d.jpg

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http://www.fccsonline.com/pic/jeep/6.1.04.f.jpg

http://www.fccsonline.com/pic/jeep/6.1.04.g.jpg

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http://www.fccsonline.com/pic/jeep/6.1.04.i.jpg

http://www.fccsonline.com/pic/jeep/6.1.04.j.jpg

http://www.fccsonline.com/pic/jeep/6.1.04.k.jpg

http://www.fccsonline.com/pic/jeep/6.1.04.l.jpg

http://www.fccsonline.com/pic/jeep/6.1.04.m.jpg

http://www.fccsonline.com/pic/jeep/6.1.04.n.jpg

http://www.fccsonline.com/pic/jeep/6.1.04.o.jpg

http://www.fccsonline.com/pic/jeep/6.1.04.p.jpg

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http://www.fccsonline.com/pic/jeep/6.1.04.r.jpg

http://www.fccsonline.com/pic/jeep/6.1.04.s.jpg

http://www.fccsonline.com/pic/jeep/6.1.04.t.jpg

http://www.fccsonline.com/pic/jeep/6.1.04.u.jpg

http://www.fccsonline.com/pic/jeep/6.1.04.v.jpg

http://www.fccsonline.com/pic/jeep/6.1.04.w.jpg

http://www.fccsonline.com/pic/jeep/6.1.04.x.jpg

http://www.fccsonline.com/pic/jeep/6.1.04.y.jpg

http://www.fccsonline.com/pic/jeep/6.1.04.z.jpg

http://www.fccsonline.com/pic/jeep/6.1.04.za.jpg

http://www.fccsonline.com/pic/jeep/6.1.04.zb.jpg

http://www.fccsonline.com/pic/jeep/6.1.04.zc.jpg

http://www.fccsonline.com/pic/jeep/6.1.04.d.jpg

OverkillZJ
03-06-2005, 03:01 PM
It's Alive!!

The exhaust on the video sounds great with a sub :thumbsup:

Nice job. Have fun beating the bag out of it. :D




Dude I didn't think you would do it.

Good job.

One piece of advice though. Watch that rear tire carrier. That tire is hanging WAY off that sucker. It is putting a shizz load of shear force on the pin and latch.

Here is what a 36 will do to a 2k trailer spindle....

http://www.wheelingadventures.com/Northern4x4/iB_html/uploads/post-10-07325-amemscotttirecarrier.jpg

And it wasn't hanging out near as far as your tire.

http://www.fccsonline.com/pic/jeep/6.1.04.i.jpg

OverkillZJ
03-06-2005, 03:01 PM
Dude I didn't think you would do it.

Good job.

One piece of advice though. Watch that rear tire carrier. That tire is hanging WAY off that sucker. It is putting a shizz load of shear force on the pin and latch.


And it wasn't hanging out near as far as your tire.



I was wondering if anyone would notice that, that was on my list of things I wish I had time to fix. I think I will have time to fix it before GSW, don't want to see my 35" tire rolling down dump bump.

OverkillZJ
03-06-2005, 03:04 PM
:thumbsup: Look forward to seeing it at Moab!


Looks and sounds sweeeeet ... congrats man. But does this mean that the phoenix saga is comming to an end? :cry: Good luck on your trek!


Looks and sounds sweeeeet ... congrats man. But does this mean that the phoenix saga is comming to an end? :cry: Good luck on your trek!

Don't worry, it's not coming to an end just yet :lol:

It's still two wheel drive, I wasn't confident enough to set the gears in the HP30. I'm staying at my buddy's in Loveland Colorado (Karstman in this thread) for almost a week of finishing the darn thing. 4 link rear (if we decide it's truly needed, Claytons sending the kit out there to meet me there) - set the front gears, and other work that I need before it's Moab ready...

Besides, I rebuilt this thing for this trip, shouldc I just keep the trip in this thread? :thumbsup:


three words- BEST THREAD EVER!!!

and yes keep it in this thread


congrats!!!! :thumbsup: thanks for the best thred ever!


Awesome!

Thanks for the well documented build. It inspired me to clean and paint some of my ZJ parts I never would have done before. Gotta keep that road salt induced cancer at bay ya know.

I vote this thread becomes a sticky. Lotsa good material. I think it's even better than a write-up. It's real with all the other stuff that goes along with an intense wrenching and build. :thumbsup:

Have a great trip. May the fates of breakage and carnage be blind to your Jeep.


:werd:


I come to NAGCA just to check up on this thread every day :o

OverkillZJ
03-06-2005, 03:05 PM
As of 2:30 am, I'm still wiring in the radio, putting on doors, greasing up the suspension, putting in the CB, wiring in the secondary battery, etc etc. And I'm driving across the US in this thign tomorrow? :eek:

Oh ya. I need to do laundry and pack. I smell and all nighter and long miserable drive.

OverkillZJ
03-06-2005, 03:06 PM
:party :party :party

Now go out an enjoy that thing!!!

I think this thread has been a bit of an inspiration to us all. I know it got me up off my duff and out in the shop a lot more often. Now I pretty much go out there every night (if for no other reason than to look around and straighten up a little bit) You're going to be cleaning up your tent for a week after you get back, but you can worry about that after the road trip! :lol:

Peace out & Drive safe!!!



Matt,

Just AWESOME. Thanks for the great diary and the ride looks SWEEEET.

Can you give us a little recap like how many days to build, $$$ spent, # of people involved in the build, stuff like that?

Yes I agree this thread should be a sticky. It is a great resourse.

Oh yea the Turbo city intake looks great.




I want a beer count, minus any coors light, and the approximate number of pizzas eaten preferably in (multi-color)pie chart form.... according to toppings. :lol:

I guess I forgot about the # of beers that is also important. :D


I don't drink that Coors light crap... Don't worry.... I'm still here. I wanted to leave 24 hours ago. I had it all together last night only to find tons of electrical gremlins. I've got the entire dash torn apart again. Need power in the Jeep...

OverkillZJ
03-06-2005, 03:11 PM
36 hours post the time I should've left.

I snapped off a steering box bolt. Grade 8. Still in the box. Upper bolt.


I suck.

This sucks.

I want to go to Colorado.


EDIT: I didn't go to bed last night either.


You can always come to GSE... :lol:


Hey Matt, I am in Loveland too if you guys need a hand, or just someone to drink beer and watch you work. I would be happy to help you out, just let me know. Plus, now I don't know what I am going to do to get my online Jeep crack fix. Guess I will have to go back to those sites with the naked girls on them ;)

I could be up for slave labor help :thumbsup: ;)



Well... 4am guys, and it's as done as it's going to be until I get to Marks anyway to finish up the suspension. Had to pull out the steering box to remove the shattered bolt, ;) what a PITA. Not pulling the box, getting the bustedbolt out.

Going on 1 hour of sleep here (last night) - I'll post some more updates when my dads driving.


Dude, your Dad is a saint, you're pretty lucky. Mine could give a rats a$$ about this whole 4x4 stuff much less ride shotgun to Moab. Have fun brotha, and good luck!


HAH! My old man is coming with me to Moab as well!! I am picking him up in Pocatello.

See you there Matt!


Since Matt hasn't updated yet..

He left this morning. I talked to him around noon and they were in Columbus. He's got quite a way's to go yet ;)

There was a stupid mistake made last night that prolonged things... I'm not going to mention what it is, I'll let him make that decision ;)


It usually is a stupid mistake.



Hey Matt, I am in Loveland too if you guys need a hand, or just someone to drink beer and watch you work. I would be happy to help you out, just let me know. Plus, now I don't know what I am going to do to get my online Jeep crack fix. Guess I will have to go back to those sites with the naked girls on them ;)

Where you at in Loveland?
I'm over near Namaqua and 34.
mark


I'm at Madison and 14th more or less. I'm right next to Walt Clark M.S. and T.V.H.S.


You on colorado4x4.org?

I'll shoot a PM when the wrench fest begins. Fortunately, I pretty much finished up my TJ last week, so we can make room in the garage for his ZJ. ;)

Matt's in St. Louis and cruising OK. SOB was asleep and letting his old man drive. Sounds like he's gonna get stuck driving most of Kansas while his dad sleeps.... :lol:

EDIT - BTW - you by chance work at Home Depot?


I'm not on colorado4x4, but yes I do work at depot. Let me know when you start spinning wrenches, I may have to work (seem to always have to work when something cool is going on). When is Matt supposed to get in? If nothing else I could stop by and shoot the poo.


He should get here in a few hours I guess.

I'll shoot a PM once we get wrenching. I figured that was your rig with the OX stickers when I read your signature.


I have to close tonight but still PM me, maybe I can stop by later...

OverkillZJ
03-06-2005, 03:11 PM
Yes, My dad is a saint. It'e true. He's not coming to GSW, he's flying back to Pittsburgh tomorrow morning, he only came since I couldn't make the drive having pulled 2 all nighters this week and 1 the previous week.

HELLO FROM THE ROAD!

Should be at Marks (Karstman) in about an hour, heading up 470 towards loveland right now.

I have some darn funny pictures and stories of break downs and parking lot alignments, as well as the beast next to a stock ZJ. Unfortunately my card reader stopped reading, hoping my card works in Marks camera to get some pictures up.

Also, Brandon (supremecommand) was nice enough to lend me his very good digital video camera for the trip, so we'll have some great action shots.

Oh, Mark, is it bad if my Jeep feels like it's going to explode every time I take the load off of the driveline? :thumbsup:

Ya, some bearings shot, axles way too far back and driveshafts over extended. We vibrated our way here under 70. Ok. Back to playing navigator since my dad won't let me drive my own Jeep at the moment :roll:

OverkillZJ
03-06-2005, 03:14 PM
Can't wait to see this BEAST!!!!!!!!!!

I like Colorado and don't really want to go home :lol:

Anyway, Mark and I put in a lot of work yesterday, cut off the rear upper CA brackets and welded on the Claytons 4-link truss. Got the bolts cut to size and on the rig, but we painted the axle before we realized we forgot to fab sway-bar mounts. I refuse to offraod this thing with out at least a small rear sway bar again, it leaned like a mo-fo when it was smaller, don't want to know how easy it'll flop now.

The Tom Wood drive shaft seems to have survived the horrible pinion angle I had it set to driving here, I didn't have enough throw in the claytons long arms to adjust it correctly; since I'm using a TJ axle with stock brackets. that's why the 4-link came along. It's a solution and an upgrade. Had a horrible grinding noise on coast on the last 200 miles here, honestly didn't think I was going to make it. Still haven't found the noise, but I'm afraid to pull the rear diff cover. I don't really want to know what I'd find.
I had a check engine light on the whole way here, code 21 (no reading from O2 sensor) - put my scan tool on it and found it to be downstream. Pulled it yesterday to find it crushed. I think When I was lining up exhaust components, I slid pipe into it too far during the test fit. Need to pick up a new one today. Fan clutch is also toast, it seems to have "friction" when you turn it with your hands, but I didn't hear that usual 5.2 "Roar" the entire way here, even in traffic where it most definately should have kicked in. Going to replace that too.

Also need to find some darn axle shafts... the ones I pulled from the junkyard had 260's in them, didn't even think to check.

