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OverkillZJ
10-14-2005, 07:52 PM
Project Phoenix Buggy: The Beast from the East



Some of you might remember a couple of years ago when I decided to revive my rusty Jeep into a nice and capable vehicle, with the goal of making it to Grand Slam West 2004.
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There was a massive thread on NAGCA: http://www.nagca.com/forum/viewtopic.php?t=12581 (http://www.nagca.com/forum/viewtopic.php?t=12581)

It’s contents have been copied to MallCrawlin as well (hella faster server), more or less as an archive: http://www.mallcrawlin.com/forum/showthread.php?t=3992 (http://www.mallcrawlin.com/forum/showthread.php?t=3992)
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I also put together a video of that years crazy trip, which can be downloaded (or $5 for the DVD.)

RIGHT CLICK, SAVE AS!

High Resolution – (320 MB) http://www.bigassjeep.com/video/phoenix2004webhigh.wmv
Low Resolution – (96 MB) http://www.bigassjeep.com/video/phoenix2004weblow.wmv

And the last video is the most recent video of us beginning the buggy build. It’ll probably be the last video for awhile until the project is done, and tested. Then will come the best video yet!

Anyway, RIGHT CLICK, SAVE AS! (35 MB) http://www.bigassjeep.com/video/phoenixteaserweb.wmv (http://www.bigassjeep.com/video/phoenixteaserweb.wmv)
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So That should bring you up to speed. The Jeep really did better than I imagined and I abused it as it was meant to be abused. I took it to Moab for GSW in 2004 and 2005, as well as a few weeks of other wheeling out west both years. Of course it was amused back east too. I kept breaking it and fixing it.

After abusing it that much, and flexing it (not to mention jumping it) so many times without a cage, it took its toll on the unibody. When it got to the point where I could no longer really open or close the doors without effort, as well as blowing up 2 more ball joints and yet another locker in the front HP30, I decided that enough is enough. I’ve grown accustomed to the type of wheeling which a full bodied ZJ can only survive so many times. My Jeep was well past that “so many times” mark. I felt like I had 3 options: sell it for next to nothing, part it out and get the already destroyed frame hauled off and crushed, or build it into a BUGGY. Being obsessed with offroading, and being rather attached to my ZJ, I chose to buggy it, and build it big to the point where I shouldn’t really have to worry about breaking things so much.

So here’s the plan:

-gut it
-cut it up almost down to the frame rails
-Build a full roll cage (you’ll see details on plans for that later)
-ditch the weak driveline to go with
-14 bolt rear w/ Detroit locker and disc brakes (4.56)
-HP60 front from a 79F350 with 35 inners, outers, drive flanges, ARB (4.56)
-Full Hydro
-e350 master cylinder
-Stak 3 speed tcase
-Corbeau suspension seats
-Waterproof sound system
-41.5” Irok
-Either driveline brake, or line lock (more likely skid steer) on the rear brake line
-Radiator and tranny cooler moved to rear / upper cage



I’m sure some of the plan will change throughout the project, but that’s the starting point anyway. I have some talented help, mainly Steve (blackbox renegade) who’s a certified welder and all round likes working on crap as much as I do; and Dave (DMG) who’s a REAL mechanic and good with gears and driveline while I just like to pretend.



First, a few pictures or how it looked in Moab just a few months earlier.

http://www.mallcrawlin.com/wheelinpics/gsw05/GSW2005%20Golden%20Spike%20(13).jpg

http://www.mallcrawlin.com/wheelinpics/gsw05/GSW2005%20Golden%20Spike%20(57).jpg

http://www.mallcrawlin.com/wheelinpics/gsw05/GSW2005%20Golden%20Spike%20(5).jpg



And the darn thing even got a few shots in an issue of 4 Wheel Drive and Sport Utility Magazine. Here’s a link to one of the pics: http://4wdandsportutility.com/freestuff/05104wd_moab_02_1280.jpg (http://4wdandsportutility.com/freestuff/05104wd_moab_02_1280.jpg)


So let’s get to it. Day 1: begin parting it out and cutting it. There was a whole lot of shock factor. There’s a video of this day here: (right click save as) http://www.bigassjeep.com/video/phoenixteaserweb.wmv (http://www.bigassjeep.com/video/phoenixteaserweb.wmv)



http://www.bigassjeep.com/pics/phoenix/9.24.05.a.jpg


http://www.bigassjeep.com/pics/phoenix/9.24.05.b.jpg


http://www.bigassjeep.com/pics/phoenix/9.24.05.c.jpg


http://www.bigassjeep.com/pics/phoenix/9.24.05.d.jpg


http://www.bigassjeep.com/pics/phoenix/9.24.05.e.jpg


http://www.bigassjeep.com/pics/phoenix/9.24.05.f.jpg


http://www.bigassjeep.com/pics/phoenix/9.24.05.g.jpg


http://www.bigassjeep.com/pics/phoenix/9.24.05.h.jpg

http://www.bigassjeep.com/pics/phoenix/9.24.05.i.jpg


http://www.bigassjeep.com/pics/phoenix/9.24.05.j.jpg


http://www.bigassjeep.com/pics/phoenix/9.24.05.k.jpg


http://www.bigassjeep.com/pics/phoenix/9.24.05.l.jpg


http://www.bigassjeep.com/pics/phoenix/9.24.05.m.jpg

http://www.bigassjeep.com/pics/phoenix/9.24.05.n.jpg


http://www.bigassjeep.com/pics/phoenix/9.24.05.o.jpg


http://www.bigassjeep.com/pics/phoenix/9.24.05.p.jpg


http://www.bigassjeep.com/pics/phoenix/9.24.05.q.jpg


http://www.bigassjeep.com/pics/phoenix/9.24.05.r.jpg


http://www.bigassjeep.com/pics/phoenix/9.24.05.s.jpg


http://www.bigassjeep.com/pics/phoenix/9.24.05.t.jpg


http://www.bigassjeep.com/pics/phoenix/9.24.05.u.jpg


http://www.bigassjeep.com/pics/phoenix/9.24.05.v.jpg

I consider this thread “chapter 2” of Project Phoenix. It’s the same vehicle (well, kind of) – just the next phase!

I’ll keep updating as things happen.

TrojanMan
10-14-2005, 07:55 PM
looking good :beerchug:

OverkillZJ
10-14-2005, 09:12 PM
Here’s the second day of cutting it up. We were hoping to get the front end and back cut down to the frame rails, but Steve felt like crap, I wasn’t motivated, Heidi didn’t know what to do, and Dave was just amused watching us be stupid for a lot of it.

We still got some done, and got to brain storm a little bit.

http://www.bigassjeep.com/pics/phoenix/10.08.05.a.jpg


http://www.bigassjeep.com/pics/phoenix/10.08.05.b.jpg


http://www.bigassjeep.com/pics/phoenix/10.08.05.c.jpg


http://www.bigassjeep.com/pics/phoenix/10.08.05.d.jpg


http://www.bigassjeep.com/pics/phoenix/10.08.05.e.jpg


http://www.bigassjeep.com/pics/phoenix/10.08.05.f.jpg


http://www.bigassjeep.com/pics/phoenix/10.08.05.g.jpg


http://www.bigassjeep.com/pics/phoenix/10.08.05.h.jpg

http://www.bigassjeep.com/pics/phoenix/10.08.05.i.jpg


http://www.bigassjeep.com/pics/phoenix/10.08.05.j.jpg

Ya, I’m cheap enough to save the 50 cents of washer fluid from the reservoir we removed from the ZJ…

http://www.bigassjeep.com/pics/phoenix/10.08.05.k.jpg


http://www.bigassjeep.com/pics/phoenix/10.08.05.l.jpg

SO MANY FREAKING WIRES TO DEAL WITH! In one wiring harness, there’s speaker wires, light wires, tail light wires, FUEL PUMP WIRES, etc. It’s going to be a huge project just figuring out what I need.
http://www.bigassjeep.com/pics/phoenix/10.08.05.m.jpg
I always thought the radiator and fan shroud could be removed while the fan was still installed, I just didn’t think it involved cutting the front crossmember off! That’s the only cutting we did all day, the rest was taking apart the engine compartment and the rest of the interior, except the dash.
http://www.bigassjeep.com/pics/phoenix/10.08.05.n.jpg

This is where we just sat there saying… Now what?
http://www.bigassjeep.com/pics/phoenix/10.08.05.o.jpg

OverkillZJ
10-14-2005, 09:40 PM
I picked up my new rear axle today. This was a score! Military surplus... It’s a 67.5” wide 14 bolt, STOCK from GM with 4.56 gears, a Detroit locker, Disc brakes, etc. As is, stock from GM. Definitely a rare find.

This thing is 495 pounds as packaged, and 450 pounds out of the crate. I took it out myself too, I was a little too anxious.

http://www.bigassjeep.com/pics/phoenix/10.14.05.a.jpg


http://www.bigassjeep.com/pics/phoenix/10.14.05.b.jpg

Here you can see what was stamped on the box: GM Rear axle destined for the US Military. I think my buggy is a better use!
http://www.bigassjeep.com/pics/phoenix/10.14.05.c.jpg

Here’s after I got it all unpackaged. Steve and I area going all the way up to Buffalo New York tomorrow morning (bright and freaking early) to pick up a pair of 60’s, but the trailer I’m using is SCARY when unloaded. We’re leaving the 14 bolt on it for dead weight.
http://www.bigassjeep.com/pics/phoenix/10.14.05.d.jpg

Here’s after practicing backing up with a trailer, A LOT, haha. I got it about .5” from the tree.
http://www.bigassjeep.com/pics/phoenix/10.14.05.e.jpg


Now time for bed, need to leave here at 7am tomorrow to ALMOST get there on time.

Kraqa
10-14-2005, 10:00 PM
your very darring to chop the from cross member with the motor in there. thos frame rails are WEEEEEK. i woudl bolt the stock rad support back in ther eto hold them from seperating. at least till youget the motor out of there.

OverkillZJ
10-14-2005, 10:04 PM
Meh, oops.

zj95
10-14-2005, 10:07 PM
whos wk?

OverkillZJ
10-14-2005, 10:11 PM
whos wk?

Dads. Traded him my lil' Corolla for a few days, I DEFINATELY got the better end of this deal.

It came with a corporate gas card too, makes moving axles around cost me ahemmm NOTHING. :supz:

zj95
10-14-2005, 10:36 PM
sweet

ogdak
10-15-2005, 03:19 AM
Wauw, this is gonna be a interesting thread again.

Kraqa
10-15-2005, 03:28 AM
WOW Who's the handsome devil in the passenger seat?
http://www.mallcrawlin.com/wheelinpics/gsw05/GSW2005%20Golden%20Spike%20(57).jpg

ELLLLLIOTTTTT
10-15-2005, 11:55 AM
only bitches ride bitch seat :flipoff2:

http://www.imagestation.com/picture/sraid173/pf680a74436d45d758b1efaacbb2cb88d/f3bac201.jpg

Kraqa
10-15-2005, 01:13 PM
what does that make you riding in the back seat then?

TrojanMan
10-15-2005, 04:27 PM
what does that make you riding in the back seat then?

bitch who takes it in the back:eek:

deadman
10-15-2005, 05:55 PM
:smt046

Nice score on the 14b!

cmarley
10-18-2005, 04:54 PM
Overkill I am new to this site but want to know what you are going to do with the lift you currently have under the zj when you full buggy it? consider selling it...?

OverkillZJ
10-18-2005, 05:01 PM
Only going to be selling the springs and maybe front track bar. The LA's stay!

ATL ZJ
10-18-2005, 06:17 PM
I like the Evan Williams tranny shifter...

How much support does the stock xmember really provide?

OverkillZJ
10-18-2005, 08:11 PM
I like the Evan Williams tranny shifter...

How much support does the stock xmember really provide?

LOL @ the tranny shifter.

I don't know how much support the stock xmember really provides up front, I think that Kraqa was just worried about the frame rails spreading under the weight... But I'd argue that it's the engine that kept them in place (tieing both sides together).

I put it back in for good measure anyway, can't hurt, right?

ZJake
10-18-2005, 08:37 PM
:smt046

Nice score on the 14b!

x2. where'd you find that setup and at what price? Boyce Equipment? 14b is what I'd like to do also :smt045 .

OverkillZJ
10-18-2005, 08:43 PM
x2. where'd you find that setup and at what price? Boyce Equipment? 14b is what I'd like to do also :smt045 .

Came across ebay seller whitejeeprubicon - it's an offroad shop in TN. I think they might have one left.

he was asking $1,299 but let's say that he'll come down a lil' :smt066

I dont' even know if he knows the history of these, fromthe looks of the auction he might not know what he has.

http://cgi.ebay.com/ebaymotors/ws/eBayISAPI.dll?ViewItem&rd=1,1&item=8005147109#ebayphotohosting

1986 military overstock.

ATL ZJ
10-18-2005, 09:04 PM
That's a lot for a 14b :eek:.. even if he came down to half price. I guess it is new and has a locker in it though.. but still, wow.

BigDaveZJ
10-18-2005, 09:06 PM
That's a lot for a 14b :eek:.. even if he came down to half price. I guess it is new and has a locker in it though.. but still, wow.


