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JeepsterJay
09-17-2005, 09:36 PM
4.0/Aw4/231/Dana 30/35

So far did a bit of body work, 5x2 1/8" rockers, & almost finished rear bumper (pics below).

Plans for between now & spring 2006
Swap the pos Dana 35 with the Locked (lockright locker) 8.25 I kept from my old XJ.
7" Rock Krawler coils, custom long arms, roof rack spare / jack carrier & custom front bumper.

When I bought the ZJ the rockers were pretty bad so I had a set of rockers made for it out of sheet metal, welded them on & didn't like them.

So I cut them off & decided to go with 5"x2"x1/8" wall rectangular tubing tied into to the A pillar & I think they turned out great & will prolly never rust.

http://nboffroadclub.com/pics/ZJ_Buggy/rockers01.JPG

http://nboffroadclub.com/pics/ZJ_Buggy/rockers02.JPG

http://nboffroadclub.com/pics/ZJ_Buggy/rockers03.JPG

http://nboffroadclub.com/pics/ZJ_Buggy/rockers04.JPG

http://nboffroadclub.com/pics/ZJ_Buggy/rockers05.JPG

I am almost finished fabbing my rear ZJ bumper.

http://nboffroadclub.com/pics/ZJ_Buggy/zjbump01.JPG

http://nboffroadclub.com/pics/ZJ_Buggy/zjbump03.JPG

http://nboffroadclub.com/pics/ZJ_Buggy/zjbump04.JPG

http://nboffroadclub.com/pics/ZJ_Buggy/zjbump05.JPG

http://nboffroadclub.com/pics/ZJ_Buggy/zjbump06.JPG

I used 18" strips of 2"x2.5"x3/16" angle here because the uni-body frame sucks & if I did not use something here I would have ripped the bumper off in no time & to mount my gas tank skid to, I drilled 4 - 1/2" holes in it & am going to weld 1/2" nuts to the side closest to the gas tank to bolt the gas tank skid to.
http://nboffroadclub.com/pics/ZJ_Buggy/zjbump08.JPG

Kraqa
09-17-2005, 10:10 PM
i hope you tied those cut out rockers into the frame some how. if not they'll probably end up like mine. crunched up into the bottom of my doors.

nice looking rig tho.

JeepinHank
09-19-2005, 10:18 AM
Excellent job on the seam for the rocker replacement.

JeepsterJay
10-05-2005, 06:56 AM
Here are a couple of pics of the rear bumper painted & installed.

http://nboffroadclub.com/pics/ZJ_Buggy/zjbump09.JPG

http://nboffroadclub.com/pics/ZJ_Buggy/zjbump10.JPG

OverkillZJ
10-05-2005, 10:01 AM
Nice

97trxuszj
10-05-2005, 02:14 PM
I made my rear bumper just like that and when you get into like the 35" tall tire range your gonna need to trim that front edge of that rear bumper back about an 1" my 34" ltbs rub on mine and its even with the line on the actual fender

JeepsterJay
08-13-2006, 11:19 PM
I started hacking up what will be my ZJ Buggy.

Here are some of the plans, but anyone who knows me knows I like to change my plans alot, but I do have most of the parts collected so the plans shouldn't change much.

6" - 7" Lift (Rock Krawler Coils and Shocks)
Sub Frame & Long Arms (With Poly Bushings or Heim Joints Depends on Available $$$)
3/4 Ton HP Dana 44 and Matching Dana 60 (Welding the 60)
Lots and lots of Fender Trimming
Custom Rear Inner Fenders
Full Cage
4 Bucket Seats (Need 2 Grey ZJ Buckets, Got Any?)
Comanche Tailgate (Maybe)
38" Michelin Xml's (Have 5 of them)
Raise Gas Tank About 6"
OBA (Have York Compressor and Tank)

Here are a few pics...

Here is it looked like when I got it.
http://nboffroadclub.com/pics/ZJ_Buggy/myzj001.jpg

The Journey Begins...
http://nboffroadclub.com/pics/ZJ_Buggy/myzj002.jpg
http://nboffroadclub.com/pics/ZJ_Buggy/myzj003.jpg

Chopped the roof
http://nboffroadclub.com/pics/ZJ_Buggy/myzj004.jpg
http://nboffroadclub.com/pics/ZJ_Buggy/myzj005.jpg

The pile of stuff that has been removed.
http://nboffroadclub.com/pics/ZJ_Buggy/myzj006.jpg

And here is what the XML's look like, I will be taking the groover to mine though.
http://nboffroadclub.com/pics/ZJ_Buggy/XML_tire.jpg

BigDaveZJ
08-13-2006, 11:42 PM
You might as well sell the rear bumper and hack a good foot or so off the back end.