Need a Powertrax No-Slip rebuild kit (again) -- Papromike sent me the kit for a limited slip... I'm not happy. This pushes the front end back a couple of days.

Also, the ring gear bolts used in my front differential were just standard bolts that didn't have the "teeth" to hold them in. Amazing the things I never knew, which is why the rigs here at Marks :thumbsup:


Mark and Jill both work today, so Silber is being kind enough to show up here in about an hour to play taxi so I can get parts to get back to work on this project :thumbsup:

Still fighting to be ready by thursday morning to leave for Grand Slam West....



good luck!! I hope you dont run into many other little nuisances along the way!

Man i cant wait to see the trail shots of that bad boy



I'm cleaning you garage tomorrow and taking my compressor back home ;)

So, atleast the first bit of that sentance should cheer you up a bit. lol :thumbsup:



Also, Brandon (supremecommand) was nice enough to lend me his very good digital video camera for the trip, so we'll have some great action shots.

You mean.. "Brandon (LordAthens)" right? Supremecommand is the email address, holmes.. *cough* :lol:

There best be some bitchin video commin down the firewire when it gets back!


Matt, hope all is going well out there. Tell Mark and Jill I said hello.

I have been pretty busy wrenching back here too. MMLs are a B*TCH! :?

http://home.comcast.net/~osterritter/wsb/media/297178/site1062.jpg

All I have left (in the garage) to put on is the Warn 9000i and the Poison Spyder Rocker Knockers. (Heidi's BB will be here tomorrow, so I will probably do that this weekend.)



Matt, e-mail me an address and I will try and get another kit fedexed out to ya.


that was the Part number in my Powertrax catalog for rebuild kit, and I verified that kit with the Guys at Powertraxx...

they dont make a limited slip,..

they only make the lockright and the no-slip.. maybe they accidentally sent the Lockright kit..


anyway, shoot me an e-mail and I'll have it mailed where ever you are going to be in a few days...


let me know quick... so I can get the ball rollin'


Matt, hope all is going well out there. Tell Mark and Jill I said hello.

I have been pretty busy wrenching back here too. MMLs are a B*TCH! :?

Jeep looks good Bill! All Mark and I have to do is get this thing working....



Matt, e-mail me an address and I will try and get another kit fedexed out to ya.


that was the Part number in my Powertrax catalog for rebuild kit, and I verified that kit with the Guys at Powertraxx...

they dont make a limited slip,..

they only make the lockright and the no-slip.. maybe they accidentally sent the Lockright kit..


anyway, shoot me an e-mail and I'll have it mailed where ever you are going to be in a few days...


let me know quick... so I can get the ball rollin'


I didn't have time to wait any longer... I had one overnighted from Randy's ring and pinion.... needed the right part right now. It's already in.






I think Bill meant WE have been pretty busy wrenching :spank:

Typical :lol:

OverkillZJ
03-06-2005, 03:18 PM
My dad sent me a new data cable for the camera to get pics up, but I haven't had time to try it yet. My Jeep should've left for Moab at 9am today in the Colorado caravan.

It's sitting in Marks garage with no gears in the front and the carrier out in the rear end. Mark needs to finish setting up the front gears, I need to patch up the back (just wanted to check the gears)... then modify the steering, move the sway bar mounts up, bleed the brakes... Test it... sleep... drive to Moab and show up at GSW a day late.


I never imagined how stressful a hobby could be.



good luck Matt. Hope all goes well. Keep us informed.



sweet man...get on them pictures -- wanna see that baby flex.



back ends on the ground... fronts still a work in progress...
silber's over here helping again, he's the man :thumbsup:



chinese food is on the way...

Still not done. Big surprise there.

Gears are done, rear tires done and on the ground. Added bend to the pitman arm for steering to clear.

Need to move sway bar up (hitting pitman arm) - align, adjust pinion angle, put on new angled upper arm to clear HP housing, etc etc.

If the Jeep stops fighting us the whole way, we'll be heading out noon tomorrow.

Realistically, I'll die working on it when I'm 80.


Well, it sounds like you are making progress, and that is a good thing. Hopefully you will not run into any addtional issues. Good luck!


Marks convinced me to leave well enough alone... Packing then leaving for GSW :thumbsup:




Marks convinced me to leave well enough alone... Packing then leaving for GSW :thumbsup:

Well, knowing Mark ithat tells me that it cannot be that bad. I know he would not let you go out and wheel with a Jeep that was unsafe or was guaranteed to break down.

Good luck! Have fun! Where's the pics?


yo matt good luck getting to moab.....sorry to hear about all the delays hope you have some fun and do some wheeling for me....it's my birthday on sunday after all.....and don't worry business is going well....... :thumbsup:



well my 21st is on the 29th! so happy June bday to us.

next, im interested in seeing the stock next to Beast photo.


screw bandwidth, on with the pics! :thumbsup:

OverkillZJ
03-06-2005, 03:20 PM
Matt just pulled up in Moab!!




Matt just pulled up in Moab!!

Nice... :thumbsup:



:cool:


Quick update for everyone on Matt's rig!

We ran Poison Spider Mesa yesterday for his shakedown run, worked great. Hit Lower Proving Grounds this morning, and Cliffhanger this afternoon. Everything is working really good and he's super stoked! There's some pics over in the GSW forum, and I'll have stuff from today up here pretty soon.



Matt's ZJ did quite well!
:thumbsup:

The jeep worked just like he wanted it too. PSM was fun, Lower Proving grounds was more fun, and Cliffhanger is always fun. Dave, thanks for the spotting.

Bill, Congrats on the Rubi!



Hey Matt, it was kickass hangin out with you this weekend. The ZJ worked great, and once you can get the hang of going from 2Lo to 4Lo in the right places, get over your fear of the cliff, and not fall for it when Mark and I tell you you're in a state that's a good 75-100 miles away, you'll be good to go! Make sure you call me when you're gonna be up in this area so we can go wheelin again. If you can bail out on Sunday I'm in for something, ZJ did great coming home.

OverkillZJ
03-06-2005, 03:25 PM
Hey Bill, get that Rubi $hit outa my thread! :spank: ;)


Anyway, I'm chilling at my brothers in Westcliffee making minor repairs and helping him settle into the new house (lots of yard work needed...)

Marks wedding is Friday, Pat and I are trailriding tomorrow and possibly Saturday. The Jeeping this trip is far from over :thumbsup:

the damage report (copied from GSW thread)

Lets see... I went out with a slightly bent moser axle shaft, I either bent a wheel or bent the shaft more because the rig now shakes viloently at 63 instead of 70 :crazy

Bent up the bull bar again, hatch flexed into the rear aftermarket bumper and got torn up in the corner, blew an outer seal in the rear 44, probably due to the bent shaft. Ripped my CB antenna and wire off on cliffhanger, somehow killed my sunroof, need to pound it closed. Several more small dents and love taps.

All in all, I only hurt aftermarket stuff and nothing on the "body" of the jeep, except for the rear hatch. I can't complain considering the way I beat on it a few times :thumbsup:

EDIT: I forgot, I've got somethign going on in the steering wheel. Air Bag light is now on constantly and cruise control no longer works.

-------------

When all's said and done, with the exception of some bent components causing vibes and the air bag / lack of cruise control, as well as some minor steering problems.. The ZJ performed far better than I expected for a totally untested rig. I'll work on getting some pics up, but I'm stuck on 24k dialup here in EBF!



I have some GREAT video I can't wait to post clips of....







I have some GREAT video I can't wait to post clips of....

IBeleventybillionhoursofPigRock, lol

I still haven't really watched all the vid you guys shot that I copied. Might get to it tonight.

[subliminal message]you want to run spring creek on saturday, you really really do, no matter how hungover you are, that's why Dave was a nice enough guy to run it in the late afternoon[/subliminal message]







I have some GREAT video I can't wait to post clips of....

IBeleventybillionhoursofPigRock, lol

I still haven't really watched all the vid you guys shot that I copied. Might get to it tonight.

[subliminal message]you want to run spring creek on saturday, you really really do, no matter how hungover you are, that's why Dave was a nice enough guy to run it in the late afternoon[/subliminal message]

LOL, like Marks commentary? TJ guy sarcasm at it's best :pant:

Where is spring creek? I'm in Westcliffe now, on Friday night I'll be in Loveland and spending the night in a hotel. If it's not too far from Loveland or here, it's a definate possibility. Depends on my brother really.



You remember Idaho Springs and Georgetown on your way out to Moab? It's right in there. I can get there in 45 minutes from my house, no clue on Loveland, but it shouldn't be too far, Mark should have a better idea, but I would guess an hour to an hour and a half. I'im kinda hoping we're up there in the dark so I can test out my new rock lights.




then you can go to beajoe's pizza, that place RULES!

It was great to meet you man, the ZJ is sweet and it's good to see it out wheeling after that massive write-up!
-Nate



Spring Creek is 1.5 from the house to the BK in Downyville. I have a family BBQ and family stuff to do Saturday so I'm out for Saturday.

Matt, just swap in my spare shaft if you need it, BUT I WANT IT BACK.

And yes, there is a lot of video of PIG ROCK!
:flipoff2:

:thumbsup:




Hey Bill, get that Rubi $hit outa my thread! :spank: ;)

Don't be a hater!!! :?

Hey, I am glad to hear that you are having a good time out there. Sounds like the Jeep did okay, Hell it did really well considering I have been wheeling with you before and I know what you mean when you say you were beating on it a bit.

I told you that CB antenna mounting point was a bad idea. :lol: ;)

Oh, and just to jab at you a little more... I just finished putting the Warn and the winchplate on. :lol: :cool: :thumb:

I can't wait to see the videos...



Spring Creek is 1.5 from the house to the BK in Downyville. I have a family BBQ and family stuff to do Saturday so I'm out for Saturday.

Matt, just swap in my spare shaft if you need it, BUT I WANT IT BACK.

And yes, there is a lot of video of PIG ROCK!
:flipoff2:

:thumbsup:

Good timing, I was about to call and ask you if you'd mind if I borrowed that spare! I have access to a press here, but no way to get the Rubi retainer plate; closest dealer is a couple of hours away. Don't worry, you'll get it back and as clean as it was given to me. Besides, you have 4 of my spares in your garage as collateral ;)
'

I think Pat and I are out for the BBQ, mainly because we're bringing Amy and are too cheap to pay for 2 hotel rooms for 2 nights; but I figure I can swing by Spring Creek, get some wheelin' in, and still get back here to Westcliffee before sunrise. (Pats taking Amy in the Saturn. Wuss.)[/code]



MATT!!!!!! you are a FOOL! jk. wish i could be out there, cool to hear the ZJ is doing "ok". you still giong to rons? i should be there, I may go to the badlands either friday or saturday that weekend, then head to rons

That's Jeepin' fool to you, JOE.

I'm debating on Rons. If I show up I'm afraid I'll have to beat him to death with the bent moser he sold me, as well as piss poor set-gears :roll:
^I bet Mark'd like to take a shot too after setting the front gears again.. and again... and again...



Mark, tried swapping in your spare. I forgot when we did the disc conversion on your TJ, we ended up going with longer bolts; it's because those custom plates from Blaine are 1/4" thick as opposed to the stock 1/8" retaining plates. I only had partial thread engagement so it stripped on 2 turns. Jeeps back on stands for the night, LOL, and we're heading out 10 am tomorrow, each of us with 4 passengers. To the hardware store at 7am it is!