4.56's, detroit, and disc brakes, BRAND NEW, and it's a lot???

OverkillZJ
10-18-2005, 09:13 PM
That's a lot for a 14b :eek:.. even if he came down to half price. I guess it is new and has a locker in it though.. but still, wow.

What kind of weed are you smoking and can you please send me some?

Price out what it costs to build a 14 bolt. An old rusty 14 bolt you need to clean up yourself and replace all bearings, seals, probably install new gears, odds are hunt down a detroit, not to mention fab up brackets, or buy brackets for a disc break conversion. Guess what the price comes out to? About that ebay auction. No, more. Plus labor.

That's a lot of work I don't have to do now. Not to mention the gears were set at the factory, and still have the gear marking compund on them.

Shipped, in it's original GM crate, perfect and new. you're saying half of $1200 is still too much? Dude, GIMME SOME OF THAT WEED!

ATL ZJ
10-18-2005, 10:05 PM
It's going under a buggy. Drums will provide more than enough braking power for that light pile of tube. I know you can find 60s with 4.56s, and even as low as 5.13 if I am not mistaken, that came in them stock. The same *should* be true for the 14bolt, or at least close.. And you aren't going to be daily driving something on 41.5s, so why go with a Detroit? Might as well just spool it, or even weld the carrier. More predictable on the trail, and you aren't going to be driving it to soccer practice anyways. Even if it needs a rebuild kit, those can be had for the 14b for $152.. But I wouldn't really mess with that unless those were clearly bad. And as for the bright and shiny housing, well you're going to have to grind off a lot of that pretty paint to add brackets and most likely a truss. I'd rather be knocking off rust and dirt with a wire wheel than semi-gloss. Maybe I'm just a broke college student, but snagging a 14bolt for $85 at my local junkyard and doing it the simple way just seems a little more attractive.

Continually lowering my standards,
Cam

OverkillZJ
10-18-2005, 10:19 PM
It's my rig and I'm not skimping on the way I planned to build it, broke college student or not.
Drums? That's another 120 pounds hanging off of my suspension, another 20% of weight that doesn't' need to be there. If I intended this only to be on the rocks then MAYBE I'd go that route, but as drums don't do a darn thing when they're wet, muddy, or full of sand, and I plan to have this rig in all of the above as well as need to stop at baha speed, I'll stick with discs. Why not spool it? It was an option. However, you're saying a spool is more predictable than a Detroit? More predictable and pushing you through turns and off of rock obstacles the wrong way maybe. I think you need to sit down and actually price out how "cheap" you can build a 14 bolt. 14 bolts that come with 4.56 gears stock are rare in the first place, factor in my need for the 8 lug, etc, I could spend a grand easily rebuilding a junker 14er not counting that Detroit.

Other than that, ZJ buggies aren't nearly as lightweight as some seem to expect. You're still stopping 2 tons of metal on top of 42" tires.

Yes, I could build a junkyard 14er for maybe 800 if I spend days of time between hunting down the parts, setting the gears, GETTING LUCKY finding the right one, and cleaning it up. it's just not worth it for the small price difference.

Continually following the plan that will build a bad ass rig instead of another ghetto jungle gym of tube,

Matt

:finga:

ATL ZJ
10-18-2005, 10:47 PM
That's a good point about the extra unsprung weight, especially since 14bolts are heavy as hell from the start. I hadn't thought about that. I run an ARB rear, which is essentially a spool when locked.. and don't find it steering me in the wrong direction, and keep it locked a good bit on the trail.

It is your rig to build as you choose, and no doubt that it'll work well for you. I just had sticker shock since I consider 14bolts cheap to start with, that's all..I did price out the cost to build one comparably (albeit not factoring in time) and it came to around 650, which is half of the original figure you listed. But you still haven't said how much you actually paid. :flipoff2:

Bottom line is you got an axle that WILL work well though, so the benefit of that added confidence alone, plus the labor you've saved is definitely worth a considerable amount. edit: sorry for ruining your thread.. haha

OverkillZJ
10-18-2005, 10:51 PM
But you still haven't said how much you actually paid. :flipoff2:



I promised him I wouldn't :smt116

I'm going to go back to admiring my shiny 14 bolt now, LOL.

I need to make my front 60 shiny this weekend... I'm building a pulley system in the garage to work with the winch I took off of the jeep, just so I can move those things around on my own.

OverkillZJ
10-23-2005, 12:19 AM
Last Saturday, Steve and I left for a short road trip to Buffalo, New York to pick up a set of front and rear 60’s from a 1979 F350. We’re not planning on using the rear, but it’s being sold as a set, so I figured I’d take it for a boat anchor if nothing else.

We left my house at about 7am, which hurts after a night of drinking! We were making good time, apparently too good considering the ticket I got. I’m not used to how well the WK handles at speed, it’s very quiet and smooth. I ended up breaking 90 a few times, which I’d never do on purpose with a trailer. Oops. That was a $163 lesson.
http://www.bigassjeep.com/pics/phoenix/10.15.05.a.jpg


Here we are getting the axles off of the flatbed onto the trailer. At one point when moving the rear, I was walking forward holding my half, and ran out of truck. Axle went crashing down pretty good, breaking some of the wire mesh on the trailer. Shouldn’t be too bad to fix.
http://www.bigassjeep.com/pics/phoenix/10.15.05.b.jpg


http://www.bigassjeep.com/pics/phoenix/10.15.05.c.jpg

Neither Steve or I had ever been to an IHOP (if you can believe it). We don’t have them anywhere near where we live, and I’ve never found time to stop at one on any of my road trips. While we were there, I parked the WK in a lil’ curb crawling fashion.

Mmmmmmmm IHOP…
http://www.bigassjeep.com/pics/phoenix/10.15.05.d.jpg

Here’s the kicker. After getting a ticket, and breaking the trailer, I did the dumbest thing yet. Since the WK is a company vehicle, and I had the corporate gas card (BP/AMOCO) – I was hoping to go completely free on the gas. I gave it $10 of gas in NY, since there are apparently no BP’s up there. When the gas light came on, I figured it was like my ZJ or WJ and calculated there was a good 5 gallons left. Negative. About 25 miles later the engine shut off, and I got to call AAA. Yes, you can point and laugh now.
http://www.bigassjeep.com/pics/phoenix/10.15.05.e.jpg

As soon as we got back, we cracked open the 14 bolt. We were like kids on Christmas. I was shocked to find what a piece of crap the stock cover in, but the guts made up for it. That’s a Dana 30 ring gear and carrier next to the 14 bolt for comparison. Notice the gear marking compound? It’s been on there for about 19 years from the GM factory.
http://www.bigassjeep.com/pics/phoenix/10.15.05.f.jpg

That’s right, I’ve got new toys!
http://www.bigassjeep.com/pics/phoenix/10.15.05.g.jpg


http://www.bigassjeep.com/pics/phoenix/10.15.05.h.jpg

http://www.bigassjeep.com/pics/phoenix/10.15.05.i.jpg

OverkillZJ
10-23-2005, 01:09 AM
We set out today to get the Jeep frame up on stands / supports or whatever, and to start all of the electrical wiring to run the tools and heaters we’re going to need in the tent this winter. We went to Home Depot to get ideas, but as soon as we got to my place we pretty much said screw it since we were dying to tear down that Dana 60 front end.

http://www.bigassjeep.com/pics/phoenix/10.22.05.a.jpg

First priority: Move my rear 60 boat anchor. If anyone local would like it (full floater 30 spline) make me an offer.
http://www.bigassjeep.com/pics/phoenix/10.22.05.b.jpg

The front 60 was still a bit to heavy to move easily between the two of us without just hurting ourselves more, so we started tearing it down while it was on the trailer to shave some weight.
http://www.bigassjeep.com/pics/phoenix/10.22.05.c.jpg

Whoever previously owned this was a lazy idiot. Looks like someone lost a snap ring, and instead welded it in place.
http://www.bigassjeep.com/pics/phoenix/10.22.05.d.jpg

Here’s what it’s supposed to look like.
http://www.bigassjeep.com/pics/phoenix/10.22.05.e.jpg

As with any 26 year old axle from the north, this thing is RUSTY. Half of the bolts / studs holding the king pins in wouldn’t budge. We wore down the nuts trying.
http://www.bigassjeep.com/pics/phoenix/10.22.05.f.jpg

It took a few tries welding nuts to them to finally get them to budge. Eventually we had to thread nuts down on the studs, and weld both sides so it wouldn’t sheer off.

http://www.bigassjeep.com/pics/phoenix/10.22.05.g.jpg

Steve suddenly saw another bolt that’d come off and went at it. Back to that whole kids on Christmas thing…
http://www.bigassjeep.com/pics/phoenix/10.22.05.h.jpg

Here’s where I completely frelled up Brandons trailer. I’m sure I’ll have a blast fixing it.
http://www.bigassjeep.com/pics/phoenix/10.22.05.i.jpg

Ya, we made a mess. We had to stop when we came across a bolt on one side we couldn’t budge, not even with my gun. It’s weird, that impact gun has always either removed any bolt I put it on, or snapped it. This thing won’t budge. I’ve been soaking it in PB hoping it comes off tomorrow.

We also don’t have a spindle socket that fits, obviously the one I have for my 30 Warn hub conversion doesn’t fit. So we stopped until tomorrow.
http://www.bigassjeep.com/pics/phoenix/10.22.05.j.jpg

I spent the next few hours cleaning up the shop and organizing tools. It’s nice to have a clean area to work in again.
http://www.bigassjeep.com/pics/phoenix/10.22.05.k.jpg


http://www.bigassjeep.com/pics/phoenix/10.22.05.l.jpg

I wired up both Optima’s to the float charger until they’re put to use again. I’ll probably only go with one battery in the buggy, and throw the other in whatever used tow rig I end up with. These things are a little over 4 years old but still seem as good as new.
http://www.bigassjeep.com/pics/phoenix/10.22.05.m.jpg

Kraqa
10-23-2005, 03:20 PM
are you gonan need any poly bushings durign this build? i need about 6 of them but at 12$ a pop that pricey. i need to get the quantities up to get the price down. let me knwo.

OverkillZJ
10-23-2005, 05:13 PM
What are you using poly on? I'll never touch the stuff on CA's again, instead of ripping like rubber, it "wallowed" the whole length of the bushing after just one season of wheeling, making the busing totally pointless...

OverkillZJ
10-23-2005, 08:53 PM
Today was “tear down da front 60 day” It’s a mess of rust, and I can’t wait to get it all shined up with new shafts,

http://www.bigassjeep.com/pics/phoenix/10.23.05.a.jpg


http://www.bigassjeep.com/pics/phoenix/10.23.05.b.jpg


http://www.bigassjeep.com/pics/phoenix/10.23.05.c.jpg

I hooked up a TV to the satellite in the garage, can watch Steelers while doing buggy stuff now.
http://www.bigassjeep.com/pics/phoenix/10.23.05.d.jpg

Here’s a couple of comparison pics of the Dana 60 gear/carrier next to the 30’s. Any guesses as to which is which?
http://www.bigassjeep.com/pics/phoenix/10.23.05.e.jpg


http://www.bigassjeep.com/pics/phoenix/10.23.05.f.jpg

Brackets go bye bye.
http://www.bigassjeep.com/pics/phoenix/10.23.05.g.jpg


http://www.bigassjeep.com/pics/phoenix/10.23.05.h.jpg

http://www.bigassjeep.com/pics/phoenix/10.23.05.i.jpg

Old rear 44 axle go bye bye. It’s going to be for sale soon (Superior 4340 shafts, 4.56 spicer gears, bearings all new as of 12,000 miles ago, Detroit locker, ZJ Disc breaks, fabbed up brackets for a TJ sway bar on a ZJ. Buy it.)

http://www.bigassjeep.com/pics/phoenix/10.23.05.j.jpg


http://www.bigassjeep.com/pics/phoenix/10.23.05.k.jpg


http://www.bigassjeep.com/pics/phoenix/10.23.05.l.jpg


http://www.bigassjeep.com/pics/phoenix/10.23.05.m.jpg

http://www.bigassjeep.com/pics/phoenix/10.23.05.n.jpg


http://www.bigassjeep.com/pics/phoenix/10.23.05.o.jpg


http://www.bigassjeep.com/pics/phoenix/10.23.05.p.jpg

Here’s the 44 on the ground a few feet closer than the 14 bolt. I swear the 14 bolt is twice the size. It’s DEFINITELY twice the weight!
http://www.bigassjeep.com/pics/phoenix/10.23.05.q.jpg


http://www.bigassjeep.com/pics/phoenix/10.23.05.r.jpg

The parts are starting to accumulate on the shelves.
http://www.bigassjeep.com/pics/phoenix/10.23.05.s.jpg

Especially the 60 parts. It’s going to take me a whole lot of time to clean that mess up and figure out what I’m reusing.
http://www.bigassjeep.com/pics/phoenix/10.23.05.t.jpg

Kraqa
10-23-2005, 08:57 PM
poly is for motor mounts and t-case/tranny mounts.