JeepsterJay
08-13-2006, 11:45 PM
Yean the rear bumper is up for sale, and I was thinking of hacking off some of the back end, I also have a Comanche sitting in my buddy's field with a good tail gate, gotta do some measuring and see if I can make it fit...

BigDaveZJ
08-13-2006, 11:56 PM
A 'manche tail gate would be kick ass on the back of a ZJ. It's crossed my mind before to do on my ZJ, but I just don't see it happening as my current plans for the rig involve mainly tube in the back. I've got mine hacked as yours is right now, and frankly see no benefit to it other than open air (and that's often more of a downfall than a benefit) so I was just curious what your plans were.

ATL ZJ
08-14-2006, 12:18 AM
Are you taking more off? If you're not, that aint a buggy. And I can say so because mine is chopped the same way.. Buggies are bare minimum 50% tube..

But enough with the technicalities. It's a good start. You followed the same lines that I did, so you know what they say about great minds. :D Ditch the tailgate idea, that's a waste of time and more weight to lug around.. I love having mine open in the back.

Keep the pics flowing!

JeepsterJay
08-14-2006, 01:11 AM
Are you taking more off? If you're not, that aint a buggy. And I can say so because mine is chopped the same way.. Buggies are bare minimum 50% tube..

But enough with the technicalities. It's a good start. You followed the same lines that I did, so you know what they say about great minds. :D Ditch the tailgate idea, that's a waste of time and more weight to lug around.. I love having mine open in the back.

Keep the pics flowing!

Yup lots more coming off...

Yeah I am back and forth on the tailgate idea, I know it would take some time to make it look good and like it should be there.

Kraqa
08-15-2006, 11:56 PM
hack 1' off the back then integrate the tailgate skin on the end it woudl look dope. just use the lift gate skin tho not the internals.

deadman
08-16-2006, 06:31 AM
kinda like that...

http://jeep.cfasp.de/upload/166357.jpg

zj95
08-16-2006, 04:01 PM
kinda like that...

http://jeep.cfasp.de/upload/166357.jpg

holy cow! thats sweet!!!!!!!!!!!

JeepsterJay
08-17-2006, 06:46 PM
hack 1' off the back then integrate the tailgate skin on the end it woudl look dope. just use the lift gate skin tho not the internals.

Fawk I never thought of that, I like that idea...

Few more pics nothing exciting... All glass except winshield is now removed.

Plans for the weekend, start building the cage, remove the rear ends, start on removable half doors etc...

Floor is in good condition
http://nboffroadclub.com/pics/ZJ_Buggy/myzj007.jpg

Ah Wiring, I hate wiring...
http://nboffroadclub.com/pics/ZJ_Buggy/myzj008.jpg

http://nboffroadclub.com/pics/ZJ_Buggy/myzj009.jpg

http://nboffroadclub.com/pics/ZJ_Buggy/myzj010.jpg

JeepsterJay
08-17-2006, 09:58 PM
kinda like that...

http://jeep.cfasp.de/upload/166357.jpg


School me on them flares, did you make them?

ATL ZJ
08-17-2006, 11:29 PM
school me on everything BUT the flares.. they are gay unless you have to have them for street legality, but what's the point of having a rig that built street legal anyways? I don't think we've seen any more pics of this rig. I could be wrong, but I don't think so :D... So post up some more shots.

nate
08-18-2006, 12:46 AM
Flares are nice when you wheel in muddy trails!

deadman
08-18-2006, 04:29 AM
I think I got one more pic - this rig ain't mine... Mine still looks the same as a few months ago.

http://jeep.cfasp.de/upload/167854.jpg

That guy is from Lithuania -Europe and it seems to be streetlegal.
39.5 Bogger and 404 mogs - to my knowledge the first Grand on mogs.

I found the guy on the whiteknight forum: http://www.whiteknight.ca/FORUMS/index.php?showtopic=6319&hl=grand+cherokee

JeepsterJay
08-18-2006, 04:44 PM
school me on everything BUT the flares.. they are gay unless you have to have them for street legality, but what's the point of having a rig that built street legal anyways? I don't think we've seen any more pics of this rig. I could be wrong, but I don't think so :D... So post up some more shots.