Of course Pat doesn't have a bench grinder, or even and angle grinder, so we'll have to put a disc on the drill to shape the bolt heads :thumbsup:



It's all in the details Matt.
:lol:
Don't F'up my seals.
:thumbsup:



You better be ready for Saturday man!

I got to some of the video tonight, mainly PSM and some of LPG. Mark, your commentary was hysterical. If it's cool with you I'm gonna try to include some of the commentary in the final video.



You better be ready for Saturday man!

I got to some of the video tonight, mainly PSM and some of LPG. Mark, your commentary was hysterical. If it's cool with you I'm gonna try to include some of the commentary in the final video.


I'll be ready... Need some minor repairs after beating the heck outa the rig in the sand today... Mark, your spare shaft fixed the wobble entirely, and doesn't leak... I'll call the dealer by your house to order the right retaining plates and get the needed parts to swap in my spares and get you yours back, if you don't mind me borrowing the garage for a few hours some time when life's settled down after the wedding :thumbsup:


Dave, I'll call you tomorrow on my way to Loveland. My brothers bringing his locked and lifted XJ too.

Bed time... jeeping with 3 girls in the ZJ who aren't used to "matthew style" driving has left me very tired. Not to mention Pat dragging me up the sand dunes. It also left me with 3 very wet girls after blasting through the water with the sunroof open :spam:


Sorry to all those who have emailed me and I haven't responded to, I have 350 emails to sort through in my inbox, and can only access it through web mail. Jeff, I need to call you tomorrow to confirm what I owe you, I can't make heads or tails of it since the webmail system won't let me sort by date; it's all mixed in together. Real PITA

OverkillZJ
03-06-2005, 03:35 PM
Please tell me that it wasn't salt water you were "blasting" though. After all that hard work. Please. I've not really kept up with the last couple of days, but I don't see how you'd be in a state near any salt water. I hope.



Unless he dumped big bags of salt in the water here in CO, there wasn't any!

:lol:

ya.... i don't know of any salt water around here... nor would I blast through it...

Dave, see ya tomorrow!





Dave, see ya tomorrow!

Sweet dude, call my cell tomorrow and I'll give you better directions on how to get to the meeting area.



Matt,

So now that it s all done, would you do it again?

What is the complete list of new parts installed and can you put a price tag on it not including labor. I gathered from all 33 pages that most of the labor was paid for in beer and pizza.

Now it is time to get a girlfriend and get yourself squared away. ;)






EDIT: I forgot, I've got somethign going on in the steering wheel. Air Bag light is now on constantly and cruise control no longer works.






sounds like your clockspring to me. :(

any updates man?

every time we drive by your road, ann's like "you miss his jeep don't you" hehe... dude i'm going through drum-playing withrdrawl!!!



Matt, please keep DeaPee away from the drums!!! :thumbsup:



Matt,

So now that it s all done, would you do it again?

What is the complete list of new parts installed and can you put a price tag on it not including labor. I gathered from all 33 pages that most of the labor was paid for in beer and pizza.

Now it is time to get a girlfriend and get yourself squared away. ;)

Would I do it again? I'll refrain from saying a direct yes or no... The ZJ took over my life entirely for quite some time and stressed me out more than any full time job every could.

Then again, I would not trade the adventures I'm having out here in Moab and Colorado for anything; and I'm planning on many more adventures, such as GSMW and GSSE that are upcoming...

List of parts installed? Hell if I know.. .If I list them I have to add them up....

labor = good friends+pizza+beer+many favors owed.

I'm still on dialup from westcliffe, so no pics yet :-/
have some great video that'll be posted next month though! :thumbsup:





sounds like your clockspring to me. :(

any updates man?

every time we drive by your road, ann's like "you miss his jeep don't you" hehe... dude i'm going through drum-playing withrdrawl!!!


Yup, clock spring... Picked up a new one at the dealer today (which is 1.5 FREAKING HOURS AWAY from here.) - $170 later.... A@#$@#(&$@#!($&!@$(#&$!#($&#!@($#!%&!#$%!#@

Also ordered some rubber pushings; the poly's gotta go! Noisy and they walk out of the arms. Pressing rubber back in at Marks starting Thursday before the final wheeling adventurs and the drive back home.

I blew an upper radiator hose off of the radiator at a trail head, stupid constant pressure clamp; my brother and one of his students ended up stealing 5 gallons of water from some local ranch since I didn't have enough with me :lol: - then we used zip ties as a clamp. Ghetto, but worked.

Both moser shafts the rear axle came with were bent, no doubt about it. Put Marks spares in and it was smooth as glass until 70. Vibes over that. Got the tires balaced at a Discount Tire here, who did an EXCELLENT JOB, and it is now smooth to 100 (literaly...)

My spare tire is bum, very out of round. Doesn't matter, that's the one that walmart forgot to charge me for anyway.

I have some unknown noises, clicking/clunking related to sharp turns in the front end, and gear wine (detroit kinda noises) from the rear. Changing all gear fluids tomorrow to see what's up.

ZJ seems to be pretty much point and shoot, with the exceptop of the CA mounta killing the breakover angle. I need to fab some mini skids.

Many many details and repairs I just don't really feel like typing up, there's too much else to do right now. Like eat, drink, get drunk, drunker, and go to bed.


And dave, I MISS MY DRUMS MORE. And guitar, and piano. But mostly the drums.

And I'm sure that Ann doesn't miss my jeep at ALL since you pretty much lived here the week til I left :thumbsup:



Matt, please keep DeaPee away from the drums!!! :thumbsup:

ONLY if you plan a PGHoffroad jeeping trip the 10th or 11th after I'm back so I can show this thing off a little (err, tow your rubi around!) :spank:




Now it is time to get a girlfriend and get yourself squared away. ;)


With all the adventures I have planned for the ZJ, as usual that leaves no time for a GF :thumbsup:


well not a steady one anyway, TOO BAD!



Wow I just spent 2 hours reading that. Simply amazing, your dedication is nothing sort of incredible. Turned out to be an awesome jeep. Kudos man... :thumbsup: My jeep is next, gotta be ready for GSMW....

- Evan

I'll see you at GSMW then, start a Jeep Journal thread over in the new "Jeep Journals" forum over at mallcrawlin.com :) http://mallcrawlin.com/phpBB/viewforum.php?f=12

This will be moving there once I find the time to copy all of the posts :thumbsup:






Now it is time to get a girlfriend and get yourself squared away. ;)


With all the adventures I have planned for the ZJ, as usual that leaves no time for a GF :thumbsup:


well not a steady one anyway, TOO BAD!


haha take her with you.. adventure days and adventure nights!


:spank:


Kinda pissed and about to be broker...

Some of you knew that most of my vibes were caused by not just one, but TWO bent Moser axle shafts in the 44....

I was kind of sad but could live with it, since it came with spares. The spares had the wrong retaining plates, so Mark was nice enough to lend me his spares, while he pressed on new bearings and plates / seals to my spares. Got a phone call today with the tone in Marks voice of "ya, you're gonna be pissed." --- the splines on the spares are twisted.

4 shafts; none good. What a crock of $hit.

Stopping by 4wheel parts on the way up to Marks tomorrow for some Jeep tunup. Here goes another $300 for shafts, seals, and bearings.

#$!@#$!@#$~~@!$##!@$!#@$#@!$!#@$#$!#@$!$#!@

Anyway, end of the trip is arriving. Fri, Sat,Sun, and Mon are camping / Jeeping days; then Tuesday or Wed it'st back to Pissburgh (oh I mean Pittsburgh) I head...

I want to climb Cleveland Rock on Holy Cross...



Matt... Big Jeep Cruise (HRJA) planned for July 15th (Thursday), is that close enough for ya?

Depends on what time, I have to take my brother and parents to the airport in the morning; they're flying HERE to Colorado from Pittsburgh.

The great Colorado switheroo.


I hate my Jeep, it's being an attention whore again.


Looks like I'm not making the last Phoenix bashing / camping trip I wanted to this weekend.

Pulled the rear diff cover due to strange noises and dirty fluid. There's a tooth missing :roll:

getting new gears and install kit tomorrow, Mark'll be setting them this weekend. If I'm LUCKY maybe I can run carnage monday (if I have time to break the gears in...)

This is a depressing setback, was planning on a great weekend of wheeling on the fourth.




Matt,
If you end up copying all of this over to my site, you're going to HAVE to host it, since you're gonna go WAAAAAAY over my bandwidth and disk space!!! :lol:

LOL, actually I'm already hosting all of the pictures, so the only bandwidth being taken up is the text :thumbsup:

My point exactly!! 500 replies and 18000 views as of when I clicked on this. Holy cow man!





Matt,
If you end up copying all of this over to my site, you're going to HAVE to host it, since you're gonna go WAAAAAAY over my bandwidth and disk space!!! :lol:

LOL, actually I'm already hosting all of the pictures, so the only bandwidth being taken up is the text :thumbsup:

My point exactly!! 500 replies and 18000 views as of when I clicked on this. Holy cow man!

What can I say, everyone loves a good soap opera :D

update: 4wheelparts rules, they have 23 genuine spicer 4.56 gear sets in stock an hour from here, and master install kits to match. Me happy! :thumbsup:
might have the jeep running tomorrow; but not ready for offroading til the gears are broken in :(



Dana 44's rule :roll:


Ummm.... ya....

Wasn't the 44's fault. Gears were never set up properly and axle was abused by previous owners. Only explenation.


darn that sucks...at least you're getting some fun out of it. To keep you posted on the pittsburgh side of off-roading...My RIGHT FRONT FENDER!!! has still seen more mud than BILLS ENTIRE TJ!

That's one hell of a strong mall-cruiser we built you there bill. Coulda saved a few grand and got an SE though...and stuck the RUBICON stickers on the side.

If he doesn't start using those axles, he's going to come out to a rubicon with a dana 30/35 and an axle lock button that turns his fog lights on after a dark, rainy night. :lol: :spank:


darn that sucks...at least you're getting some fun out of it. To keep you posted on the pittsburgh side of off-roading...My RIGHT FRONT FENDER!!! has still seen more mud than BILLS ENTIRE TJ!



Sorry to disappoint you Dave, but the Phonix / Junk Cooler will NOT go on mud runs! I'll drive through shallow mud pits if it's ON a trail, or on the way to some rocks... But I hate working under Jeeps with mud falling on my face!




That's one hell of a strong mall-cruiser we built you there bill. Coulda saved a few grand and got an SE though...and stuck the RUBICON stickers on the side.

If he doesn't start using those axles, he's going to come out to a rubicon with a dana 30/35 and an axle lock button that turns his fog lights on after a dark, rainy night. :lol: :spank:

That axle swap could be arranged.... With air tools and your axle already out, I imagine we'd have them swapped in under an hour with enough help...

We'll plumb the air lines later!



H&K USP .40 Compact...
http://manta.univ.gda.pl/~kazik/tools/zdjecia/weapon/hk/uspbrass.jpg

The ultimate in TJ axle protection!!!