OverkillZJ
10-23-2005, 09:12 PM
poly is for motor mounts and t-case/tranny mounts.

Ok, that makes more sense!

chadjans
10-24-2005, 01:40 AM
Overkill I am new to this site but want to know what you are going to do with the lift you currently have under the zj when you full buggy it? consider selling it...?

There isn't much to sell in regards to a ZJ lift.

Cody
10-24-2005, 08:01 PM
Why not spool it? It was an option. However, you're saying a spool is more predictable than a Detroit? More predictable and pushing you through turns and off of rock obstacles the wrong way maybe.

lol, I've never had my spool pull me off anything. I've also never had it ratchet or break or make noise or anything. when I go from full stop to full throttle there is no point of engagement--it's just there. works 100% of the time and is strong and light weight. I wouldn't want a front spool, but I fail to see any advantage to an auto locker in the rear...even if they were priced the same I would still go spool. Just my experience.



Continually following the plan that will build a bad ass rig instead of another ghetto jungle gym of tube,

nothin wrong with that sucka. :smt039

Nice score on the 60 and good call on the 14 bolt disks.

Cody

Cue-Ball
10-24-2005, 08:20 PM
Looking like fun Matt, keep the pix coming

OverkillZJ
10-24-2005, 10:07 PM
I hate spools. I think that anyone who uses a spool should DIE!

I already have the Detroit so you can all STFU about it :finga:

BigDaveZJ
10-24-2005, 10:08 PM
I hate spools. I think that anyone who uses a spool should DIE!



Well SCREW YOU too!!! :overkill:



:flipoff2:

OverkillZJ
11-02-2005, 02:51 PM
All I've been doing lately is trying to track down parts I need from vendors, planning, and debating.

That and getting 120 and 240 out to the garage. The electric turned into a $500 project, I may've gone overboard on that a lil' bit. Not a suprise.

deadman
11-02-2005, 03:01 PM
All I've been doing lately is trying to track down parts I need from vendors

I've done the same stuff the last week... me and a friend drove to Belgium to pick up a D60/14b combo out of a K30 for $650. :supz:

If you want to compare... Best prices I found were:

King pin rebuild kit $39.99 per side
D60 Master Install Kit $92.00
D60 low pinion 7.17's $179.99
D60 35 spline Detroit $479.99
D60 Spicer u-joint w/out zerk $35.00 each

ILikeMud
11-03-2005, 05:12 PM
Damn, I want your axles.

JpRngr
11-03-2005, 09:45 PM
The electric turned into a $500 project, I may've gone overboard on that a lil' bit. Not a suprise.

What, did you have to fix a hole in the wall?:smt106 :smt118

Kraqa
11-03-2005, 10:57 PM
matt you go two days to tell me what break parts you want cause i'm going to that uber cheep wrecker on saterday.

TrojanMan
11-04-2005, 01:17 AM
That and getting 120 and 240 out to the garage. The electric turned into a $500 project, I may've gone overboard on that a lil' bit. Not a suprise.

Not possible. I'm sure you'll appreciate every penny when you get out to use it. Just like any other addition to a shop.

OverkillZJ
11-04-2005, 10:05 AM
What, did you have to fix a hole in the wall?:smt106 :smt118


Ya, but unlike Dave's garage, I TRIED to put this 1" hole in the wall! I spent half an hour trying to get it through my cinder block, then Steve showed up with his hammer drill and god it done lin about 30 seconds.

Still not as easy as the hole I put in Dave's garage though! :smt025

OverkillZJ
11-13-2005, 12:29 AM
First off, Steve found me a sweeeet new seat for the buggy that was about 1/3rd cost because it was installed in a showroom vehicle at 4wd. I dig it. It's my office chair until the buggies ready. I'll need another chair, here's to hoping I come across one cheap!

http://www.bigassjeep.com/pics/phoenix/officechair.jpg


I haven’t had too much time to work on the buggy project, but I’ve got some done. This is like the last 2 weeks worth of updates. Most of what I’ve done is finish the electrical for the garage and tent as you can see in the following pics:

I should have enough power to run vegas now.
http://www.bigassjeep.com/pics/phoenix/11.12.05.a.jpg

Wire nuts suck.
http://www.bigassjeep.com/pics/phoenix/11.12.05.b.jpg

Wire nuts for 8 gauge wire suck more.
http://www.bigassjeep.com/pics/phoenix/11.12.05.c.jpg

2 outlet boxes mounted on the ceiling for the florescent lights to plug into.
http://www.bigassjeep.com/pics/phoenix/11.12.05.d.jpg

2 dual outlet boxes at either side of the garage, each with 2 separate 20 amp circuits..

http://www.bigassjeep.com/pics/phoenix/11.12.05.e.jpg


http://www.bigassjeep.com/pics/phoenix/11.12.05.g.jpg

Old welder plug in the garage tied in with the tents welder plug now.

http://www.bigassjeep.com/pics/phoenix/11.12.05.f.jpg

Now to get the power out to the garage. This just plain sucked.

http://www.bigassjeep.com/pics/phoenix/11.12.05.h.jpg

http://www.bigassjeep.com/pics/phoenix/11.12.05.i.jpg

All done, and waterproof for when I want to hose down the buggy.
http://www.bigassjeep.com/pics/phoenix/11.12.05.j.jpg


http://www.bigassjeep.com/pics/phoenix/11.12.05.k.jpg


http://www.bigassjeep.com/pics/phoenix/11.12.05.l.jpg


http://www.bigassjeep.com/pics/phoenix/11.12.05.m.jpg


And now for the Jeep stuff. Needed much bigger jack stands, so we welded two of my old wheels together and then a small jack stand on top. I think they’re about 2.5-3 feet high but I didn’t measure. They’re perfect.
http://www.bigassjeep.com/pics/phoenix/11.12.05.n.jpg

Party foul. My bad.
http://www.bigassjeep.com/pics/phoenix/11.12.05.o.jpg

Now that the jeeps up on its own stands, time to take that front axle out.
http://www.bigassjeep.com/pics/phoenix/11.12.05.p.jpg


http://www.bigassjeep.com/pics/phoenix/11.12.05.q.jpg


http://www.bigassjeep.com/pics/phoenix/11.12.05.r.jpg

Steve shined up that old front 60, still needs cleaned a lil’ more and painted up, but he got about 50 pounds of rust and grease off of it.
http://www.bigassjeep.com/pics/phoenix/11.12.05.s.jpg

I have way too many axles right now. In addition to what’s in the garage, I have an extra rear 60, and my old al44 and an old 35 laying around.
http://www.bigassjeep.com/pics/phoenix/11.12.05.t.jpg

We took the cover off of the HP30 expecting to see a busted 30. This is what we found. Yours truly is now on a rampage to argue that the Dana 30 is utterly useless under a heavy vehicle, let alone one with a v8.
http://www.bigassjeep.com/pics/phoenix/11.12.05.u.jpg


http://www.bigassjeep.com/pics/phoenix/11.12.05.v.jpg


http://www.bigassjeep.com/pics/phoenix/11.12.05.w.jpg


http://www.bigassjeep.com/pics/phoenix/11.12.05.x.jpg


http://www.bigassjeep.com/pics/phoenix/11.12.05.y.jpg

This seemed appropriate. I think I’m just going to part the axle out instead of resetting gears just to sell it. I have more on my plate than I can get done anyway.
http://www.bigassjeep.com/pics/phoenix/11.12.05.z.jpg

I decided to hose off the Jeep to clean it up a bit, it was still pretty mud covered. I drilled 6 or so ¼” drain holes when I realized that it didn’t have any.
http://www.bigassjeep.com/pics/phoenix/11.12.05.aa.jpg

Why does it always end up being a hovercraft once a year? I seriously hope this buggy build lasts me more than a year, I’m getting kind of sick redoing everything.

http://www.bigassjeep.com/pics/phoenix/11.12.05.bb.jpg

My dad cleaned out his garage, and came across a bunch of my old stickers. I started putting them on my tool cabinet. Notice the appropriate addition to the cRusty’s offroad sticker?

http://www.bigassjeep.com/pics/phoenix/11.12.05.cc.jpg

That’s all for now. Back at it tomorrow. We’re planning on finally cutting up more of the ZJ. It’s about time, it’s been a MONTH.

JohnBoulderCO
11-13-2005, 01:07 AM
Wow, you have been busy today. Looking good.

ELLLLLIOTTTTT
11-13-2005, 10:15 AM
i know a guy who needs a locker for his HP30. He's a real handsome, charming guy... you should probably just GIVE it to him. ;)

benzj
11-13-2005, 05:38 PM
I know a guy (he is better looking, and a true southern gentleman, compared to the guy Puma knows.) that needs the housing, shafts, knuckles, balljoints, the whole-shabang, but, I don't need dat' dar' lucker--so PumaBalls can have it.

Elliott, give me a call---Gotta question bout the HP30.

Thanks.
Bennett

OverkillZJ
11-13-2005, 05:48 PM
Better PM me with an offer on it soont hen because Steve is about ready to buy the hubs and shafts from me :)

Ask the guy ya know, but I won't ship it, too much of a PITA to get it to a shipping place when you don't own a truck and have to borrow a trailer!

TrojanMan
11-13-2005, 06:19 PM
I know a guy (he is better looking, and a true southern gentleman, compared to the guy Puma knows.) that needs the housing, shafts, knuckles, balljoints, the whole-shabang, but, I don't need dat' dar' lucker--so PumaBalls can have it.

Elliott, give me a call---Gotta question bout the HP30.

Thanks.
Bennett

umm.. I don't need any hp30 parts:confused:

OverkillZJ
11-13-2005, 10:28 PM
Got a lot done today. Started with pulling the gas tank. I thought it would be close to empty, but I think it was about half full or so.
http://www.bigassjeep.com/pics/phoenix/11.13.05.a.jpg

There was enough gas in it to fill up both my Corolla and Steve’s YJ which were both at about half tank.
http://www.bigassjeep.com/pics/phoenix/11.13.05.b.jpg

Then on to cutting up the Jeep. The oxy proved to be the easiest to cut with through the deep / messy stuff that would’ve bent up sawzall blades. The problem is that it runs hot enough to light the herculiner on fire! We had it in some pretty good flames.
http://www.bigassjeep.com/pics/phoenix/11.13.05.c.jpg


http://www.bigassjeep.com/pics/phoenix/11.13.05.d.jpg


http://www.bigassjeep.com/pics/phoenix/11.13.05.e.jpg


http://www.bigassjeep.com/pics/phoenix/11.13.05.f.jpg


http://www.bigassjeep.com/pics/phoenix/11.13.05.g.jpg


http://www.bigassjeep.com/pics/phoenix/11.13.05.h.jpg
We weren’t sure if we were going to be using the rear portion of the frame rails or not, but after seeing them without the floor board above, we decided they’re complete crap and will be cutting from the tranny tunnel back and just building from scratch.
http://www.bigassjeep.com/pics/phoenix/11.13.05.i.jpg

Cut out the rockers too.
http://www.bigassjeep.com/pics/phoenix/11.13.05.j.jpg


http://www.bigassjeep.com/pics/phoenix/11.13.05.k.jpg

That’s right… Planning mode! We planned out most of the rear end and part of the cage. We’re hoping to get the main hoop bent soon so that we can plan better before we get the tubing bender over here that we’re borrowing. The front end.. That’s another story. I don’t even want to think about what we’re doing there just now.

http://www.bigassjeep.com/pics/phoenix/11.13.05.l.jpg


We also got some pounding music in the tent and garage with the extra equipment I had laying around.
http://www.bigassjeep.com/pics/phoenix/11.13.05.m.jpg

Set of good speakers in the tent and garage!
http://www.bigassjeep.com/pics/phoenix/11.13.05.n.jpg

So there it sits until next weekend.
http://www.bigassjeep.com/pics/phoenix/11.13.05.o.jpg

jeep4x4nut
11-13-2005, 11:02 PM
At first sight of the back halfing....i thought here goes Kraqa again. But i like the idea of round tubing!

Kraqa
11-13-2005, 11:22 PM
lol.

"I'l start frm the tranny tunnle and go back"

then i can just see when you get ot the front.
"ok i'l rebuild frm the fire wall forward"

looks good matt. I used a zip disk to cut mine away. i dont' have torches.

TrojanMan
11-13-2005, 11:29 PM
liar, you said you didn't get any flame pictures.:mad:


How much does it weigh now?:smt046

OverkillZJ
11-13-2005, 11:33 PM
I said I didn't get any pictures of the "fire incident" - the pics are all little flames!

It weights like... nothing. It's a big of a problem, because the back end is sliding around on the jack stands. It really wouldn't take too much force to knock it over right now.

ogdak
11-15-2005, 02:30 PM
You are definatly moving fast.
looks good though.

Kraqa
11-15-2005, 03:53 PM
Alother thing to look out for. that floor flex's ALOT. so when it comes time to mount your cage try and support it more towards the middle or closer to the motor. i supported mine near the end liek you and my floor flexed abotu 1/2" up cause of the weight.

ELLLLLIOTTTTT
11-15-2005, 05:56 PM
looks like it may in fact be ready in time for GSW.