We have lots of mud here on the East Coast that is why I was wondering about the flares, I would like to make some kind of flare that is easily removable.

chadjans
08-20-2006, 11:25 PM
Take the windshield out.

ELLLLLIOTTTTT
08-20-2006, 11:44 PM
looks like that guy has more than a nice rig...

http://jeep.cfasp.de/upload/166366.jpg

:best:

BlackDiamondBound
08-21-2006, 12:59 AM
looks like that guy has more than a nice rig...

http://jeep.cfasp.de/upload/166366.jpg

:best:


lol

Jeeperoni91
08-21-2006, 12:05 PM
looks like that guy has more than a nice rig...

http://jeep.cfasp.de/upload/166366.jpg

:best:


agreed:smt045

rrock802
08-22-2006, 12:36 AM
looks like that guy has more than a nice rig...

http://jeep.cfasp.de/upload/166366.jpg

:best:

try playing with the numbers in the address...especially if you only change the last number to an 8:smt041

Nick
08-22-2006, 01:23 AM
change it to 70 not to shabby

Jeeperoni91
08-22-2006, 03:33 PM
my lord fellas, this is fun now.

JeepsterJay
08-27-2006, 08:40 PM
Had a few hours to work on the Jeep today.

Took the rear bumber off, dropped the gas tank and pulled the rear end...

Then the Sawzall and Angle Grinder came out...

I wasn't sure how much to cut so I just started measuring and marking with a sharpie and went at the fenders and took a little more than 4" off of the length of the ZJ.

I am going to make some box style inner fenders like on a TJ/YJ/CJ. I just bought a cheap sheet metal break from PA to make them I will let you guys know how it works.

Here are a few pics.

http://nboffroadclub.com/pics/ZJ_Buggy/myzj011.jpg

http://nboffroadclub.com/pics/ZJ_Buggy/myzj012.jpg

http://nboffroadclub.com/pics/ZJ_Buggy/myzj013.jpg

http://nboffroadclub.com/pics/ZJ_Buggy/myzj014.jpg

http://nboffroadclub.com/pics/ZJ_Buggy/myzj015.jpg

http://nboffroadclub.com/pics/ZJ_Buggy/myzj016.jpg

ATL ZJ
08-27-2006, 09:04 PM
I like where this is going.. Any reason for keeping the little bit of sheetmetal in the back other than for cosmetic reasons? And keep the pics coming. :D

JeepsterJay
08-28-2006, 04:12 PM
Well my plan for now is to build box style inner fenders that will attatch to the remaining sheet metal in the back.

As I mentioned before we have alot of mud on the East Coast and wanted to do somthing to help keep some of the mud out.

ogdak
08-28-2006, 04:38 PM
Nice tailpipe.

PatM
08-29-2006, 12:01 AM
Got any more detailed pics of the rockers? I bashed mine good this weekend and am thinking abou this route.

ATL ZJ
08-29-2006, 03:12 PM
Well my plan for now is to build box style inner fenders that will attatch to the remaining sheet metal in the back.

As I mentioned before we have alot of mud on the East Coast and wanted to do somthing to help keep some of the mud out.


I would really recommend doing a slight dovetail on yours. It'll keep the mud out and get your body father away from all the rocks and trees we have on this side of the country.. Seems like I am always raking my quarterpanels against something..

The way you have the quarterpanels trimmed would allow you to really easily bend them right behind the C pillar.. Then all you'd have to do would be to trim the outermost rear corners of the floor back there, which you might not even have to do. Then patch in tube or sheetmetal to get some rigidity and you're set.. I really wish I had done it that way but it's too late now with the way I tied my cage into the sheetmetal back there. Check my build thread for a visual of what I'm talking about if you want..

Kraqa
08-29-2006, 09:18 PM
x2 on the dove tail. Best mod ever.

and i love where this is going!!

JeepsterJay
08-30-2006, 05:17 PM
Got any more detailed pics of the rockers? I bashed mine good this weekend and am thinking abou this route.

I may have a few more pics, I will check.
It was pretty straight forward, 5x2x1/8" tubing and 1x1x1/8" angle, cut the old rockers out and weld the new ones in.

I thought about doing the dovetail too and I like the idea and that is the way I will probably go. I would like to do the same to the front and it the front will be way more of a PITA to do.

Any tips on what bushings to use for the long arms, I am going to do bushings at both ends for now to keep the cost down. I have found some that I think will work, here is the link http://www.suicidedoors.com/PolyBushingfor4-LinkEnd.php

Oh, and I have paid my subscription and I am still not showing as a supporter, just wondering if it takes a while?