Wait for it........ wait for it.......

The Rubi will be hitting the trail soon enough. The Bull Bar will be on by the end of this upcoming weekend, and I am done with the build-up for a while. Then we can show DeaPee the difference between wheelin' and driving on muddy roads in South Park. Hey Dave, you ready for that Connellsville creek crossing yet? :lol:





That's funny... I've never seen your old Jeep on anything but dirty/muddy road!!! :thumbsup:

You needed to come out more... That thing has been around.
http://www.wayniaktech.com/images/ryanspics/ryansnewjeep1.jpg
http://www.wayniaktech.com/images/ryanspics/ryansnewjeep2.jpg
http://www.wayniaktech.com/images/ryanspics/ryansnewjeep3.jpg

Even when it was bone stock (With 31" A/Ts) I had it out on the trails...
http://home.comcast.net/~osterritter/wsb/media/297178/site1023.jpg

:nana:

OverkillZJ
03-06-2005, 03:59 PM
Sorry jeepsaharahgirl, but pictures of your Jeep driving DOWN chinamans THE WRONG WAY,doesn't impress anyone here... Not to mention you took the easiest line possible at the waterfall...

Now get this pissing match the hell out of my thread, it's not where it belongs.

----

changing the rear gear fluid after 300 miles of gear break in and heading back to pittsburgh; slowly til they're worn in.




All the frustration... Such a hater! :lol:

Hater or not; I just got back to Pgh.... nap time...



welcome back...hey bill, wanna go over matt's tonight :lol: j/k dude get some sleep...then get on those videos we all been waiting to see.

You could've come over, since uh, YOU DON'T KNOW WHERE I LIVE NOW! HA!

I'm about... half moved at this point....


When I'm settled in I'll get videos and pics up.. There's some cool ones.

By the way, I almost flopped my ZJ in my new driveway ramping the retaining wall; I forgot the sway bar was on :crazy

It was the closest I've ever come to rolling; without rolling...



That's some funny chit Matt.
Any pics of the house?

You still want those bearing retainers?


Ya, I have a few pics of the house online ;) http://www.fccsonline.com/house/
http://www.fccsonline.com/house/1.jpg

it has massive amounts of jeep parking... http://www.fccsonline.com/house/8.jpg


I was going to pick up new shafts from 4WDH on Monday; but now that you mention it, ya, I'm gonna need those plates!



http://www.fccsonline.com/house/44.jpg

That sure looks like a lot of grass to me ;)

Matt, I'll give a call tonight, after we're done WHEELING. I need your new address.
:slap1:


gimme a call anyway, but send it to my old address, all tools are still at the old house and UPS/FedEx/USPS will leave boxes at the door here :thumbsup:




....my new wallpaper

http://www.fccsonline.com/pic/jeep/moabpose.jpg

I have a higher res version, but its almost 2 megs.

And I don't even get any credit for taking that pic specifically for you to use as a desktop wallpaper! Geez!!! Last time I skip a day of wheeling new trails to lead someone through a trail I was on two days before and be their total camera bitch. :lol: :lol: :lol: :lol: :lol: :lol:


... :(

The credit card bill for the last 2 months has arrived, and the totals will not be posted. Suffice to say that the Phoenix has elevinty billion times its value invested... It won't be making any more Grand Slams this year, possibly nothing until GSE next year. No way I'm making GSW next year.

6,000 miles of gas alone is expensive enough, not to mention all new shafts and rear ring gears, "and then some"...

I need to go work several more jobs to pay this off, and can't afford to break anything else for a looong time....

I'll post pics of what it did do soon enough though...




No way I'm making GSW next year.

6,000 miles of gas alone is expensive enough, not to mention all new shafts and rear ring gears, "and then some"...




:roll:

You forgot to mention that half the money was spent on illegal fireworks!

Looks like we might have to start the "Send Adam and Matt to GSW Fund"!!!



brw brw brow; another bites the dust; brw brw brow; another bites the dust;


Flopped the ZJ again :roll:

Big vnotch in Wellsville owned me. That place always owns me.

Also blew up the front diff, jammed the front locker, snapped a rotor (ya, I was surprised too) - killed the passenger door, mirror, and tailight... Ripped off a shockmount... Bent the currie steering... and bent / snapped a couple of axle shafts.

Pictures to follow as soon as someone sents them to me...




Flopped the ZJ again :roll:



:v8: what a Sally.


Looking at the pictures, it really wasn't as bad as I remembered it. I don't even think it really qualifies as a flop.

Oh well; enjoy.

http://www.fccsonline.com/pic/jeep/trips/wellsville.8.30.04/wellsville.08.28.04.a.jpg

http://www.fccsonline.com/pic/jeep/trips/wellsville.8.30.04/wellsville.08.28.04.b.jpg

http://www.fccsonline.com/pic/jeep/trips/wellsville.8.30.04/wellsville.08.28.04.c.jpg

http://www.fccsonline.com/pic/jeep/trips/wellsville.8.30.04/wellsville.08.28.04.d.jpg

http://www.fccsonline.com/pic/jeep/trips/wellsville.8.30.04/wellsville.08.28.04.e.jpg

http://www.fccsonline.com/pic/jeep/trips/wellsville.8.30.04/wellsville.08.28.04.f.jpg

http://www.fccsonline.com/pic/jeep/trips/wellsville.8.30.04/wellsville.08.28.04.g.jpg

http://www.fccsonline.com/pic/jeep/trips/wellsville.8.30.04/wellsville.08.28.04.h.jpg


Back on topic... (I deleted the last post, not a mod.)

The front end of the ZJ seems to be stuck "locked" and causing any steering needed to be VERY hard. It took me a good 10 tries to get from Boyce Rd into my own driveway (decently sharp turn.) I hit the telephone poll at the corner of my driveway not once, but 3 times trying to get it in. :lol:
The neighbors came out front to see what all the noise was about, and traffic was blocked going both directions while I tried getting the thing into my driveway. At one point I even contemplated pulling winch cable to a tree at the bottom of my driveway just to slide the front end into place since it won't steer.

It's turning like a tank.

Anyway, Last week I got it into the middle of my driveway, and I've just let it sit there and on random occasions would flip it the bird in disgust. Today I decided it was in the way and I at least had to get it into the corner of my own driveway, so that friends, associates, and customers can actually use my driveway without almost hitting a big ugly Jeep sitting in the middle of it. It took me about 20 times of forward and reverse to move it 20 feet, since all were sharp turns. It's amazing, the wheels will be turned full lock, but when you try to GO, it just pushes the wheels forward instead of turning. Tank style. None the less, I eventually got it to slide where I want it until I get around to fixing it. I'm already looking forward to the next round of repairs and upgrades, but due to business and school (ahem, 18 credits of hard classes) I think I'm putting it on hold until January when I really have time to work on it.

Besides, I still have so much work to do on the new house! Like uh, putting up the Jeep tent... Building the office in the basement.. etc etc...

But fret not; I still have plenty of pictures to post from the last big trip that should keep all you phoenix-thread-whores occupied until the next large round begins. I've got some good ideas for this winter too... They involve a welder, but no tubing bender just yet ;)

I should have all the video transferred from my buddies camera in the next month or so, should be worth the wait (I hope.)


These are from over a month ago, but I thought they were fun pics so I’ll throw them up here. It was just from a few of us at the Houston Playground messing around, a little area about 20 minutes from my house. As luck would have it, the camera broke before I got to the cool hill climb with a decent ledge. I probably shouldn’t have even tried it in the rain, but it made it up anyway. I got to strap the WJ too, that was fun.



http://www.fccsonline.com/pic/jeep/trips/playgroundjuly/DSCN2760.JPG

http://www.fccsonline.com/pic/jeep/trips/playgroundjuly/DSCN2761.JPG

http://www.fccsonline.com/pic/jeep/trips/playgroundjuly/DSCN2762.JPG

http://www.fccsonline.com/pic/jeep/trips/playgroundjuly/DSCN2764.JPG

http://www.fccsonline.com/pic/jeep/trips/playgroundjuly/DSCN2765.JPG

http://www.fccsonline.com/pic/jeep/trips/playgroundjuly/DSCN2766.JPG

http://www.fccsonline.com/pic/jeep/trips/playgroundjuly/DSCN2767.JPG

http://www.fccsonline.com/pic/jeep/trips/playgroundjuly/DSCN2768.JPG

http://www.fccsonline.com/pic/jeep/trips/playgroundjuly/DSCN2769.JPG

http://www.fccsonline.com/pic/jeep/trips/playgroundjuly/DSCN2770.JPG

http://www.fccsonline.com/pic/jeep/trips/playgroundjuly/DSCN2771.JPG

http://www.fccsonline.com/pic/jeep/trips/playgroundjuly/DSCN2772.JPG

http://www.fccsonline.com/pic/jeep/trips/playgroundjuly/DSCN2773.JPG

http://www.fccsonline.com/pic/jeep/trips/playgroundjuly/DSCN2774.JPG

http://www.fccsonline.com/pic/jeep/trips/playgroundjuly/DSCN2775.JPG

http://www.fccsonline.com/pic/jeep/trips/playgroundjuly/DSCN2776.JPG

http://www.fccsonline.com/pic/jeep/trips/playgroundjuly/DSCN2777.JPG

http://www.fccsonline.com/pic/jeep/trips/playgroundjuly/DSCN2778.JPG

http://www.fccsonline.com/pic/jeep/trips/playgroundjuly/DSCN2781.JPG

http://www.fccsonline.com/pic/jeep/trips/playgroundjuly/DSCN2784.JPG

http://www.fccsonline.com/pic/jeep/trips/playgroundjuly/DSCN2785.JPG

http://www.fccsonline.com/pic/jeep/trips/playgroundjuly/DSCN2786.JPG


I do believe that Kris's stock WJ showed up Dave's built TJ :lol: :thumbsup:

http://www.fccsonline.com/pic/jeep/trips/playgroundjuly/DSCN2788.JPG




I have really enjoyed following this thread the past few months. Its always great to watch a complete rebuild in progress. Hopefully one of these days I can make it out to Moab and wheel with some of you guys. Thats a great ZJ you've got Matt, keep up the good work.

Thanks, it was great until I destroyed it 2 weeks ago (again.)

which means ROUND 3, FIGHT!
:lol:


The threads on pause for a little while, since the Jeep is. I need to reseal the driveway before I can put the tent back up, and then wire electricity too it also. Also having the basement waterproofed (dug up) since it's like Noah's Ark when it rains. Then building a home office in it with a back entrance....

In other words, a few more things on my plate. I figure I'll start tearing into the Jeep whenever I feel the need for a release in another month or so though. Stay tuned :thumbsup:



Matt... Did you hear that? I think your ZJ wants to be wheeled again... :roll:

Why not take a weekend and we can rip it apart and fix it. At least we can make it trail-worthy again. I know that Dave and I can clear out our schedules and devote at least a weekend to helping you.



Matt... Did you hear that? I think your ZJ wants to be wheeled again... :roll:

Why not take a weekend and we can rip it apart and fix it. At least we can make it trail-worthy again. I know that Dave and I can clear out our schedules and devote at least a weekend to helping you.

Howabout... NO!

Way too much going on right now, seriously, I don't have time to breathe let alone fix the Jeep...