OverkillZJ
11-15-2005, 09:42 PM
HA... all I've done is cut things off.... Doesn't mean pooooooooooo

ptownTSI
11-15-2005, 10:23 PM
puma i heart your avatar.

zjeepin
11-16-2005, 02:49 PM
so wanna tell us what yer smokin there matt?

OverkillZJ
11-16-2005, 02:51 PM
LMAO, it's just a cheapass "black and tan" cigar. Need some cubans for the day we finally get to testing the thing.

zjeepin
11-16-2005, 03:12 PM
yeah yeah, thats what they all say... im surprised im the first to catch that one.. project looks awesome matt, cant wait to see it finished. do you have a target date for completion?

OverkillZJ
11-16-2005, 03:17 PM
Target date for completion... It'll be done by Spring assuming I have funds, but that's a pretty darn big assumption. I'm majorly short on money for the project!

I'm still hoping for a miracle to get this thing to GSW in a uhaul truck.

zjeepin
11-16-2005, 04:26 PM
Target date for completion... It'll be done by Spring assuming I have funds, but that's a pretty darn big assumption. I'm majorly short on money for the project!

I'm still hoping for a miracle to get this thing to GSW in a uhaul truck.

that would be huge miracle, that front axle is what 69" wide without tires? i'd say there's hope for towing it with a uhaul but i put mine on a uhaul trailer once and it barely fit.

OverkillZJ
12-11-2005, 01:46 AM
http://www.bigassjeep.com/pics/phoenix/11.21.05.a.jpg

I decided it was time to finally get the Corolla back in the garage, and get the blasted axles out of the garage.
http://www.bigassjeep.com/pics/phoenix/11.21.05.b.jpg

I ended up buying a 2 ton engine lift to move them on my own, makes life OH SO MUCH EASIER!
http://www.bigassjeep.com/pics/phoenix/11.21.05.c.jpg

Ya.. I have a few grand of axles sitting in my basement. Some old, some new. Man oh man has this hobby taken over my life over the years.



Today we pretty much just pissed around… I did get a nice industrial kitchen card/table I’ll be u sing as a welding table though. It didn’t have anywhere to clamp the ground clamp, so I welded up a 3/16” piece of steel under it to provide a good clamping surface. Welding 3/16” to 24 gauge or so sheet proved harder than I’d thought, but it came out to be a pretty clean weld. Not like it’s structural anyway!

Notice the nice new chop saw on the bottom of the cart. My latest toy. Oh, I meant tool.
http://www.bigassjeep.com/pics/phoenix/12.10.05.a.jpg

We spent most of the day fixing Steve’s YJ which was running like a paraplegic in the special Olympics. Seemed only fair to help him out once in awhile considering he spends more time wrenching on my Jeep than his. Got that all fixed up, then Jeff and I were just messing around the rest of the night.

http://www.bigassjeep.com/pics/phoenix/12.10.05.b.jpg

Mmmmm… Shop safety is always a concern. And by shop safety, I meant that I was careful not to drop my cigar.
http://www.bigassjeep.com/pics/phoenix/12.10.05.c.jpg

Jeff didn’t drop his either.
http://www.bigassjeep.com/pics/phoenix/12.10.05.d.jpg

Lil’ bastard wouldn’t stay lit!
http://www.bigassjeep.com/pics/phoenix/12.10.05.e.jpg

I did get some good welding practice in at least. Practice in writing my name on an old section of axle tube!
http://www.bigassjeep.com/pics/phoenix/12.10.05.f.jpg
Jeff tried, but mines prettier!

http://www.bigassjeep.com/pics/phoenix/12.10.05.g.jpg

We welded random crap together.. Ya, that was really productive.
http://www.bigassjeep.com/pics/phoenix/12.10.05.h.jpg

When that got old, TO THE JEEP TENT! Mmmmm…alcohol…cigars…..SAWZALL!
http://www.bigassjeep.com/pics/phoenix/12.10.05.i.jpg


http://www.bigassjeep.com/pics/phoenix/12.10.05.j.jpg


http://www.bigassjeep.com/pics/phoenix/12.10.05.k.jpg

That’s all for now, this was the first “play day” I’ve had for over a month. Too busy. Next week I work every day including weekend, but I should earn enough to but everything I need to build my insane front 60. You’ll see, it’ll be pretty. Promise.

Right now I’m really in planning and “acquire parts needed” mode. Soon enough we’ll be in full blown “buggy building” mode.

ILikeMud
12-11-2005, 02:08 AM
Coming along really nicely man.

xtremzj
12-11-2005, 02:39 AM
wow. im a tech at at a dealership, you put are garage to shame! what do you do for work?

OverkillZJ
12-11-2005, 03:04 AM
wow. im a tech at at a dealership, you put are garage to shame! what do you do for work?

You're either smoking something, your you're dealership is in real trouble to be behind the times of my tent / 1 car garage :finga:

I'm an IT consultant for small businesses. Mostly small business networks and other stuff that I'd love to do for free but happen to get paid for :coffee:

nate
12-11-2005, 03:30 AM
So why bother keeping the rest of the unibody? To me it would just be easier to put the ZJ driveline and some sheetmetal on a tube chassis... no?

OverkillZJ
12-11-2005, 04:12 AM
It'd be much easier to start with tubing, but where's the fun in that? This is what I've got, this is what I'm building.

ogdak
12-11-2005, 05:35 PM
This is what I've got, this is what I'm building.
That's the spirit,
Keep those pic's coming

chadjans
12-12-2005, 12:00 AM
This is what I've got, this is what I'm building.

Sounds sooo familiar.

xtremzj
12-12-2005, 07:53 PM
good point... we are pretty far behind huh

chadjans
12-13-2005, 01:58 AM
good point... we are pretty far behind huh

Speak for yourself.

OverkillZJ
01-21-2006, 12:36 AM
I was supposed to work today. But.. Steve was like “don’t work, it’s nice out, let’s work on the ZJ buggy.” It really didn’t take much convincing, so we put in a good days work, only starting at maybe 1pm.

Anyway, my metal came just about 2 weeks ago on a big truck. The truck had to come down my neighbors driveway and drive across some of the lawn to get to my driveway, otherwise the truck would pretty much be stuck without being able to turn around. The DOM is 1.75” ID 1020 w/ .120 wall. The box is 2x4 ¼” wall. 3/16” would have been just fine, but I wanted a little bit more weight in the rear end since the V8 up front is quite heavy, and ZJ buggies are often too light in the rear.
http://www.bigassjeep.com/pics/phoenix/1.20.06.a.jpg

Measuring for the first cut to actually start ADDING things to the vehicle, instead of just removing them. We were pretty happy at the concept of actually building, instead of just tearing down for once.
http://www.bigassjeep.com/pics/phoenix/1.20.06.b.jpg

Chop saw seems to work quite well!
http://www.bigassjeep.com/pics/phoenix/1.20.06.c.jpg

Prepping the frame rails to weld a piece of box as a cross member. It turned out to be a very good structural starting point for building our frame which all the tube will come off.

http://www.bigassjeep.com/pics/phoenix/1.20.06.d.jpg

While Steve was working on that (he’s the metal God) I decided to start pulling the transfer case, driveshaft’s, skid place, cross member, and tranny mount. It all needs to come out in order to make room for a new Stak transfer case, and some 1410 ujointed shafts.
http://www.bigassjeep.com/pics/phoenix/1.20.06.e.jpg

Steve welding together some of the sheet metal making up the unibody, which separated as we cut it.
http://www.bigassjeep.com/pics/phoenix/1.20.06.f.jpg

Finally! Adding something to the buggy!
http://www.bigassjeep.com/pics/phoenix/1.20.06.g.jpg

First weld came out amazingly well, considering it’s ¼” plate to crappy unibody.
http://www.bigassjeep.com/pics/phoenix/1.20.06.i.jpg

With that new cross member on, we started measuring exactly where the tires would end up, in order to build the box section of the new vehicle.
http://www.bigassjeep.com/pics/phoenix/1.20.06.j.jpg


Yes, we were as excited as we look.
http://www.bigassjeep.com/pics/phoenix/1.20.06.k.jpg


http://www.bigassjeep.com/pics/phoenix/1.20.06.l.jpg


http://www.bigassjeep.com/pics/phoenix/1.20.06.m.jpg

http://www.bigassjeep.com/pics/phoenix/1.20.06.n.jpg


http://www.bigassjeep.com/pics/phoenix/1.20.06.o.jpg


http://www.bigassjeep.com/pics/phoenix/1.20.06.p.jpg

Everyone wants to see the master welding.
http://www.bigassjeep.com/pics/phoenix/1.20.06.q.jpg


http://www.bigassjeep.com/pics/phoenix/1.20.06.r.jpg


http://www.bigassjeep.com/pics/phoenix/1.20.06.s.jpg


http://www.bigassjeep.com/pics/phoenix/1.20.06.t.jpg

We were pretty damn pleased with the final product. It’s a start of what we hope to be a very successful project, and extremely capable ZJ buggy.
http://www.bigassjeep.com/pics/phoenix/1.20.06.u.jpg


http://www.bigassjeep.com/pics/phoenix/1.20.06.v.jpg




http://www.bigassjeep.com/pics/phoenix/1.20.06.x.jpg


http://www.bigassjeep.com/pics/phoenix/1.20.06.y.jpg


http://www.bigassjeep.com/pics/phoenix/1.20.06.z.jpg


http://www.bigassjeep.com/pics/phoenix/1.20.06.aa.jpg

I also managed to get out everything I wanted to from under the Jeep while Steve was doing the metal work.
http://www.bigassjeep.com/pics/phoenix/1.20.06.w.jpg


http://www.bigassjeep.com/pics/phoenix/1.20.06.bb.jpg

I’ve begun to collect the massive amount of parts we need for this project. I’m now back in “get it done right mode” and as much as I’m shopping around for great prices, I refuse to skimp on this buildup. I intend for this to last me a long, long, long long long long time.
http://www.bigassjeep.com/pics/phoenix/1.20.06.cc.jpg

Here is a side shot of my new Dana 60HP Dedenbear knuckles. I couldn’t figure out the missing metal until I talked to them: turns out they use the same casting for Chevy and Ford knuckles: But for the ford caliper brackets to clear, they machine some material off of the knuckle. I think they could’ve at least painted it to make it look like a finished product, but whatever. They’re hella beef.
http://www.bigassjeep.com/pics/phoenix/1.20.06.dd.jpg

My cats (this one’s Noel) are enjoying all the Jeep parts: they come in boxes!
http://www.bigassjeep.com/pics/phoenix/1.20.06.ee.jpg

Cue-Ball
01-21-2006, 12:52 AM
A Stak TC very cool.

So are you going to be reusing those driveshafts or are you going to be selling them?

BigDaveZJ
01-21-2006, 12:57 AM
It's about time you got some fawking work done on that thing!!

OverkillZJ
01-21-2006, 01:13 AM
Dirk - selling the drive shafts is still up for grabs, I'm holding out until I hear back from Tom Woods on his opinion of my situation. Odds are that I'll end up selling both shafts and the tcase, and getting some 1410 shafts: and order my Stake with 1410 yokes on it.

Dave - yes, it is about time. As you know I've had a LOT of work lately. I've taken on about 45% more work than usual in order to pay for this project before GSW. The problem is, that takes away from my wrenching time. I'm confident I'll get it done, and, as usual, go over my initial plans.

It's funny how my original plan was "do nothing but cut and build a cage" - because now it's all out buggy... I'll settle for nothing less than "awesome." I'm not a quiter, but that's not always a good thing. I'm a perfectionist. This vehicle will be sweet, and capable, I promise.

Cue-Ball
01-21-2006, 01:19 AM
Dirk - selling the drive shafts is still up for grabs, I'm holding out until I hear back from Tom Woods on his opinion of my situation. Odds are that I'll end up selling both shafts and the tcase, and getting some 1410 shafts: and order my Stake with 1410 yokes on it.


Once you get it all figured out let me know, maybe we can work a deal for the shafts, I need a new rear one for sure and maybe easier to just get both of yours and be done. No rush though i am still working on getting my shit finished up.

I swear it is depressing you will have built a solid rig, and then cut it up and built a buggy and I will still be building my first one, I tell you building a Jeep AND raising a family is a PITA.

Oh well such is life.

OverkillZJ
01-21-2006, 01:25 AM
I swear it is depressing you will have built a solid rig, and then cut it up and built a buggy and I will still be building my first one, I tell you building a Jeep AND raising a family is a PITA.


This kind of hobby with anything in life, let alone family, is hard enough: such as growing a business. Holy cow, where did the time go? I simply forgot the concept of "relaxation" and do what I need to do to get what I want. In this case: BUILD A BADASS ZJ BUGGY.

I wouldn't let me cutting up my "nice rig" scare you. Fact is it did quit well, but there is a price to pay for following buggies around in a full bodied rig... I twisted it to hell. The floorboard is still twisted. The first time we tacked everything in place, it was 1/4" off because of the twisted unibody.