PatM
08-31-2006, 12:18 AM
I may have a few more pics, I will check.
It was pretty straight forward, 5x2x1/8" tubing and 1x1x1/8" angle, cut the old rockers out and weld the new ones in.

I thought about doing the dovetail too and I like the idea and that is the way I will probably go. I would like to do the same to the front and it the front will be way more of a PITA to do.....



I think I'm just scared to cut my body up. And besides I want to be able to do it myself and garage does not have power yet, so the welder sits in the corner collecting dust.

SuicideTireZJ
08-31-2006, 02:46 AM
I totally dig keeping the rear fenders. Make it look like a ZJ AND a buggy at the same time, but another vote for dovetailing fo sheezie. Narrowing your rear end like 6" on each side not only keeps your sheetmetal away from things that could hit it, but also make it a few inches shorter which is good for the departure angle. Bonus points if you keep the stock taillights and incorporate half the liftgate in there!

JeepsterJay
09-17-2006, 10:59 PM
Well no pics of the build, but I did do a little more sawzall work and started taking all that shit that is glued to the floor, that is some fun stuff.

Here are some pics of my new (to me) Daily Driver / Tow Rig...

It is a 1995 Jeep Grand Cherokee, Fully Loaded w/Leather and Tow Package and only 183k on it, couldn't pass up the wicked deal I got on it...

http://www.nboffroadclub.com/pics/95zj01.jpg

Here is the best part

http://www.nboffroadclub.com/pics/95zj03.jpg

http://www.nboffroadclub.com/pics/95zj02.jpg

chadjans
09-17-2006, 11:37 PM
Grands make horrible tow rigs.

zj95
09-17-2006, 11:59 PM
Grands make horrible tow rigs.
why do you say that??
mine does really really good..

i towed a 6800 pound trailer (before the lift),and i still tow a 16 foot tandom axle trailer with 2 quads, and a 18 foot boat( not at the same time.) and it does fine with them all

Jay: if you keep the grand the way it was built it makes a great tow rig

ATL ZJ
09-18-2006, 12:45 AM
why do you say that??
mine does really really good..

i towed a 6800 pound trailer (before the lift),and i still tow a 16 foot tandom axle trailer with 2 quads, and a 18 foot boat( not at the same time.) and it does fine with them all

Jay: if you keep the grand the way it was built it makes a great tow rig
You must have low standards.

Those loads sound like they'd be pushing it with even a half ton pickup. A ZJ doesn't even fall into the half ton category.. The small rotors on the dana 30, 35, and AL44 axles aren't intended to stop too much more than the weight of the Jeep itself. I hope you have a good brake controller and decent trailer brakes.

Not to mention the transmissions they put in these things.. The wheelbase and unibody don't help the cause either..

chadjans
09-18-2006, 01:21 AM
Tell you what.... Ride with me in my tow rig towing about 7K (what a built rig with trailer equals) through the hills at 80mph, getting 15mpg and you will wish you never towed with a unibody grand with small brakes and no frame.

zj95
09-18-2006, 01:31 AM
Tell you what.... Ride with me in my tow rig towing about 7K (what a built rig with trailer equals) through the hills at 80mph, getting 15mpg and you will wish you never towed with a unibody grand with small brakes and no frame.

thats like comparing apples to oranges..

your talking about a 2500, not a jeep..

i never said it was a truck.. it does have limitations

and no i would never pull a large trailer without trailer brakes..

BigDaveZJ
09-18-2006, 10:54 AM
But do you use an apple to make orange juice?? Nope!! I've ridden in a ZJ, pulling a 16ft trailer, with another ZJ on the trailer. In an emergency yeah it'll work, but if you're going to use it for that purpose any amount of time, a truck is the only way to go.

MUDDTRACKS
09-18-2006, 04:31 PM
It can be done but i would use that as my last option.

We used Jim311's zj to pull My shit home on a trailer about 45 miles and it did ok but not something you want for long trips

JeepsterJay
09-19-2006, 04:55 PM
I don't plan on using it to tow very far, we usually wheel within 50kms of where we live.

I was going to lift it, but I think I am going to leave it as is and just buy some nice wheels and good tires for it and thats it.

rockhardmj
12-03-2006, 11:25 PM
You might as well plan on another Hummer'd ZJ on the east coast...
We are gaining on them west coaster's now, Don't plan to do it till the nice weather hits in the spring and i get a new mig welder...

Oh, and btw, kick ass rig, keep it up!