I'm sitting in a 5 hour long database class right now... Guess I should be paying attention...

Don't worry, I'll be back at it as soon as things settle down a bit.

OverkillZJ
03-06-2005, 04:00 PM
Well... It's been over a year since the first post in this thread. I've created a website at http://www.bigassjeep.com that will soon be php-nuke based and I'll be posting all updates there with picture gallary's and such.

I've just finished mastering the DVD of the video and only need to print up some labels for them then they'll be ready to ship for those of you that asked.

I'll also be posting the pictures I have from last year in this thread shortly, but more so, I should start work on the ZJ again next month weather permitting. I decided not to work on it in the cold winter in the tent, as I think I spent a good grand on fuel and electricity alone just keeping it above freezing while I worked on the rig....

I'll have a list up of planned repairs before my next planned wheeling trips:

GSW
GSSE
GSMW
and Whatever we plan in my local club...

I have the luxury of waiting for the weather this time! :thumbsup:

OverkillZJ
03-06-2005, 04:03 PM
In on pg 41. Took me 3 days to read the thread once I found it.

Matt,

You are an inspiration to all, and this thread gives me strength and confidence. You are officially my new hero.

:thumb: BTT


If I'm your hero, you're in BIG trouble!




In on pg 41. Took me 3 days to read the thread once I found it.

Matt,

You are an inspiration to all, and this thread gives me strength and confidence. You are officially my new hero.

:thumb: BTT


If I'm your hero, you're in BIG trouble!

:lol: :lol: :lol: I take it that im in BIG trouble too then :thumbsup:





If I'm your hero, you're in BIG trouble!

I prefer to live dangerously. :banana:





If I'm your hero, you're in BIG trouble!

I 2nd that.

OverkillZJ
03-06-2005, 04:03 PM
Ok, we’re back! The thread begins again :) (And I’m going to be copying this thread over to www.mallcrawlin.com/forum as well. It’s a much more technical forum, but specifically not newbie friendly (hey, I warned you.)

I’m just playing catch up here, but here’s some pics from November when some guys from my local club (www.pghoffroad.com) helped me put up the frame for the Tent in preparation of fixing up some more things on the Phoenix.


http://www.bigassjeep.com/pics/phoenix/11.23.04.a.jpg


http://www.bigassjeep.com/pics/phoenix/11.23.04.b.jpg


http://www.bigassjeep.com/pics/phoenix/11.23.04.c.jpg


http://www.bigassjeep.com/pics/phoenix/11.23.04.d.jpg


http://www.bigassjeep.com/pics/phoenix/11.23.04.e.jpg


http://www.bigassjeep.com/pics/phoenix/11.23.04.f.jpg


http://www.bigassjeep.com/pics/phoenix/11.23.04.g.jpg


http://www.bigassjeep.com/pics/phoenix/11.23.04.h.jpg

OverkillZJ
03-06-2005, 04:04 PM
Even though we got the tent frame together 4 months ago, I haven’t found the time to anchor it to the concrete and put the tarp up, let alone wire electrical to it.
http://www.bigassjeep.com/pics/phoenix/3.05.05.a.jpg

I got some new toys: Hobart Mig 180, a coupla welding masks, and a set of unibits for the drill press I’m stealing from my dad.
http://www.bigassjeep.com/pics/phoenix/3.05.05.b.jpg

You can see tat I’ve started drilling holes in order to get the 6 gauge wire all the way out to the garage (240) – it’s big freakin’ wire.
http://www.bigassjeep.com/pics/phoenix/3.05.05.c.jpg

Another problem is that when I opened up the electrical box to attach it to the un used 50 amp breaker in there, I found some VERY piss-poor wiring by the previous homeowner. I need to rewire most of this house just so its safe.
http://www.bigassjeep.com/pics/phoenix/3.05.05.d.jpg

As a side note, here’s a picture of the water management system that was put in after the floods we had here a few months ago. I had water coming in the back wall, through the room that’s going to be my office when I finish it, and out through the garage. Not anymore, this system will pump 6,000 gallons of water even after the power goes out (besides, I can jump start my car from it) ;)
http://www.bigassjeep.com/pics/phoenix/3.05.05.e.jpg

Here’s the new set of Yukon gears and rebuild kit, as well as new carrier for the front axle. I blew it up pretty good last wheelin’ season. Also got a new bench grinder for the one that I cooked cleaning up rusty parts during the majority of the project.
http://www.bigassjeep.com/pics/phoenix/3.05.05.f.jpg

Here’s the garage at the new house, it’s very roomy compared to the old one (that crappy shack!) The Jeep doesn’t even come close to fitting into it height wise (I tried letting all the air out of the tires, it’s still not even close.) I’m considering how to put in a higher garage door. It’d be tight to put it in there, but heating the tent costs an absolute fortune, which is one reason I chose not to finish putting it together and working on it throughout the winter. The Corolla fits nicely though.
http://www.bigassjeep.com/pics/phoenix/3.05.05.g.jpg

In preparation for last nights meet and greet, I had to get the ZJ rolling semi-safely again. Showing up in a daily driver is just wrong.
http://www.bigassjeep.com/pics/phoenix/3.05.05.h.jpg

More new tools: I picked up a set of Metric deep socket impacts (only had SAE) as well as a new brake line flaring kit, and some magnetic angle brackets.v
http://www.bigassjeep.com/pics/phoenix/3.05.05.i.jpg

I have some nice shiny new Dana 44 Superior axle shafts as well, some of you might remember that I drove back from Colorado borrowing a friends. Time to put these shafts together (install seals, lugs, bearings) and in the Jeep.
http://www.bigassjeep.com/pics/phoenix/3.05.05.j.jpg

Here’s another thing I’ll have to fix, ripped the passenger side rear shock mount right off. I’m going to get some basic axle tabs and weld them to the axle, hopefully behind the CA mounts so I don’t have so much hanging down any more.
http://www.bigassjeep.com/pics/phoenix/3.05.05.k.jpg


http://www.bigassjeep.com/pics/phoenix/3.05.05.l.jpg

I also have to replace some leaky seals: Tranny output as well as tcase output.
http://www.bigassjeep.com/pics/phoenix/3.05.05.m.jpg

Motor mounts are completely shot too.
http://www.bigassjeep.com/pics/phoenix/3.05.05.n.jpg

I’m also getting rid of those blasted poly bushings, I’ve already replaced the UCA bushings with good old stock rubber.
http://www.bigassjeep.com/pics/phoenix/3.05.05.o.jpg

I need to find a new steering cap too. I don’t know what vehicle I got this steering reservoir from, but it’s not stock. It twists on, not “push and turn” – I yelled at my dad for over tightening it on our way to Colorado, but at about Kansas I noticed that maybe it was a lil’ loose cause we lost it! This is the closes fit we could find, but offcamber and heavy throttle it ejects fluid through that overflow nipple, letting the levels get dangerously low.
http://www.bigassjeep.com/pics/phoenix/3.05.05.p.jpg

The overflow coolant reservoir is always empty, must be a crack in it, or a puncture in the line somewhere. Need to fix.
http://www.bigassjeep.com/pics/phoenix/3.05.05.q.jpg

Also, on my way up to CT to Clayton Offroad (back when all he had was a tent even smaller than mine!) I broke the tranny kickdown cable. Temporarily fixed it with some picture wire, and haven’t fixed it the right way since. Ya, it’s pretty ghetto.
http://www.bigassjeep.com/pics/phoenix/3.05.05.r.jpg

Idler pulley is making some noises, so it needs to be replaced before it leaves me stranded.
http://www.bigassjeep.com/pics/phoenix/3.05.05.s.jpg

Here I am pressing on the new bearings to one of the new axle shafts.
http://www.bigassjeep.com/pics/phoenix/3.05.05.t.jpg

It might not be in the tent, but in good weather, this setup is MUCH easier to work with than what I used to have.
I only replaced one of the axle shafts for now, as it’s all I have time for. I’ll get to the other one later.
http://www.bigassjeep.com/pics/phoenix/3.05.05.u.jpg

Just for kicks, here’s a couple of pics from our www.pghoffroad.com meet and greet last night. We made some noise!
http://www.bigassjeep.com/pics/phoenix/3.05.05.v.jpg

Did I mention we have some REALLY tall people and some REALLY short people? Dave, the “midget” Nick and Jerome.
http://www.bigassjeep.com/pics/phoenix/3.05.05.w.jpg

And to top it off, Yota’s can do some insane donuts. I wasn’t about to try this in the phoenix considering what happened to poor Jason at GSW last year!

Video, might want to right click and save as, 4 megs: www.bigassjeep.com/pics/trips/pghoffroad3.05.05/yotaburnout.mov



That’s all for now, I have spring break in a couple of weeks, so I’m sure I’ll be out there working on it a LOT. Frankly, I’d like to get it trail ready in that two weeks, and ready to go out west so I can focus on school and work unlike last year where the Jeep came first.

As a side note, I was just accepted into Robert Morris University for the Fall semester for Information Systems Management; so schools about to begin taking up a lot more time. I have a feeling this might be my last summer of my “mega west wheeling trip” so I intend to make the most of it!

BigDaveZJ
03-07-2005, 12:39 AM
And since you got like eighty bazillion posts for transfering this over . . .



+1

OverkillZJ
03-07-2005, 12:43 AM
And since you got like eighty bazillion posts for transfering this over . . .



+1

No padding in my thread, jackass!!!

Cue-Ball
03-07-2005, 04:47 PM
Looking good. I love the pic of the Jeep under the tent frame coverd in snow that is just too funny.

OverkillZJ
03-07-2005, 11:14 PM
Looking good. I love the pic of the Jeep under the tent frame coverd in snow that is just too funny.

Ya, I was amused by that too :)

phillyzj
03-08-2005, 02:55 AM
nothing wrong with a broken kickdown cable. I busted the connector on the TB end months ago, the zip ties seem to be doing a good job. I don't think it really hurts anything to go without it if it let's go...though it's rather interesting to drive.

OverkillZJ
03-08-2005, 10:45 AM
nothing wrong with a broken kickdown cable. I busted the connector on the TB end months ago, the zip ties seem to be doing a good job. I don't think it really hurts anything to go without it if it let's go...though it's rather interesting to drive.

My tranny sure didn't like being without it, jeep bucked and hopped like a mechanical bull. I just want to put something in there a lil' more substantial tha the picture wire; I'm thinking maybe a small turnbuckle.

OverkillZJ
03-09-2005, 01:17 AM
Ok, I know I promised some DVD's like 6 months ago, but they're finally done and for sale.

The video can be downloaded for free from www.bigassjeep.com but it is web quality. I put a lot of work into it, so I wanted to offer up the high resolution DVD version. It has full motion menus and about 1.25 hours of good Jeeping video.

http://www.bigassjeep.com/pics/phoenix/phoenixdvd2k4.jpg
Contents of the DVD are: a few runs at GSW 2004 (Cliffhanger, Poison Spyder, and Lower Proving grounds.) Other footage is my dirt road trip from Moab Utah to Westcliffe Colorado (me talking to cows). Other trails include: Old China Man’s Gulch, Spring Creek, Holy Cross, Carnage, Some others I forget….