I'm a rare case though, I really did beat the hell out of my ZJ to every sense of the word. There are few who car, or will wheel their rig like that... I wouldn't recommend it if you like sheet metal ;)

Kraqa
01-21-2006, 05:04 AM
fuck ya mattty boyeeee.


looks dope i liek the rear end., i see how that will tie into you sliders nicly.. definatly a difrent way of doign it but i dig it.

you always take the actioj n shots. welding cutting. what a whore you are.

i'm akl aboot the finished prooduct.

lets get this shit on a move i wana see this dthink rollin. i just sold my dodge so its gonna be hard for me to get material backl and forth but that frnt axle shout be at my house soon and just wait till i get my new front suspension working . im takign a 3d modling couse in sold works so it will be on the computer befroe i actuall build it.

i wana ee some god damn progress on dis bitch beatch!!

OverkillZJ
01-21-2006, 10:39 AM
Holy cow Kris! It takes EFFORT to read your typing when you're high, LMAO!

I like the rear end too. Mostly Steve's idea, but I can't think of a better way structuraly. Everything's very tied in.

nate
01-21-2006, 12:12 PM
Those "machined" knuckles look like a drunk guy clearanced them with a grinder :eek:

ILikeMud
01-21-2006, 02:50 PM
Stak case is awesome, what kinda gears are you gonna run it it?

Coming along, will definately be an awesome rig when your done.

ATL ZJ
01-21-2006, 03:45 PM
I like that. A lot. You're definitely thinking a little differently there with the dovetail and departure angle consideration.. :mrgreen:

zj-monster
01-21-2006, 04:48 PM
http://www.bigassjeep.com/pics/phoenix/11.13.05.l.jpg
Here's and oddball question for the Corbeau TRS seat you have there. Did you end up re-using the stock seat bracket or did you use another bracket? How much of a differnce is there in ride hight compared to the stock seat? I can't tell if you just set the seat in there with a bracket or not but I just wanted to throw that question in there.

It sucks that there isn't a solid seat market for Grand's, which doesn't bother me since I like to fab shit up anyway. I will tell ya this, racing seats are a hell of a lot more comfortable than stock seats. :smt023

nate
01-21-2006, 05:02 PM
So I wonder when I'm going to decide to chop mine up? I know one day it'll happen. Just paid it off this month though, so it might be a little while.

OverkillZJ
01-21-2006, 06:09 PM
The seats a GTS, and it's sitting on a Dewalt toolbox... so ya, no idea on the height. It didn't come with hardware, gotta make it!

zj-monster
01-21-2006, 06:31 PM
The seats a GTS
Damn, that's a case of beer I owe now. I have a TRS sitting in my garage that looked just like your GTS.


it's sitting on a Dewalt toolbox
Don't ya wish that you could just bolt it to the toolbox and be done?


It didn't come with hardware, gotta make it!
Same here, I was asking cuz I haven't even tried to bolt it up to the stock brackets yet. Doubt it will even work but that's what fabbing will solve! :smt023

Keep up the good work man!

ILikeMud
01-21-2006, 10:36 PM
I'm gonna be tossing my stock seats once I do my lift and what not, was just gonna weld my rails to the new seats.
Are you totally fabbing up new brackets and sliders?

Deltron
01-21-2006, 10:54 PM
looks good man, I like the dovetail, just curious why you left the 2x4 open on the end instead of tying it into the side 2x4. seeing those pictures just makes me wanna build something....mmmm new front bumper ahhhhhhhhh

OverkillZJ
01-21-2006, 11:00 PM
Back at it. First thing of the day was Steve capping off the open ended box in the rear end.
http://www.bigassjeep.com/pics/phoenix/1.21.06.a.jpg


http://www.bigassjeep.com/pics/phoenix/1.21.06.b.jpg


http://www.bigassjeep.com/pics/phoenix/1.21.06.c.jpg

Steve decided to get some aggression out with a BFH on the next part of the ZJ getting chopped up.. what was left at the front corner of the rockers.
http://www.bigassjeep.com/pics/phoenix/1.21.06.d.jpg


http://www.bigassjeep.com/pics/phoenix/1.21.06.e.jpg


http://www.bigassjeep.com/pics/phoenix/1.21.06.f.jpg


http://www.bigassjeep.com/pics/phoenix/1.21.06.g.jpg


http://www.bigassjeep.com/pics/phoenix/1.21.06.h.jpg

I FINALLY got my air chisel back, and it came in handy today.
http://www.bigassjeep.com/pics/phoenix/1.21.06.i.jpg


http://www.bigassjeep.com/pics/phoenix/1.21.06.j.jpg


http://www.bigassjeep.com/pics/phoenix/1.21.06.k.jpg

Meanwhile, I finished stripping whatever isn’t needed in the engine bay. We’re about ready to bob the front end when we find time now.
http://www.bigassjeep.com/pics/phoenix/1.21.06.l.jpg

I got pissed at some of the brake line fittings rounding off since I can’t find my brake line tool, so I ended up just taking an angle grinder to them. I guess I need some new lines now!
http://www.bigassjeep.com/pics/phoenix/1.21.06.m.jpg

http://www.bigassjeep.com/pics/phoenix/1.21.06.n.jpg


http://www.bigassjeep.com/pics/phoenix/1.21.06.o.jpg

Since Steve was still busy with metal work and I was kind of stalled on other projects, I decided to start the part I’ve been dreading first. FIGURING OUT WHAT WIRES TO GET RID OF AND WHAT TO KEEP! What a freaking nightmare… I followed the wires, and kind of just kept taking the dash apart as I did. Looks like the whole thing needs to come out to clean up the wiring situation as much as I’d like to. This is going to be a lot of work.
http://www.bigassjeep.com/pics/phoenix/1.21.06.p.jpg


http://www.bigassjeep.com/pics/phoenix/1.21.06.q.jpg

Here’s the pile of all the crap I removed. CB, radio, VIC, light controls, climate controls, all the wood grain, vent cover things, blah blah blah…
http://www.bigassjeep.com/pics/phoenix/1.21.06.r.jpg

And of course, the game in which the PITTSBURGH STEELERS WILL CRUSH THE DENVER BRONCOS is tomorrow, so did a ghetto paint job for our team colors. The final paint job will be the same colors, but done more nicely.
http://www.bigassjeep.com/pics/phoenix/1.21.06.s.jpg

That’s all for now, looks like I’m back to calling around to vendors and getting parts in for the next phase: get wheels and axles under it so we can bend some tube!

Kraqa
01-21-2006, 11:39 PM
i dig the banana boat theme.

ELLLLLIOTTTTT
01-21-2006, 11:48 PM
Is Steve the guy that welded the truss on your D44? if so... those welds AREN'T going anywhere. The progress is looking good, Matt.

nate
01-21-2006, 11:59 PM
Your buddy is going to have some sunburned hands!

black box renegade
01-22-2006, 04:28 AM
yeeeep that was me that welded the 44 truss. i figure, even if i dont have a grand, im still gonna be on here...to take some credit for all this work!

thanks for the credit, puma

and nate...i dont really get sunburnt from welding. it doesnt bother me much, and ive always been one for pain, so a little weld spatter doesnt get to me either.

ogdak
01-22-2006, 10:00 AM
Glad to see some progress,
looks good.

OverkillZJ
01-23-2006, 01:50 PM
Just the pics....

http://www.bigassjeep.com/pics/phoenix/1.23.06.a.jpg
http://www.bigassjeep.com/pics/phoenix/1.23.06.b.jpg

ATL ZJ
01-23-2006, 01:55 PM
Those are cute.. ;)

OverkillZJ
01-23-2006, 02:24 PM
About as cute as a t-rex!

Kraqa
01-23-2006, 03:18 PM
wow the 42" really make the tire look skinny. why dont; you just give them to me.

OverkillZJ
01-23-2006, 03:30 PM
Howabout ummm NO!

Ya, they don't look 14" wide because they're so tall. It freaked me out when I first looked at them!

Cue-Ball
01-23-2006, 03:31 PM
I was thinking the same thing they don't look wide at all.

chadjans
01-23-2006, 03:34 PM
http://www.classycookware.com/en-us/pizza_cutter.jpg

ogdak
01-23-2006, 03:38 PM
I was thinking the same thing they don't look wide at all.

Same here.

Kraqa
01-23-2006, 03:46 PM
they will widen otu alot on those rims.

OverkillZJ
01-23-2006, 03:47 PM
http://www.classycookware.com/en-us/pizza_cutter.jpg


LMFAO

chadjans
01-23-2006, 03:59 PM
My friend Dave, 42 inch TSL's didn't look that narrow. I'd be concerned. Give them to me. Put them back on the truck and forward them, to me. Seriously, a spare? That is one decision I can't make myself.

And Kris, seriously your typing is really begining to make my hair hurt.

Chad

OverkillZJ
01-23-2006, 04:13 PM
Ya, Kris's typign is gonna get his ass banned! ;)

I like my pizza cutters, I think I'll keep them.


I really debated over the spare.. but it came down to this: I'm spending another small fortune to go out west again, and I'm putting all htis work into the buggy. If I got out there and somehow destroyed a tire, and couldn't wheel because I didn't have a spare... I'd be pissed. I got the spare, the wheel, and even the beadlock kit.... like $500, but that's $500 that could prevent me having a miserable trip!

Kraqa
01-31-2006, 09:23 PM
500 well spent if you ask me. if it takes a 42" tire to get in there its gonna take a 42" tire to get out. plus you can't run a difrent size tire on locked axles.

OverkillZJ
01-31-2006, 10:42 PM
It’s been a busy few days for Steve and I, and oddly enough Steve did more work on the buggy than I did. These pictures aren’t in order if you’ll notice the dates, they’re kind of grouped by category.

Just playing with the tires.
http://www.bigassjeep.com/pics/phoenix/1.31.06.a.jpg

This is exactly where the axle and tires will sit, only thing is that the Buggy itself will be at least 6” higher than it’s sitting right now. It’s going to fit nicely.
http://www.bigassjeep.com/pics/phoenix/1.31.06.b.jpg

Seeing tires anywhere near it lit a fire under my butt to really push this project forward.
http://www.bigassjeep.com/pics/phoenix/1.31.06.c.jpg

I had to.
http://www.bigassjeep.com/pics/phoenix/1.31.06.d.jpg


http://www.bigassjeep.com/pics/phoenix/1.31.06.e.jpg

My cat very confused.
http://www.bigassjeep.com/pics/phoenix/1.31.06.f.jpg

Steve decided we needed an axle stand, and he’s right! Made from scrap he had laying around, and my old blown 44 ring gear.
http://www.bigassjeep.com/pics/phoenix/1.31.06.g.jpg

The stands not quite done here, but here’s the rest of the bracketry getting cut off of the 60.
http://www.bigassjeep.com/pics/phoenix/1.31.06.h.jpg

Here’s the stand all done. The straps actually work out VERY well. We used my old door latches from the ZJ on one side, and ¾” holes on the other.
http://www.bigassjeep.com/pics/phoenix/1.31.06.i.jpg

I figure it’s time to show off some of the parts I have waiting to be installed. Here’s the 35 spline ARB we’re putting in this Saturday.
http://www.bigassjeep.com/pics/phoenix/1.31.06.j.jpg

35 spline Poly Performance drive flanges. Man I love the skulls.
http://www.bigassjeep.com/pics/phoenix/1.31.06.k.jpg

Even though we can make our own brackets, we decided at this point it’s better to spend a few extra $’s to just order pre made ones from BTF. Same decision was made for the rear 4 link truss, and differential covers.
http://www.bigassjeep.com/pics/phoenix/1.31.06.l.jpg

Here’s all the SKF bearings from Napa for my hubs (well, drive flanges now!) I’d never heard of SKF until I googled it and found responses on Pirate 4x4, turns out they don’t suck so I’ll run them.
http://www.bigassjeep.com/pics/phoenix/1.31.06.m.jpg

There’s lots more in this pile we don’t need to go into details on. King pin rebuild kits, LED tail lights, ring and pinion for the 60, dedenbear knuckles + high steer arms, wheels, and install kit for the 60.
http://www.bigassjeep.com/pics/phoenix/1.31.06.n.jpg

35 spline 4340 Yukon shafts for the front 60, and Longfield SuperJoints.
http://www.bigassjeep.com/pics/phoenix/1.31.06.o.jpg

Here you can see the sheer size and beef of these things. What a different world from the 30’s and 44’s I’m used to working on.
http://www.bigassjeep.com/pics/phoenix/1.31.06.p.jpg

Problem… Apparently Yukon sucks, and on a couple of their shafts the yoke ears are just plain too small. After calling Bobby Longfield and talking to him about it, he said it wasn’t the first time, and that it’d be fine to take some material off of the caps to make them fit. I’ll tell you one thing: with that tight fit and the fact they almost gouged their way in there, I’m certainly not worried about spinning any caps!
http://www.bigassjeep.com/pics/phoenix/1.31.06.q.jpg

So here it is all put together.
http://www.bigassjeep.com/pics/phoenix/1.31.06.r.jpg

I spent hours and hours cleaning up the caliper brackets, and of course painting them gold. That’s Steelers gold, not yellow. Period.
http://www.bigassjeep.com/pics/phoenix/1.31.06.s.jpg