Besides, there's some footage of Big Dave driving my poor lil' Jeep, who doesn't want to see that?


I’m asking for $5 each. I’m not really looking to make profit here, but I need to justify the mailing, ink, cases, media, etc. Hell, I’m going to make a whole dollar a sale, WOHOO!

To purchase: Please send $5 via paypal for each DVD to jeepzj@fccsonline.com
If you’d like to pay by check, please email me for an address. I’ll take parts or gas cards for my 2005 trip as well ;)

OverkillZJ
04-10-2005, 01:20 AM
Got the welder all wired up. Did I ever mention that pulling 8 and 12 gauge wires at once alone kind of sucks?

http://www.bigassjeep.com/pics/phoenix/4.09.05.a.jpg

Dropped them down at the panel (which is a mess in itself. Looks like the last homeowners thought they knew how to wire.. It's just bad... http://www.bigassjeep.com/pics/phoenix/4.09.05.b.jpg

Wires fed through to the plug in the garage
http://www.bigassjeep.com/pics/phoenix/4.09.05.c.jpg

plug all put together and wired http://www.bigassjeep.com/pics/phoenix/4.09.05.d.jpg

Wired the nema-50 plug to the 50 amp circuit that was open since I have a gas stove instead of electric http://www.bigassjeep.com/pics/phoenix/4.09.05.e.jpg

I love my mig welder setup :thumbsup:
http://www.bigassjeep.com/pics/phoenix/4.09.05.f.jpg


What my house always looks like before a pgh-offroad meet and greet (last minute crap...)
http://www.bigassjeep.com/pics/phoenix/4.09.05.g.jpg
http://www.bigassjeep.com/pics/phoenix/4.09.05.h.jpg

I replaced both rear shafts, they're now Superiors. Changed the diff fluid and replaced the rear brake pads, old ones were worn down to nothing.

OverkillZJ
04-17-2005, 06:50 PM
Well I got back to work on the ZJ yesterday, and wasn’t too happy with what I found. First I tore the diff apart since I knew there was something wrong in there. Sure enough…. Ring gears shot, but worse, my $390 no-slip locker is destroyed since the 4 pins that hold the two halves of the locker together sheered off. I’m theorizing that one got caught up in the gears taking a few of the teeth out. The locker broke due to the worn out carrier causing the spacing of the locker to be wrong. Moral of the story? When you rebuild an axle, don’t skimp. Replace it when in doubt so it doesn’t ruin your good parts with it… From the looks of that locker, I’d been in 3 wheel drive for awhile. I’m thinking I’m going to replace it with a Detroit. That gets rid of the carrier as a weak point altogether.
http://www.bigassjeep.com/pics/phoenix/4.16.05.a.jpg

You know that indistructible Currie steering? Ya, not so indestructible! I only bent the tie rod itself slightly, but I killed the end where it connects to the pitman arm big time, needs replaced.

http://www.bigassjeep.com/pics/phoenix/4.16.05.b.jpg

Then I realized the track bar had to come off since I need to fix that wallowed out hole I found last year, and I’m replacing the shocks and control arm bushings anyway, so I guess that just led to the whole axle being removed anyway!
http://www.bigassjeep.com/pics/phoenix/4.16.05.c.jpg


http://www.bigassjeep.com/pics/phoenix/4.16.05.d.jpg

This is such déjà vu…
http://www.bigassjeep.com/pics/phoenix/4.16.05.e.jpg


http://www.bigassjeep.com/pics/phoenix/4.16.05.f.jpg


http://www.bigassjeep.com/pics/phoenix/4.16.05.g.jpg


http://www.bigassjeep.com/pics/phoenix/4.16.05.h.jpg

At least my new work area is MUCH nicer…
http://www.bigassjeep.com/pics/phoenix/4.16.05.i.jpg

I think I just need new springs for the passenger side mirror, but not to replace the entire thing. This is good… must be cheaper…

http://www.bigassjeep.com/pics/phoenix/4.16.05.j.jpg

Here are the pins which sheered off. UGH.
http://www.bigassjeep.com/pics/phoenix/4.16.05.k.jpg

Parts pile…
http://www.bigassjeep.com/pics/phoenix/4.16.05.l.jpg


http://www.bigassjeep.com/pics/phoenix/4.16.05.m.jpg

OverkillZJ
04-25-2005, 10:40 PM
Finally got to setting the new gear and Detroit locker in the front HP30 with the help of friends. Dirk’s (Cue-Ball) parts list saved my ass yet again with the exploded parts diagram. One of them is 1200 pages of diagrams like this, every jeep from 88-90, which fits in my case since the axle is from an 89 XJ.

http://www.bigassjeep.com/pics/phoenix/4.24.05.a.jpg

Lots and lots of dirt in the axle tubes, but guess the seals were doing their job keeping it out of the diff.
http://www.bigassjeep.com/pics/phoenix/4.24.05.b.jpg

This… was just funny. Steve got owned by the random snow. Snow in April. Weird.
http://www.bigassjeep.com/pics/phoenix/4.24.05.c.jpg


http://www.bigassjeep.com/pics/phoenix/4.24.05.d.jpg

We used Silber’s patented method of getting those stupid seals to seat. ½” threaded rod through the tube to squeeze them in place. We maybe torn one of them a lil’, but I’ll just do it again if need be…
http://www.bigassjeep.com/pics/phoenix/4.24.05.e.jpg


http://www.bigassjeep.com/pics/phoenix/4.24.05.f.jpg


http://www.bigassjeep.com/pics/phoenix/4.24.05.g.jpg

This isn’t the final pattern, and is actually the first one we got. Dave (gear guy) wants to add another small shim to move it a lil’, but we discovered that my bearing puller SUCKS so we had to put off the project for a few days, and he’ll borrow one from where he works.

Notice the shiny new full Detroit :D
http://www.bigassjeep.com/pics/phoenix/4.24.05.h.jpg

Steve has a problem with my hammer. Actually, he’s such a “union bastard” that he won’t use most of my Chinese crap tools, he took the liberty of writing dildo on my “cheapass dildo of a hammer” – Thanks Steve!
http://www.bigassjeep.com/pics/phoenix/4.24.05.i.jpg

Coast Side.
http://www.bigassjeep.com/pics/phoenix/4.24.05.j.jpg

nate
04-26-2005, 04:01 AM
So this "gear guy" does he feel that is a good pattern? To me that looks like the pinion is into the ring too deep. I am not a "gear guy" by any means though. Hard to tell from those pics though, there's not a good pattern put into the marking stuff... if you hold the carrier from spinning some and turn the pinion it will be easier to read.

OverkillZJ
04-26-2005, 10:34 AM
The pattern is too deep, we couldn't reset it to move it out a little since my bearing puller appearently sucks. That patter is witha lot of pressure against the gears while rotating the pinion, it's rather clear in person but the camera washed it out with the flash.

OverkillZJ
05-01-2005, 12:07 AM
Dyna beads came in. Don’t know what they are? http://www.innovativebalancing.com/
They’re an alternative method to balancing tires instead of wheel weights. I got sick of knocking weights off on the trail and driving a vibrating Jeep home. Most of the guys on much bigger tires that run them seemed to like them, thought I’d give it a shot. 10oz per tire for my 35’s, I only did my front two tires today since they happened to be off.
http://www.bigassjeep.com/pics/phoenix/4.30.05.a.jpg

To install, you remove the wheel weights (very easy with the right cheap tool) – remove the valve stem, and pour the beads in slowly. Then you install the special valve stem that you need, and fill ‘er up.
http://www.bigassjeep.com/pics/phoenix/4.30.05.b.jpg

The long one is the new “special” valve stem.
http://www.bigassjeep.com/pics/phoenix/4.30.05.c.jpg

Decided to start practice welding on an old 35C from a YJ I had laying around.
http://www.bigassjeep.com/pics/phoenix/4.30.05.d.jpg

But in light of the weather (lots of rain lately) I decided to cut a chunk of the axle out and practice inside.
http://www.bigassjeep.com/pics/phoenix/4.30.05.e.jpg

I was surprised to find that the axle tube was 5/16” thick, that’s ¼” stock next to it for comparison. I was under the impression that axle tubes were just under ¼”
http://www.bigassjeep.com/pics/phoenix/4.30.05.f.jpg

I’ll be welding on shock tabes from www.bluetorchfab.com soon, so I bought 2 extra’s to practice with before doing them on the axle that’s under my Jeep.
http://www.bigassjeep.com/pics/phoenix/4.30.05.g.jpg


http://www.bigassjeep.com/pics/phoenix/4.30.05.h.jpg

Decided to test the weld by beating the crap out of it.
http://www.bigassjeep.com/pics/phoenix/4.30.05.i.jpg

Bent it back and fourth 4 times, couldn’t get the weld to give. Sweet.
http://www.bigassjeep.com/pics/phoenix/4.30.05.j.jpg

Speaking of welds, I’m nervous that one of the welds holding my claytons truss to my rear 44 might be cracking. It could just be the paint, but I’m not sure. Whatchya think?
http://www.bigassjeep.com/pics/phoenix/4.30.05.k.jpg


http://www.bigassjeep.com/pics/phoenix/4.30.05.l.jpg


http://www.bigassjeep.com/pics/phoenix/4.30.05.m.jpg

OverkillZJ
05-19-2005, 10:47 AM
If you look at the dates on the pictures, you’ll notice it’s been awhile since I’ve done an update 

Anyway, pressing in new rubber bushings to the front claytons long arms.
http://www.bigassjeep.com/pics/phoenix/5.18.05.a.jpg

Cut off 8” of the overhang on the rear spare tire carrier.
http://www.bigassjeep.com/pics/phoenix/5.18.05.b.jpg

Evil birds decided to take a crap on the Jeep.
http://www.bigassjeep.com/pics/phoenix/5.18.05.c.jpg

I yet again have a big pile of tires.
http://www.bigassjeep.com/pics/phoenix/5.18.05.d.jpg

Gears were almost done here, we ended up loosening up the pinion pre load a lot 2 nights ago.
http://www.bigassjeep.com/pics/phoenix/5.18.05.e.jpg

Garage is starting to look like a project zone.
http://www.bigassjeep.com/pics/phoenix/5.18.05.f.jpg

Dave’s the man. CUBANS FOR MOAB :finga:
http://www.bigassjeep.com/pics/phoenix/5.18.05.g.jpg


Got some welding done on the rig that needed patched up, pinch welds that I’d just a lot off of and such.
http://www.bigassjeep.com/pics/phoenix/5.19.05.a.jpg

Used Warn Hub conversion arrived. Came with 297’s and stock inners though, so I’ve ordered up some 760’s, full circle clips, and warn chrome moly inners.

http://www.bigassjeep.com/pics/phoenix/5.19.05.b.jpg

Also picked up a good set of trail spares. I’m sick of taking my shop tools (and taking too many) so I’m making a very specific trail/travel kit that’ll stay in the Jeep itself. I’m cutting down on spares and fluids too.
http://www.bigassjeep.com/pics/phoenix/5.19.05.c.jpg

This used to be a Radio Shack display case that I got off of Brandon. Now it’s a workbench on wheels so I can wheel it outside when I’m doing messy things like grinding, without stinking my house up.
http://www.bigassjeep.com/pics/phoenix/5.19.05.d.jpg