Also ground down the ‘rusted to hell’ brake pads that came with this junker axle, they look to be reusable, which is good considering replacements are over $70 a side.
http://www.bigassjeep.com/pics/phoenix/1.31.06.t.jpg

At this point it was almost midnight, on a work/school night, but we didn’t really call it quits for awhile after that.
http://www.bigassjeep.com/pics/phoenix/1.31.06.u.jpg

We ended up leaving it here last night, knuckles all ready to go together.
http://www.bigassjeep.com/pics/phoenix/1.31.06.v.jpg

While I was at school for 9 hours (AHHHH) Steve was hard at work over the new found buggy building obsession.
http://www.bigassjeep.com/pics/phoenix/1.31.06.w.jpg

Here’s how we tried removing the King Pins a couple days ago. Mind you, they’re in there at 600 ft pounds. We broke the first aircraft grade bolt we tried using to remove the kingpins, and then we rounded off the next since it wasn’t a perfect fit.
http://www.bigassjeep.com/pics/phoenix/1.31.06.x.jpg

Luckily, Napa had the hex key in stock. Awesome.
http://www.bigassjeep.com/pics/phoenix/1.31.06.y.jpg

Now that they’re out, time for the new king pins!
http://www.bigassjeep.com/pics/phoenix/1.31.06.z.jpg


http://www.bigassjeep.com/pics/phoenix/1.31.06.aa.jpg


http://www.bigassjeep.com/pics/phoenix/1.31.06.bb.jpg


http://www.bigassjeep.com/pics/phoenix/1.31.06.cc.jpg


http://www.bigassjeep.com/pics/phoenix/1.31.06.dd.jpg

Now it’s starting to look like something! SWEET!
http://www.bigassjeep.com/pics/phoenix/1.31.06.ee.jpg

OK. On to the SWEET Blue Torch Fabworks 4 link truss for my Corp 14 bolt axle. We mocked it up and clamped the two pieces together to figure out where to drill the 3 holes.
http://www.bigassjeep.com/pics/phoenix/1.31.06.ff.jpg


http://www.bigassjeep.com/pics/phoenix/1.31.06.gg.jpg


http://www.bigassjeep.com/pics/phoenix/1.31.06.hh.jpg


http://www.bigassjeep.com/pics/phoenix/1.31.06.ii.jpg


http://www.bigassjeep.com/pics/phoenix/1.31.06.jj.jpg


http://www.bigassjeep.com/pics/phoenix/1.31.06.kk.jpg

Is that thing not just beautiful? I love the pinion guard. The pinion yoke is so well protected now, that I’m not concerned about the strap style 1410 driveshaft yoke I was debating on replacing with ujoint style. That saves over $140.
http://www.bigassjeep.com/pics/phoenix/1.31.06.ll.jpg

We almost had a fatality when my welder card decided to dump my welder on the Rubicon. The wheels now welded in place :D

http://www.bigassjeep.com/pics/phoenix/1.31.06.mm.jpg


That’s all for now. There’s sure to be more next week, but it’s a STEELERS SUPERBOWL WEEKEND.

DCHZJ
01-31-2006, 11:03 PM
Damn looking good. Kinda missing a few parts since i saw it last...like everything LOL. Can't wait to see it finished. looks awesome so far.

OverkillZJ
01-31-2006, 11:18 PM
Ya... We just kind of kept cutting until we found a good starting point. And there wasn't really one LOL.

ATL ZJ
02-01-2006, 01:22 AM
It's about time you gave up on d30 hub conversion kits and bought some real parts :flipoff2:

ILikeMud
02-01-2006, 01:33 PM
Coming along nicely.

http://www.bigassjeep.com/pics/phoenix/1.31.06.f.jpg

Damn that's a big pussy.

ogdak
02-01-2006, 02:05 PM
You sure are on the move, Looking good.

Cue-Ball
02-01-2006, 05:24 PM
Looking good, now your moving.

luvthejeep
02-01-2006, 09:30 PM
Coming along nicely.

http://www.bigassjeep.com/pics/phoenix/1.31.06.f.jpg

Damn that's a big pussy.


lmao looks like the fat ass cat is making the tire stack squat to one side- lmao

i keep hearing the cat say "wish i could fit my fat ass in one of these" lol:smt040

OverkillZJ
02-01-2006, 10:01 PM
My company isn't called "Fat Cat Computer Systems, LLC" for nothing :finga:

ILikeMud
02-01-2006, 11:25 PM
LOL.

nate
02-01-2006, 11:28 PM
Cop car?? Post 115 first pic.

OverkillZJ
02-01-2006, 11:42 PM
Let's just say I have a variety of friends :)

OverkillZJ
02-04-2006, 09:11 PM
Well, it’s beadlock time. I must give credit where credit is due: all I really did on this part of the project was painting. Between school, work, and planning a lil’ Superbowl party for the inevitable Steelers victory, I haven’t been much help on my own buggy.

Grinding off the paint on the wheel lip where the beadlock ring needs to be welded.
http://www.bigassjeep.com/pics/phoenix/2.04.06.a.jpg

170 grade 5 bolts, locknuts, and 340 washers. That’s a lot of hardware, luckily my local hardware store ROCKS, and actually supplies all of the hardware for Kennywood.
http://www.bigassjeep.com/pics/phoenix/2.04.06.b.jpg

Weld time!
http://www.bigassjeep.com/pics/phoenix/2.04.06.c.jpg

Air tight, period.
http://www.bigassjeep.com/pics/phoenix/2.04.06.d.jpg

All piled up and done. After welding the first 3, we ran out of C25 gas for the welder. The gas supply store closed at 5, and it was about 4:30. Yet we were 45 minutes away. Steve drove that YJ faster than I thought a poor ol’ YJ could go, and we got there just in time.
http://www.bigassjeep.com/pics/phoenix/2.04.06.e.jpg

Since I was there, I upgraded my little 40 tank to an 80, only $50 to upgrade including the gas. Not bad, now we won’t run out so darn much!
http://www.bigassjeep.com/pics/phoenix/2.04.06.h.jpg

I painted the outer rings STEELERS GOLD in the tent, where I had to cover everything I wasn’t painting due to the amount of overspray. My face and hair were painted Gold, and I was high off my ass. I got pretty sick from all the paint though, NASTY.
http://www.bigassjeep.com/pics/phoenix/2.04.06.f.jpg

Painted up the wheels / inner rings.
http://www.bigassjeep.com/pics/phoenix/2.04.06.g.jpg


Next day: time to mount up some tires! Notice the thickness of the sidewalls next to the ruler. A little beefier than my ol’ MTR’s, eh!
http://www.bigassjeep.com/pics/phoenix/2.04.06.i.jpg

TEAMWORK!
http://www.bigassjeep.com/pics/phoenix/2.04.06.j.jpg

Gary next to the first one all mounted up. It’s be-freakin-autiful.
http://www.bigassjeep.com/pics/phoenix/2.04.06.k.jpg

That’s right. GO STEELERS.
http://www.bigassjeep.com/pics/phoenix/2.04.06.l.jpg


http://www.bigassjeep.com/pics/phoenix/2.04.06.m.jpg

Big tires at 42”
http://www.bigassjeep.com/pics/phoenix/2.04.06.n.jpg

All done. Notice the garage ‘puter I added too. It’s the same laptop that was in my Jeep for the GSW 04 trip, which was essentially destroyed when the screen tore off. A new motherboard and hard drive later, makes a decent garage computer with an old CRT screen! It makes looking up torque specs and the like very handy. Plus I have AutoTap on it, for scanning for codes on ODBII Jeeps like my buggy. I imagine it’s going to come in very handy when I’m trying to figure out why it won’t run when I try cutting down the wiring harness.
http://www.bigassjeep.com/pics/phoenix/2.04.06.o.jpg


Also, FYI, I've made a shortcut to get to this thread: http://BUGGY.BIGASSJEEP.COM will forward you.

BigDaveZJ
02-04-2006, 09:47 PM
TEAMWORK!

http://www.bigassjeep.com/pics/phoenix/2.04.06.j.jpg


Teamwork eh? Methinks the guy on the cell is related to Torx Bolt!

black box renegade
02-04-2006, 10:25 PM
Teamwork eh? Methinks the guy on the cell is related to Torx Bolt!

Well, i know im no "Torx Bolt," because I wrestled those bastards on to the rims! For some reason, the first three were easy...and the last two were enough to make me start goin apeshit.

avenged7foldhc
02-04-2006, 10:52 PM
im the guy on the cell phone and actually they didnt get that tire on that rim, after i got on the phone i got it in by myself :0) blackbox can vouch.. course he failed to mention that in his reply... mustaforgot i have an acct here! dammitsteve!

black box renegade
02-04-2006, 10:57 PM
Ok, ok. You did one by yourself, I did 3 myself, and you helped me w/ the dreaded last one that we had so much trouble with!

nate
02-04-2006, 11:03 PM
Those rings are Yellow.

nate
02-04-2006, 11:08 PM
You guys are a bunch of "Minons" Matt's Minons. Hell I wanted little trolls to come in the garage and work on my Jeep when I slept. I guess Matt doesn' t have to wish. :D

Cue-Ball
02-04-2006, 11:11 PM
AWESOME!!!

black box renegade
02-04-2006, 11:16 PM
I'll put it to you like this: Its a guinea pig project for me. Practice for my spring build, if you will. Plus, I <3 wrenching, and fabrication...so it's nothin but fun for me! Hopefully I'll get to meet a bunch of ya at GSW 06...

Kraqa
02-04-2006, 11:30 PM
wow looks good.

ILikeMud
02-05-2006, 02:16 AM
Those are some big meats.

Still yellow :p

Krash80
02-05-2006, 04:31 AM
holy crap...matt has friends!!!!

WTF?

Kraqa
02-05-2006, 03:34 PM
i thought matts only friend was the gigapet key chain model.

SuicideTireZJ
02-05-2006, 05:05 PM
BWAHAHAHAHA I almost want the Steelers to lose just to see what happens to all you guys. But I'll cheer 'em on anyway because if they lose this website will probably be yellow and black until NEXT football season!

black box renegade
02-06-2006, 03:44 AM
http://myspace-094.vo.llnwd.net/00478/49/01/478381094_l.gif

zj-monster
02-06-2006, 09:15 AM
I see you chose a stool instead of the racing seat. :smt023
http://www.bigassjeep.com/pics/phoenix/1.31.06.c.jpg

ELLLLLIOTTTTT
02-06-2006, 09:57 AM
Teamwork eh? Methinks the guy on the cell is related to Torx Bolt!

:flipoff2:

SCAMPER ZJ
02-11-2006, 12:26 PM
I painted the outer rings STEELERS GOLD in the tent, where I had to cover everything I wasn’t painting due to the amount of overspray. My face and hair were painted Gold, and I was high off my ass. I got pretty sick from all the paint though, NASTY.

Matt, you MUST acquire a respirator!! (And if you already have one, you need to USE it!!) :D

Looking very nice, BTW! http://www.mallcrawlin.com/forum/images/smilies/023.gif

OverkillZJ
02-11-2006, 08:00 PM
There will be no buggy updates this week... Steve and I seem to have found our way into another HUGE project, this one finishing my basement into a very nice office. I've outgrown this room I'm using as an office now. We dove in head first today, we'll be doing this til' its done then back to the buggy.

I can't believe how much re-wiring of this house I have to do to make the office work. It's going to be fun. It's going to be sweet.

nate
02-11-2006, 08:08 PM
Psstt.... Is steve your "friend" :gay:





:D

OverkillZJ
02-11-2006, 08:22 PM
Steve's a carpenter: and he's paid by the hour. I know he does dammmmn good work, so why would I hire someone else?

nate
02-11-2006, 08:35 PM
Does he walk in the house with just his tool belt on? :smt003




P.S.... I'm just fawking with ya. It was just funny reading Steve this and Steve that.

black box renegade
02-11-2006, 08:41 PM
yeaaaa, well steve is right here. so watch it all yinz non pittsburghers!

ELLLLLIOTTTTT
02-11-2006, 09:14 PM
Psstt.... Is steve your "friend" :gay:


Nate, please be more PC.

They're called life partners. :-D

OverkillZJ
02-11-2006, 09:15 PM
Who wants banned?

nate
02-11-2006, 09:19 PM
:smt008 :butthead:

Kraqa
02-11-2006, 09:41 PM
Who wants a mustash ride?
there yougo matt. Fixed!

happycamper
02-11-2006, 11:40 PM
holy crap...matt has friends!!!!

WTF?
Well, it's my first post, and I'm here to verify that Matt indeed actually does have even more friends!! I'm one of the lucky ones that gets to see the build up first hand.

I figured I better register since Matt did make my homepage Mallcrawlin when he tweaked my computer!

Cheers :drinkers:

OverkillZJ
02-11-2006, 11:58 PM
LMAO, they're coming out of the woodwork now! :finga:

happycamper
02-12-2006, 12:03 AM
I swear as soon as I graduate and get a job I'll be a paying member!!:D

Kraqa
02-12-2006, 06:17 AM
$10 says this guy is matts alter ego.

black box renegade
02-12-2006, 10:59 AM
No Kris, Jeff is an actual person...Mallcrawlin is being overtaken by the soft-toppers of Pittsburgh!