Remember how much this tire used to stick out? Cut it off and re-welded it shorter. I love having a welder.
http://www.bigassjeep.com/pics/phoenix/5.19.05.e.jpg

http://www.bigassjeep.com/pics/phoenix/5.19.05.f.jpg

Finally got that old spare carrier off of the roof too, it’s been on there since 2002.
http://www.bigassjeep.com/pics/phoenix/5.19.05.g.jpg

New drill bits
http://www.bigassjeep.com/pics/phoenix/5.19.05.h.jpg

Painted up the front lowers, shiny again.
http://www.bigassjeep.com/pics/phoenix/5.19.05.i.jpg

Took off the interior passenger front door panel, so I could get the busted mirror off.
http://www.bigassjeep.com/pics/phoenix/5.19.05.j.jpg

Need to fix soon.
http://www.bigassjeep.com/pics/phoenix/5.19.05.k.jpg

I also managed to move the spare on the rear over a lil’ too so I can see out of the back on the drivers side better.
http://www.bigassjeep.com/pics/phoenix/5.19.05.l.jpg

2 of my caliper bolt holes in the dana 30 knuckles were stripped out, so I drilled them bigger, tapped them, and used some Helli-coiles.
http://www.bigassjeep.com/pics/phoenix/5.19.05.m.jpg

Began separating the good warn outers from the crappy stock inners, in preparation of the other parts that are on the way.
http://www.bigassjeep.com/pics/phoenix/5.19.05.n.jpg

OverkillZJ
05-21-2005, 08:43 PM
Back to work, being the weekend and all and that the weather didn’t totally suck. Exception of that random storm that got me pretty good.

Anyway, My tranny was leaking at the output seal, and the SYE on the transfer case was leaking at its output seal too. Not bad, but when you’re planning an 8,000 mile trip you don’t really want to leave much to go wrong. Fix what you know can go wrong. First took off the tcase skid.
http://www.bigassjeep.com/pics/phoenix/5.21.05.a.jpg

Drained the amsoil.. man, there goes some money.
http://www.bigassjeep.com/pics/phoenix/5.21.05.b.jpg

Removed the bolts holding the tranny and tcase together. Rested it on a jack, and pulled it backwards.
http://www.bigassjeep.com/pics/phoenix/5.21.05.c.jpg

Made a mess of more expensive Amsoil ATF on my driveway.
http://www.bigassjeep.com/pics/phoenix/5.21.05.d.jpg

Removed the yoke, and old seal, and installed the new one in the tcase.
http://www.bigassjeep.com/pics/phoenix/5.21.05.e.jpg

Installed the yoke again.
http://www.bigassjeep.com/pics/phoenix/5.21.05.f.jpg

Removed the old seal on the tranny output shaft. Man, that made a bigger mess that I got to roll around in.
http://www.bigassjeep.com/pics/phoenix/5.21.05.g.jpg

Putting new seal on.
http://www.bigassjeep.com/pics/phoenix/5.21.05.h.jpg

This is a true PITA when you don’t have help. My back hurts.
http://www.bigassjeep.com/pics/phoenix/5.21.05.i.jpg

Painted up the Claytons cross member as long as it was off. It was pretty rusty.
http://www.bigassjeep.com/pics/phoenix/5.21.05.j.jpg

Made the mistake of forgetting about my shift linkage when I lowered the tranny and tcase on the jack. This if the pivot point of it, need to get a replacement. Crap.
http://www.bigassjeep.com/pics/phoenix/5.21.05.k.jpg

But all in all, not bad for a days work!
http://www.bigassjeep.com/pics/phoenix/5.21.05.l.jpg

MaineZJ
05-21-2005, 10:08 PM
This is a true PITA when you don’t have help. My back hurts.
Bah - it's not even 100lbs... I put mine in without using a jack.

OverkillZJ
05-22-2005, 03:01 AM
This is a true PITA when you don’t have help. My back hurts.
Bah - it's not even 100lbs... I put mine in without using a jack.

:finga:

I did that last time, learned my lesson never to do it again. My backs bad enough without me being more of a dumbass than I already am.

LouisianaZJ
05-22-2005, 03:05 AM
those SYE seals suck ass. i just gave up on mine. it will leak no matter how many times i replace it

OverkillZJ
05-27-2005, 10:36 PM
Changed out my motor mounts, you can see that they needed it in the second pic. Should raise the engine up enough to keep the HP pinion yoke from rubbing on the header downpipe.
http://www.bigassjeep.com/pics/phoenix/5.27.05.a.jpg


http://www.bigassjeep.com/pics/phoenix/5.27.05.b.jpg

I was debating on where exactly to weld the new shock tabs, and how to cut out he old ones with it over my head.
http://www.bigassjeep.com/pics/phoenix/5.27.05.c.jpg

Decided not to, obviously.
http://www.bigassjeep.com/pics/phoenix/5.27.05.d.jpg


http://www.bigassjeep.com/pics/phoenix/5.27.05.e.jpg

Found a new use for used latex gloves, capping off the brake line so you don’t end up with an empty reservoir, requiring you to bleed the whole brake system.
http://www.bigassjeep.com/pics/phoenix/5.27.05.f.jpg

Isn’t this what it looked like about this time last year, while I was rushing to get out of there?
http://www.bigassjeep.com/pics/phoenix/5.27.05.g.jpg

Took a rest for a few… mmmm… hammock….
http://www.bigassjeep.com/pics/phoenix/5.27.05.h.jpg

Cut off the old shock mounts
http://www.bigassjeep.com/pics/phoenix/5.27.05.i.jpg

Primered the rusty rock trails to paint them up.
http://www.bigassjeep.com/pics/phoenix/5.27.05.j.jpg


http://www.bigassjeep.com/pics/phoenix/5.27.05.k.jpg

Painted up the subframe.
http://www.bigassjeep.com/pics/phoenix/5.27.05.l.jpg

Painted over the rusty door where I flopped it. I suppose eventually the whole Jeep will end up spray painted anyway.
http://www.bigassjeep.com/pics/phoenix/5.27.05.m.jpg

Front driveshaft all painted up
http://www.bigassjeep.com/pics/phoenix/5.27.05.n.jpg

The Finished Parts hanger.
http://www.bigassjeep.com/pics/phoenix/5.27.05.o.jpg


Warn inner shafts arrived today, and ujoints, going to put that front axle together this weekend and hopefully get it under the Jeep. Shocks are to arrive on Tuesday.

Kraqa
05-27-2005, 10:45 PM
http://www.bigassjeep.com/pics/phoenix/5.18.05.b.jpg

YAAAAAAAA finally that thing hung out further then a Kraq-whore's piss flaps.


and spray the whoel truck dammit. flat green. john deer green.

OverkillZJ
05-29-2005, 11:30 PM
Been at it for a couple more days. Here’s my driveway looking like a mess of jeeps yet again. Jeff stopped by, his hub was SHOT to the point I wouldn’t even be driving on it. Just so happens that I have Marks old hubs which I have no use for, so I gave him one and bolted it up. Problem solved.
http://www.bigassjeep.com/pics/phoenix/5.29.05.a.jpg


http://www.bigassjeep.com/pics/phoenix/5.29.05.b.jpg

Here’s some pics of Steve fixing up some welds on my rear truss, and welding on my new shock mounts. I really hope I measured right!
http://www.bigassjeep.com/pics/phoenix/5.29.05.c.jpg


http://www.bigassjeep.com/pics/phoenix/5.29.05.d.jpg


http://www.bigassjeep.com/pics/phoenix/5.29.05.e.jpg


http://www.bigassjeep.com/pics/phoenix/5.29.05.f.jpg


http://www.bigassjeep.com/pics/phoenix/5.29.05.g.jpg


http://www.bigassjeep.com/pics/phoenix/5.29.05.h.jpg

Ok, I have Warn inners, outers, and 760’s w/ full circle clips. Now for the whole.. assembly… thing…
http://www.bigassjeep.com/pics/phoenix/5.29.05.i.jpg

I hate needle bearings. I really do.
http://www.bigassjeep.com/pics/phoenix/5.29.05.j.jpg

Found my magical box of Jeep stuff.
http://www.bigassjeep.com/pics/phoenix/5.29.05.k.jpg

Put the KC’s on the front. Ws hoping to fit 4 without it looking retarded or blocking air flow, but I can’t do it. Oh well, 2’s plenty.
http://www.bigassjeep.com/pics/phoenix/5.29.05.l.jpg

I have a passenger side rearview mirror! Total cost: $2 at the hardware store for new springs. They’re not as strong as the stock ones, but they seem to do the job just fine.
http://www.bigassjeep.com/pics/phoenix/5.29.05.m.jpg

Shiny. Front shafts assembled, front shaft painted up.
http://www.bigassjeep.com/pics/phoenix/5.29.05.n.jpg

Pressing in new bushings into the rear lower control arms. Don’t ask why it took us forever. We were stupid.
http://www.bigassjeep.com/pics/phoenix/5.29.05.o.jpg

Went shoppppping
http://www.bigassjeep.com/pics/phoenix/5.29.05.p.jpg

Went paaaaaainting
http://www.bigassjeep.com/pics/phoenix/5.29.05.q.jpg

Cut off the stock steering stabilizer mount. It interferes with my steering, and I’d eventually like to do hydro assist that would require my own custom mount anyway. I’ve had no problems not running a stabilizer at all.
http://www.bigassjeep.com/pics/phoenix/5.29.05.r.jpg

Some grade 8 hardware for the diff bolts that also hold the diff guard.
http://www.bigassjeep.com/pics/phoenix/5.29.05.s.jpg

I had to re-tap a lot of bolts, and cleaned off a ton w/ the wire wheel. Took hours.
http://www.bigassjeep.com/pics/phoenix/5.29.05.t.jpg

I was just practicing welding caps in on one of my old shafts with stretched yoke ears. Still hearing arguments for and against this, so I’ll reserve judgment on whether or not I’m doing it on my new front shafts until the last minute…
http://www.bigassjeep.com/pics/phoenix/5.29.05.u.jpg


http://www.bigassjeep.com/pics/phoenix/5.29.05.v.jpg


http://www.bigassjeep.com/pics/phoenix/5.29.05.w.jpg

Got both rear axles painted up too. If it wasn’t supposed to rain tomorrow, I bet I’d have this thing sitting on springs. We’ll see what the weather lets me do.
http://www.bigassjeep.com/pics/phoenix/5.29.05.x.jpg


http://www.bigassjeep.com/pics/phoenix/5.29.05.y.jpg

Lots of bolts and parts all shined up and ready to go!
http://www.bigassjeep.com/pics/phoenix/5.29.05.z.jpg


Also took apart the used Warn hub conversion to inspect, and decided to get new seals and bearings just in case. Should arrive at Napa on Tuesday, so if all goes well I should be test driving on Wednesday! That’s if I can find a new 153x u-joint for my rear axle shaft. If you can believe it, I lost one of the caps from my Tom Woods gold seal u-joint, I’m not too happy about that. My local Napa stopped carrying Spicer (AHHHH ) so I might have to take a couple of hours tomorrow to drive to 4WDH to get a Spicer joint. I don’t like the no names, I break enough without running crap.

nate
05-30-2005, 05:05 AM
What T Case do you have? 231? They are like 70lbs.. pussy haha. I just undid the bolts and kinda sorta bench pressed mine.