OverkillZJ
02-12-2006, 11:17 AM
$10 says this guy is matts alter ego.
You're a mod, you can see IP addresses. Figure out that it's not me :smt110

Kraqa
02-13-2006, 08:42 PM
you and your computer tricks matt. i see right through you. where are the update pics?


:flipoff2:

zj95
02-15-2006, 01:11 AM
sweet

I
R un
O ver
K ids

SuicideTireZJ
03-07-2006, 03:27 AM
Dude, quit working on your damn garage and get this heep running! It's been almost a month!

ILikeMud
03-07-2006, 11:57 AM
It's an office he's working on ;)

Still gonna have it done for GSW?

OverkillZJ
03-07-2006, 01:14 PM
It'll be done, right now I'm just trying to keep up with daily dudties. I'm pretty sure I have mono or something, I've been unable to function for almost a month now. The schedule I had before required 20 hour days to get it all done, not gonna happen at the moment.

I've been making sure to get all the parts in since that doesnt take much energy, as long as it's all here, it'll be done before june.

Kraqa
03-11-2006, 10:12 PM
ahhhh progress?

OverkillZJ
03-12-2006, 12:39 AM
What part of "no time right now" didn't you understand?

Freakin' Canadians.

nate
03-12-2006, 01:01 AM
Great time to start the office build huh?

I do shit like that too. Start like 4 projects when I barely have time for 1.

Sudz
03-16-2006, 12:32 AM
It's an office he's working on ;)

Still gonna have it done for GSW?

yeah, he should have the office done by then...

ZJZJ
03-17-2006, 09:41 AM
Come on Matt. I am living my ZJ life through you vicariously since I gave up on wheeling the ZJ and parted it out and shipped about what you had left of yours to the scrap yard. LOL Get busy and get that thing built!!! Hopefully I can make it down to Wellsville sometime this summer and meet you there to see what we can break.

JohnBoulderCO
03-17-2006, 09:51 AM
Come on Matt. I am living my ZJ life through you vicariously
Matt has groupies!

Kraqa
03-17-2006, 03:19 PM
lets go matt. even i'm almost ready to fire mine up.

chadjans
03-17-2006, 03:44 PM
Quote:
Originally Posted by OverkillZJ
110%.

May I remind....

ZJZJ
03-17-2006, 04:28 PM
Matt has cooties!


Fixed it for ya.

OverkillZJ
03-17-2006, 07:35 PM
I've never missed a deadline.

Waiting on my Corbea seats and PSC steering parts.

Office will be done in 2 weeks, then back to buggy.

ZJZJ
03-23-2006, 09:50 AM
Are ya done yet? Huh? Huh? Huh?

OverkillZJ
03-23-2006, 03:35 PM
We're at SEMA right now getting ideas for the buggy, bugger off.

DCHZJ
03-23-2006, 03:42 PM
We're at SEMA right now getting ideas for the buggy, bugger off.

Lucky bastard I think i will hit it up next year.

Cue-Ball
03-23-2006, 03:43 PM
We're at SEMA right now getting ideas for the buggy, bugger off.

Post up some pix

OverkillZJ
03-28-2006, 08:32 PM
I'm getting back into buggy mode on Saturday. I'm pretty much saying screw my other responsibilities. I need to get this thing to GSW.

http://www.bigassjeep.com/pics/phoenix/3.28.06.a.jpg
http://www.bigassjeep.com/pics/phoenix/3.28.06.b.jpg
http://www.bigassjeep.com/pics/phoenix/3.28.06.c.jpg

AgitatedPancake
03-29-2006, 02:41 AM
THATS THE SPIRIT! Nice seats =P

ogdak
03-29-2006, 12:12 PM
Nice to see you back in buggy-modus

gearhead313
03-29-2006, 11:23 PM
"Its big pimpin, spending G's"

:D

OverkillZJ
04-10-2006, 12:51 AM
I found a little time to get back to it. Step one was clean out the tent, pine needles + metal shavings + rain = nasty.

http://www.bigassjeep.com/pics/phoenix/4.9.06.a.jpg

Time to cut up what’s left of the room, I was sick of staring at it.
http://www.bigassjeep.com/pics/phoenix/4.9.06.b.jpg


http://www.bigassjeep.com/pics/phoenix/4.9.06.c.jpg


http://www.bigassjeep.com/pics/phoenix/4.9.06.d.jpg


http://www.bigassjeep.com/pics/phoenix/4.9.06.e.jpg


http://www.bigassjeep.com/pics/phoenix/4.9.06.f.jpg

Much better, nice to have my driveway back.
http://www.bigassjeep.com/pics/phoenix/4.9.06.g.jpg

Took off the mechanical fan, belt, and power steering.
http://www.bigassjeep.com/pics/phoenix/4.9.06.h.jpg

Took out some other stuff you probably can’t even notice.
http://www.bigassjeep.com/pics/phoenix/4.9.06.i.jpg

Pile of stuff removed.
http://www.bigassjeep.com/pics/phoenix/4.9.06.j.jpg

PSC sent my full hydraulic steering parts, it was like Christmas. Still a couple details short, and working on a way to mount the 1405 pump to the 5.2 itself.
http://www.bigassjeep.com/pics/phoenix/4.9.06.k.jpg

Nittany guarding the parts after I’d unpackaged them.
http://www.bigassjeep.com/pics/phoenix/4.9.06.l.jpg

Up to this weekend. I installed the stock fuel tank and pump temporarily to get the engine running enough to work on the wiring. With no fan belt/alternator, I put the Corolla to work in that aspect.
http://www.bigassjeep.com/pics/phoenix/4.9.06.m.jpg

Got to work on the wires. Holy crap, I never want to do that again.
http://www.bigassjeep.com/pics/phoenix/4.9.06.n.jpg

Thank God I wasn’t trying to disarm a bomb, this took me all day.
http://www.bigassjeep.com/pics/phoenix/4.9.06.o.jpg

Put the headlights / turn signals in place so I could figure out wiring of them.
http://www.bigassjeep.com/pics/phoenix/4.9.06.p.jpg

Much better, eh? All that’s left is wiring for: fuel pump, fuel level, brake light, reverse lights, left turn, right turn, ignition hot, and constant hot.
http://www.bigassjeep.com/pics/phoenix/4.9.06.q.jpg


http://www.bigassjeep.com/pics/phoenix/4.9.06.r.jpg

Any wiring that came out in long pieces I coiled up to reuse.
http://www.bigassjeep.com/pics/phoenix/4.9.06.s.jpg

I’m keeping the stock steering wheel, but even though the air bag module is removed, I didn’t feel comfortable knowing that the air bag was still in there.
http://www.bigassjeep.com/pics/phoenix/4.9.06.t.jpg

When I took it apart, I realized I can’t take the entire bag out as it’s integrated with the mounting system, but I was able to remove just the inflation portion of it.
http://www.bigassjeep.com/pics/phoenix/4.9.06.u.jpg

I had a little air compressor incident that involved my fingers and a plastic fan. My fingers won. Guess I need a new fan to cool the motor.
http://www.bigassjeep.com/pics/phoenix/4.9.06.v.jpg

Cut off one side of the front end, took longer than I expected, but I was trying to do it without losing any fingers.
http://www.bigassjeep.com/pics/phoenix/4.9.06.w.jpg

Since we’re setting gears shortly, time to clean the garage. With all the drywall / wood work in the new office one room away, it was covered in dust. I got ¼ of a 55 gallon garbage back full of dust and sediment type junk.
http://www.bigassjeep.com/pics/phoenix/4.9.06.x.jpg

All clean and organized much better, found a place for the new parts washer too.
http://www.bigassjeep.com/pics/phoenix/4.9.06.y.jpg


That’s all for this week, I intend to work on it every weekend until it’s done.

ogdak
04-10-2006, 02:11 AM
Good to see you back at it.

nickzj08
04-10-2006, 02:40 AM
I cant wait to see this thing done. Ive been following this thread and your builds for a while so Im glad to see you back at it too.

gearhead313
04-10-2006, 08:36 AM
mmmmmmm I love wiring hehehe, did you get it all squared away?


...and you should be able to make something to put the new pump where the old one was............I see its already off the motor!

Kraqa
04-10-2006, 10:16 AM
hahaha suxks to be you. my wires for my truck only require 3 to make it run.

good to see yoru back at her.

may the best man win. err a i mean see you there!!!! :flipoff2:

Kraqa
04-15-2006, 09:49 PM
matt....lets go.....i see no progresss!!!!!!!


i kept my stock stearing wheel too i just took the rubber cover off the bad and glued it back to the wheel. i was not as smart as you.

chadjans
04-16-2006, 12:13 AM
Here is an idea: put your fat ass cat on a diet.

:smt117

OverkillZJ
04-16-2006, 03:48 AM
Fatass cat has been on a diet of years. I'm more concerned about keeping myself on my own diet now that I'm not drinking with all you western fawkers :finga:

I didn't get anything done today... had an emergency work call this morning, and this afternoon I had to cut my 1.5 acre yard with a 17 years old POS lawn mower I could barely get running, and had to fab up a chute for instead of bagging it all....

Tomorrow I'm getting easter church service (those of you that know me know I'm THRILLED ABOUT THAT.)

But all those problems aside.. Besides the MASSIVE AMOUNT of taxes I didn't think I'd owe, and MASSIVE AMOUNT of girl problems that just reared their ugly (yet oddly sexy!) asses, as well as AMAZING AMOUNT of you MFers who say I can never complete this thing and get it to GSW... I've found a new motivation... I will finish this thing at any cost to my sanity, for the simple fact that I'll prove once again that I can do anything I want to do when I put the effort forth.

One bad ass J buggy coming up, and being displayed at Grand Slam West 2006. I don't care what it takes, I'm getting it done, money / time / sanity or not.

I'm a firm believer in following through.

Krash80
04-16-2006, 04:02 AM
I'm a firm believer in feeding my cat Fancy Feast six times a day.


???????????????:smt104 :smt104 :smt104

OverkillZJ
04-16-2006, 04:29 AM
Fancy feast my ass... howabout CHEAP DAMN DRY CAT FOOD!

If I'm eating crap to help with financials to pay for buggy parts, I'm sure as hell not giving the cats fancy feast!

ILikeMud
04-16-2006, 10:23 AM
lol.

Best of luck on finishing it man.

Cody
04-17-2006, 12:34 AM
I'm of the same mindset. If I decide I want to do something and commit to it, it's hard to get me to give in. Thats why I've had the marathon builds before GSW a couple of those years. At least you've already started on it....and it looks good.

keep crackin at it.

Cody

DCHZJ
04-17-2006, 08:17 AM
http://www.bigassjeep.com/pics/phoenix/3.28.06.a.jpg



i Sat in these in Matts Living room.....damn comfy and look even better in person. The Belt latch is very cool, just twist and your out.
I tell you Matt if i was not 4 hours away i would be helping you out when i could on that project.

OverkillZJ
04-19-2006, 09:47 AM
I’m in the middle of finals week, and also in the middle of the most work I’ve ever had floating around at once for my computer business.

So naturally, after stressing out, I spent hours yesterday when I should’ve been working on STUDYING, as well as NOW when I’m posting this!

I figure this is something on my to-do list, so why not work on it a lil’ ;)


First up: this is how deep the stock pump is. It has about 2” of “spring” in order to reach the bottom for fuel feeding and support. Since my new fuel cell is 12” deep, I’ll need to modify it a little bit to somehow provide support for the stock pump unit, as they do not do well swaying around with no bottom support.
http://www.bigassjeep.com/pics/phoenix/4.19.06.a.jpg

http://www.bigassjeep.com/pics/phoenix/4.19.06.b.jpg

Steve and I began mocking up the rear axle. We decided we really need to get the thing sitting at ride height before we can make a better decision of where to put the lower tabs. Either way, it’s going to be hella close, and I’m being hopeful the LA’s won’t need to be modified.

http://www.bigassjeep.com/pics/phoenix/4.19.06.c.jpg


http://www.bigassjeep.com/pics/phoenix/4.19.06.d.jpg


http://www.bigassjeep.com/pics/phoenix/4.19.06.e.jpg

Up to today. DMG was working on my 60 gears a little bit, we’ve been having trouble since my pullers weren’t big enough, so he had to take it to the Dodge dealership where he works to use their setup which is much nicer. Then we pretty much forgot the order of the pinion setup, considering it’s been so long since we took it apart.

I began by mocking up my PSC steering pump. It’s a 1405 P-Pump going in the stock location. There is no real “adapter kit” for this, and PSC doesn’t even have a pulley to fit it that’ll work for my ZJ’s V8 as well as fit over the shaft of the large pump, so I got a Ford Superduty and will just have an extra rib, and will have to press it on far enough to line up. Was JpnRngr;s idea, as he’s done this on a generation 1 ZJ, though there appears to be some differenes.