As for the shafts, I found mine were starting to spin, so I tacked them in 2 spots. I talked to the guys at 6 States and they said it wouldn't hurt the joints enough to worry about it.

OverkillZJ
05-30-2005, 08:48 AM
What T Case do you have? 231? They are like 70lbs.. pussy haha. I just undid the bolts and kinda sorta bench pressed mine.


231 HD so it's close to 80, problem is I put the Jeep on stands too low, there's not enough room to get under the case and push up :weedman:

TrojanMan
05-30-2005, 01:16 PM
The regular 231 weighs 65 lbs, the 231HD weighs 72 lbs.

OverkillZJ
05-30-2005, 07:09 PM
The regular 231 weighs 65 lbs, the 231HD weighs 72 lbs.

Mines special.

TrojanMan
05-30-2005, 08:13 PM
The regular 231 weighs 65 lbs, the 231HD weighs 72 lbs.

Mines special.

hahahahaha its a fatty :weedman:

chadjans
05-30-2005, 08:41 PM
You have to grind the lip down on the bushing shell to get it to press into the control arm end ring.

OverkillZJ
05-30-2005, 11:50 PM
You have to grind the lip down on the bushing shell to get it to press into the control arm end ring.

Negative, Clayts arms have a recesed sleve that allows an unmodified bushing to be installed.

What you have to do is have a hole for the bolt sleve instead of a press plate under it so you're not pressing metal against metal like dumbasses after a long days wrenching causing you to bend the press.

I looked at it the next morning and realize in 2 seconds what i'd done wrong, I should've quite while I was ahead!

nate
05-31-2005, 05:13 AM
Yup been there, done that. Broke an oil pump in a 231 wrenching when I was too tired... and a bit drunk. $50 mistake so not "too" bad.

OverkillZJ
09-03-2005, 02:17 PM
Well, this update has been a long time coming. A lot has happened in the last three months, so I’m going to play catch up before I tell you the current state of the Jeep as well as what the future will hold for the Jeep. It survived Grand Slam West in Moab, a lot of other wheeling out west, a hail storm in Kansas with ice the size of a baseball smashing in the windshield, and it survived Grand Slam South East in Tellico for the most part. I got enough Jeeping in this summer for a lifetime. Let’s just say this next rebuild phase will be the biggest yet, and I need to save up for a tow rig.

I’ll get to that later, and keep throwing up my late updates once in awhile to get caught up, but for now, here’s the old stuff I neglected to post from awhile back:

As usual, putting the Jeep together just a few days before the big Jeep-Out-West trip with just a few days to spare, while trying to rap up all the business and personal stuff that needs to be out of the way before taking off for a full month.
http://www.bigassjeep.com/pics/phoenix/9.03.05.a.jpg


http://www.bigassjeep.com/pics/phoenix/9.03.05.b.jpg

I did decide to tack the caps on the new joints/shafts as well as running the full circle clips. The shafts and joints held even when the front Detroit locker blew up, but we’ll get to that later.
http://www.bigassjeep.com/pics/phoenix/9.03.05.c.jpg

Lots of new seals and bearings for the front hub conversion.
http://www.bigassjeep.com/pics/phoenix/9.03.05.d.jpg


http://www.bigassjeep.com/pics/phoenix/9.03.05.e.jpg


http://www.bigassjeep.com/pics/phoenix/9.03.05.f.jpg


http://www.bigassjeep.com/pics/phoenix/9.03.05.g.jpg


http://www.bigassjeep.com/pics/phoenix/9.03.05.h.jpg

I re-routed the rear brake line to traverse the upper control arm instead of the lower, where it was rather exposed to rocks and the like. This new way seems to work out much better.
http://www.bigassjeep.com/pics/phoenix/9.03.05.i.jpg

Sitting and looking like it’s together, but not really done yet.
http://www.bigassjeep.com/pics/phoenix/9.03.05.j.jpg

Since the dyna beads didn’t seem to be quite enough to balance the 35” MTR’s with cheap steel wheels, I got the tires balanced. Couldn’t drive the Jeep since on my first test drive, the police freaked out on me. I’d broken off the rear shock mounts on the test drive (mis-measured the mounts, the eyes ripped off.) I discovered that if I kept pumping the brakes while slowing down at a red light, I could actually make the rear end of the Jeep bounce OFF of the ground with no shocks to absorb the bounce. I guess the police officer behind me didn’t like that, he followed me the entire way home.
http://www.bigassjeep.com/pics/phoenix/9.03.05.k.jpg

Thanks for Tom Woods for expressing me a new gold seal joint (for cheap too) to replace the one I’d lost a cap on.
http://www.bigassjeep.com/pics/phoenix/9.03.05.l.jpg

Here you can see how Steve saved my ass by making new tabs from some steel I had laying around and welded to the other side of the good tab, correcting my original mistake.
http://www.bigassjeep.com/pics/phoenix/9.03.05.m.jpg

http://www.bigassjeep.com/pics/phoenix/9.03.05.n.jpg


http://www.bigassjeep.com/pics/phoenix/9.03.05.o.jpg


http://www.bigassjeep.com/pics/phoenix/9.03.05.p.jpg


http://www.bigassjeep.com/pics/phoenix/9.03.05.q.jpg


http://www.bigassjeep.com/pics/phoenix/9.03.05.r.jpg


http://www.bigassjeep.com/pics/phoenix/9.03.05.s.jpg


http://www.bigassjeep.com/pics/phoenix/9.03.05.t.jpg

Replaced the infamous idler pulley, keep the old one in the trail box as a spare.
http://www.bigassjeep.com/pics/phoenix/9.03.05.u.jpg

I was all excited to put the door panels back on. I don’t know why, considering the doors are probably going in the dumpster soon!
http://www.bigassjeep.com/pics/phoenix/9.03.05.v.jpg

Shaved down the bottom bolt on my ghetto shaved 44.
http://www.bigassjeep.com/pics/phoenix/9.03.05.w.jpg


http://www.bigassjeep.com/pics/phoenix/9.03.05.x.jpg


http://www.bigassjeep.com/pics/phoenix/9.03.05.y.jpg

Put a couple nifty lil’ hood lights under the, well, hood. They’re already broken.
http://www.bigassjeep.com/pics/phoenix/9.03.05.z.jpg


http://www.bigassjeep.com/pics/phoenix/9.03.05.aa.jpg

Got rid of the XM radio so I could install Siruis. Sirius kicks @$$.
http://www.bigassjeep.com/pics/phoenix/9.03.05.bb.jpg


http://www.bigassjeep.com/pics/phoenix/9.03.05.cc.jpg

To my horror I found that I’d stripped out the bleeder screw on the front left caliper and was unable to repair it. In a rush since I was leaving the next day, I just got a new caliper and gave the old one up as a core.
http://www.bigassjeep.com/pics/phoenix/9.03.05.dd.jpg

Bled the brakes.
http://www.bigassjeep.com/pics/phoenix/9.03.05.ee.jpg

Of course, the all important ROCK LIGHTS! I’ve gotten a lot of use out of the 200 watts of light under the Jeep.
http://www.bigassjeep.com/pics/phoenix/9.03.05.ff.jpg

Removed the foam behind the kick panel so I could install my switches there.
http://www.bigassjeep.com/pics/phoenix/9.03.05.gg.jpg

Finally making use of the wiring box under the hood.
http://www.bigassjeep.com/pics/phoenix/9.03.05.hh.jpg

Made some good use of that dash space by making brackets that allowed me to mount the CB on the uneven surface.
http://www.bigassjeep.com/pics/phoenix/9.03.05.ii.jpg

I stopped taking pictures at that point in the rush, since it was 2am and I was planning on leaving for Dave’s in Colorado to stay with Hotel Mallcrawlin at sunrise. So the “finished” pictures were taking at Dave’s place a few days later.
Serius Radio… ROCK!
http://www.bigassjeep.com/pics/phoenix/9.03.05.jj.jpg


Finally wired up the sensors and gauges, have Tranny temp and Water temp working, still haven’t put in an oil temp sensor yet though.

http://www.bigassjeep.com/pics/phoenix/9.03.05.kk.jpg

Have a speaker under the wheel well to make fun of people on the trail now. I find myself using it to yell at idiots on the road too though.
http://www.bigassjeep.com/pics/phoenix/9.03.05.ll.jpg

The Jeep was loaded as hell since I picked up Puma297 and Kraqa at the airport on the way to Dave and Pam’s house. I’ll update more later about the adventure itself and the fate of the Jeep.
http://www.bigassjeep.com/pics/phoenix/9.03.05.mm.jpg

BigDaveZJ
09-03-2005, 02:56 PM
Don't forget the part where you put a hole in my garage!!

That didn't happen for another few weeks from where you're at in the story now.

ELLLLLIOTTTTT
09-04-2005, 03:41 PM
http://www.bigassjeep.com/pics/phoenix/9.03.05.ll.jpg

yea fun for yelling at people on the trail or perhaps blasting it in your ear while you change diff fluid. :finga:

OverkillZJ
09-04-2005, 03:50 PM
[img]
yea fun for yelling at people on the trail or perhaps blasting it in your ear while you change diff fluid. :finga:

Oh don't worry, I didn't forget. You'll get what's coming to you :overkill:

TrojanMan
09-04-2005, 05:00 PM
my pa speaker > yours.. but mine is under the hood so it's muffled. maybe i'll put mine there too.

OverkillZJ
09-04-2005, 05:05 PM
my pa speaker > yours..

Mine was free. Free > *.*

If I really wanted a loud PA speaker, it'd be, well, absurdly loud. I don't full around when it comes to sound systems if I'm trying to get a good result, man I wish I still had my old stage rig :weedman:

Cue-Ball
09-04-2005, 05:27 PM
I have a kick ass one for mine. It is a Federal Signal 200watt low profile one that is usually used on police cruisers, talk about getting peoples attention, yea baby.

TomH
10-03-2006, 11:42 PM
OK, so when you finish it's still only a ZJ, but damn...

Just kidding.

You know what you did wrong. (As an IT Consultant, you know what happens to systems that wait too long to start the sprint to the finish.)

Go back to the beginning of the thread and get amped like the rest of us. It will come back to you. In more ways than one, you got the tools to get it done.

http://www.hachiya.us/images/jeep/rear-uncovered.jpg
http://www.hachiya.us/images/jeep/rear-covered.jpg
http://www.hachiya.us/images/jeep/rear-lift.jpg

Not so much "been there - done that" as "am there - doin' that"

Get back to work!

OverkillZJ
10-04-2006, 10:45 AM
Get back to work? Dude - this project was finished and destroyed like two years ago.... It's a buggy now...

canadian_driver
10-04-2006, 10:46 AM
well then, way to look up threads over a year old. look at the more recent "project poenix"

OverkillZJ
10-04-2006, 10:50 AM
Well I've gotat give him credit for his first plast at least have pics of a decent axle build :finga:

TrojanMan
10-05-2006, 10:12 AM
All your doors are MINE