Looks like the TJ p pump conversion bracket will work, but will need to be spaced out almost 2” in order for the pulley to line up.
http://www.bigassjeep.com/pics/phoenix/4.19.06.f.jpg


http://www.bigassjeep.com/pics/phoenix/4.19.06.g.jpg


http://www.bigassjeep.com/pics/phoenix/4.19.06.h.jpg

http://www.bigassjeep.com/pics/phoenix/4.19.06.i.jpg


http://www.bigassjeep.com/pics/phoenix/4.19.06.j.jpg

I used some shock bolt sleves to space out the pump as needed, until I was able to get it to line up. It looks like the stock belt fits without going around the A/C, but it is WAY too tight, as the tensioner seems a little beyond max travel. I’ll have to find a belt that’s maybe 1” longer…
http://www.bigassjeep.com/pics/phoenix/4.19.06.k.jpg

Here I measured that the engine side of the PSC bracket needs to be 2 and 5/16” from the engine block itself (I want it out another 1/16” further than it was for fitting).
http://www.bigassjeep.com/pics/phoenix/4.19.06.l.jpg

Instead of making another adapter that bolts to this crappy (known to crack) stock adapter, and THEN the PSC adapter, I’ll just be having a machine shop make one like this out of a 2 and 5/16” thick block of aluminum. It’ll make the whole setup much simpler and stronger. Anyone have a CNC machine sitting around?
http://www.bigassjeep.com/pics/phoenix/4.19.06.m.jpg


That’s all the work I did on it, now for the parts that I’ve been collecting in preparation for the big build:

Thanks to Dirk at 4x4oil.com – we have AMSOIL! I will not be using the Amsoil in the diff’s as break in fluid, it’d be a waste. That’s going to be some Wal-Mart synth or something else cheap.
http://www.bigassjeep.com/pics/phoenix/4.19.06.n.jpg

Of course SteelCityOffRoad.com needs to show of their Power Tank product line, and for simplicity purposes, I’ll be using this A package with 10lb tank in order to run the ARB air locker, and air up tires if needed.
http://www.bigassjeep.com/pics/phoenix/4.19.06.o.jpg

RCI Aluminum fuel cell.
http://www.bigassjeep.com/pics/phoenix/4.19.06.p.jpg

Here’s the adapter ring from Blue Torch Fabrication which will allow me to use my stock pump in this tank, GREATLY simplifying the EFI system. I looked into aftermarket, and it’s just too many little things to go wrong using my current timeframe. Stock is simple, and stock works. The ring will need to be TIG welded on by some race shop, I’m not even attempting to weld aluminum even if I had the gas.
http://www.bigassjeep.com/pics/phoenix/4.19.06.q.jpg

Short fuel line and massive amount of adapters to make this all work with the stock system.
http://www.bigassjeep.com/pics/phoenix/4.19.06.r.jpg

That’s it at the moment. I just ordered up my 16” Fox Coil-overs yesterday (Emulsions) and weld in bungs to make the steering links.

Really what I’m worried about on this build is funding to by the Stak transfer case, driveline brake, and I really should do new drive shafts but don’t want to.

ILikeMud
04-19-2006, 03:03 PM
Finally getting some work done on it eh Matt?

I hear you on the finals thing though, I should be finishing some projects but instead I spent 3hrs dicking around in the machine shop.

Looking good though, should be ready for GSW.

OverkillZJ
04-24-2006, 10:37 PM
I didn’t get to work on it as much as I hoped this weekend, it’s finals week, study time all the time… Last final is on Friday, and then I’m really just going to see how much I can get done on this thing every single day. I’ll admit I’m getting nervous, considering I was hoping it’d be done by now, and a lot of people that had an interest in helping got tied up with their own projects during my downtime. I don’t even have a tow rig yet, or the money to buy one, or even the transfer case I need, but I’m still putting 110% of my effort into making this thing happen before June. It’ll be done, and it’ll be at GSW. Somehow.

http://www.bigassjeep.com/pics/phoenix/4.22.06.a.jpg

I cut the last “big piece” off of the rig today. I still need to go around it and clean up the sharp edges and round off a few corners, but overall once I finish welding the box side rails into place, it’s ready for some tube bending. I’m hoping to get the axles and tires under it first to make it easier, but that should only take a few days of hard work if it goes well. DMG is going to try setting the gears over the next couple of evenings, then I should be able to put that front axle together, and see about brackets

http://www.bigassjeep.com/pics/phoenix/4.22.06.b.jpg

I put the cross-member and transmission mount back in place in order to get the rig up on blocks, and at ride height. It’ll make planning it all out a much easier task.
http://www.bigassjeep.com/pics/phoenix/4.22.06.c.jpg

I replaced my good clock spring, with the one I broke years ago, but the horn button still works in (and that’s all I need.) I’m going to sell the good clock spring to help add a few dollars to the project.
http://www.bigassjeep.com/pics/phoenix/4.22.06.d.jpg

Steering wheel, back together. One thing crossed off the list.
http://www.bigassjeep.com/pics/phoenix/4.22.06.e.jpg

The bead lock tires didn’t hold air for more than a few days, probably because of “too many cooks in one kitchen” syndrome when everyone helped put them together. I highly doubt Steve’s welds leak much, if any air, so I’m assuming the leaks are due to the over tightened valve stems and off-center mounting of the tires. I also got some tire bead sealer instead of the grease used to mount them up.
http://www.bigassjeep.com/pics/phoenix/4.22.06.f.jpg

I put the fuel cell together a lil’ to mock up where the BTF adapter ring needs to go, so I can get it welded up.
http://www.bigassjeep.com/pics/phoenix/4.22.06.g.jpg

It looks like this will work well, but I’ll have to somehow extend the legs on the stock pump, so that it has pressure against it, instead of swaying with the swishing gas of the tank.
http://www.bigassjeep.com/pics/phoenix/4.22.06.h.jpg

Loaded up the cell / pump parts, and the power tank in the Corolla. Today I got the powertank filled at Sky Oxygen so it’s ready to run my ARB once I plumb it, and I dropped off the cell to Jay at Domination Chassis. When he’s done with it, I’ll be ready to plumb up the cell and get the Jeep running even though it won’t be permanently mounted yet.
http://www.bigassjeep.com/pics/phoenix/4.22.06.i.jpg

The Delta solid state controller for my Taurus fan came, but I’m still looking for the fan itself. After looking at the rig cut up, I think I’ll be OK running the radiator in the front, and won’t lost much ground clearance by doing that. I’ll feel better about not running such huge hoses to the back of the rig, and taking up more space. Simple is good.
http://www.bigassjeep.com/pics/phoenix/4.22.06.j.jpg

Here’s the good clock spring for sale, I got it in an emergency on the other side of the country for $150 almost 2 years ago. At the time I didn’t want to drive back home with no cruise or air bags.
http://www.bigassjeep.com/pics/phoenix/4.22.06.k.jpg


http://www.bigassjeep.com/pics/phoenix/4.22.06.l.jpg


At the moment, I’m sitting here “writing my final paper” – no, wait, I lied. I’m sitting here figure out what worldly possessions I can sell off in order to get the last bit of money I need to finish the driveline, and buy a piece of crap track that will barely tow the thing across the country. It’ll happen if I can find the right way to do it.

Cody
04-24-2006, 10:47 PM
Wanna buy my truck? I got a buddy going to NC next week--sure he could drive it ;)

OverkillZJ
04-24-2006, 10:51 PM
Sure, you can have my whole truck fund. At the moment, that's about 5 junior bacon cheesburgers!

Cody
04-25-2006, 01:18 AM
Sure, you can have my whole truck fund. At the moment, that's about 5 junior bacon cheesburgers!

no deal!

ZJZJ
04-26-2006, 11:08 AM
Forget the truck fund. Ship the rig out and back and ride the train or greyhound to GSW. LOL

DCHZJ
04-26-2006, 12:43 PM
Forget the truck fund. Ship the rig out and back and ride the train or greyhound to GSW. LOL

Ya and by the time it hits GSW all he will have is a frame and everything will be stripped off.

ATL ZJ
04-26-2006, 01:05 PM
I don't think you're gonna make it. Prove me wrong ;)

I'd be going nuts in your position.. It took all I had to focus on studying for exams last night knowing that I've only got 14 days to acquire tube, learn how to bend, chop the rear, complete the cage, rebuild my steering, and tackle the fuel delivery issues I've got going on. You've got twice as much time, but you've got a whole rig to build from scratch. Good luck.

chadjans
04-26-2006, 03:26 PM
Wanna buy my truck? I got a buddy going to NC next week--sure he could drive it ;)

No you can't sell it. You have to haul back the motor I am supposed to be bringing to you at GSW.

Chad

OverkillZJ
04-27-2006, 10:46 AM
I came home yesterday to find a few presents from UPS: a Ford Taurus 3.8 electric cooling fan - and better: 4 16” Fox Coil-Over Shocks.

The springs for them are shipping out today, tomorrow the we’re picking up the tubing bender, and Saturday we’ll try finishing that darn 60 gear set. My last final is done at about 1pm tomorrow, so after that, I’m in full fledged build-a-juggy mode.

http://www.bigassjeep.com/pics/phoenix/4.27.06.a.jpg

I finally took the time to torque down and air up 4 of the bead locks / tire’s, and one of them has the mother of all leaks where one weld stopped and the other starts. 3 of the other’s leak too, but I’ll see how much air they lose over the next few days, it might not be worth the effort to fix!
http://www.bigassjeep.com/pics/phoenix/4.27.06.b.jpg


http://www.bigassjeep.com/pics/phoenix/4.27.06.c.jpg

Dave worked on the gears some more, but as it’s a thick gear set and so we’re using a 4.10 and down ARB carrier, the first pattern we ran off was just so far out in left field we couldn’t stop laughing at it.
http://www.bigassjeep.com/pics/phoenix/4.27.06.d.jpg


http://www.bigassjeep.com/pics/phoenix/4.27.06.e.jpg

Back at it on Saturday!

ILikeMud
04-27-2006, 10:49 AM
Get 'er done Matt!

SCAMPER ZJ
04-29-2006, 07:02 PM
One bad ass J buggy coming up, and being displayed at Grand Slam West 2006. I don't care what it takes, I'm getting it done, money / time / sanity or not.

I'm a firm believer in following through.

Amazing. Hope you can get it all done Matt, I'm really looking forward to seeing the finished product* at GSW, the ZJ is undergoing quite a transformation!!

*said project is never truly "finished" but you know what I mean:D

JohnBoulderCO
04-29-2006, 08:21 PM
Go Go Go Get It Done!!!!!!

OverkillZJ
04-29-2006, 09:09 PM
I'm out here in the garage trying to git git git er done, I'm going on 12 hours today, and I'm sure I'll put atleast that in tomorrow... I'm trying to at least get 1ll 5 tires holding air leak free before bed, but holy cow are beadlocks a PITA. If I'd realized how time consuming they could be, I"d just have bought some...

Matt
04-30-2006, 02:39 AM
I admire your work ethic, ;) godspeed my friend.

See you at GSW with a head full of gray hair. :D

chf64
04-30-2006, 03:36 PM
What size springs and what spring rates are you going to run on your 2.5's?

OverkillZJ
05-02-2006, 12:10 AM
Thanks to Cebby (Mike) of http://toolandfab.com (http://toolandfab.com/), I have a JD-2 bender on loan with the ultimate custom hydro conversion. After you learn what the heck you’re doing (or kind of what you’re doing) the thing is truly perfect.

http://www.bigassjeep.com/pics/phoenix/5.01.06.a.jpg

The test bend my dad felt better suited as a way to hang me (finally).
http://www.bigassjeep.com/pics/phoenix/5.01.06.b.jpg

We tried some 1.75” exhaust pipe out of curiosity, I guess that’s about what you’d expect it to do!
http://www.bigassjeep.com/pics/phoenix/5.01.06.c.jpg

First order of business: mount the buggy seats. To do that, we mounted up he stock seat briefly to figure out where I used to be comfy wheeling with it at.
http://www.bigassjeep.com/pics/phoenix/5.01.06.d.jpg


http://www.bigassjeep.com/pics/phoenix/5.01.06.e.jpg

Steve’s front bracket came out pretty sweet, not positive it’s going to work though, as the further in/forward you move the seats the higher they get. I think to make it all work, my head might be through the cage, and that’s no good.
http://www.bigassjeep.com/pics/phoenix/5.01.06.f.jpg

Ez-tech’s 3d bending software really is amazing though, you just need to be sure to do the calibrations and setup the tooling/material options correctly. I’d say the most important aspect is be patient and KNOW WHERE YOUR BENDS START.
http://www.bigassjeep.com/pics/phoenix/5.01.06.g.jpg

Took some time repairing beadlocks, have two completely and 100% leak free, one I need to put back together and 2 that still need some patch welds.
http://www.bigassjeep.com/pics/phoenix/5.01.06.h.jpg

http://www.bigassjeep.com/pics/phoenix/5.01.06.i.jpg


http://www.bigassjeep.com/pics/phoenix/5.01.06.j.jpg

Backyard fab shop.
http://www.bigassjeep.com/pics/phoenix/5.01.06.k.jpg

I didn’t really know what I wanted to do for a cage, so my mom came over to help draw up a few ideas. This one I liked the concept of the most. Mind you, this is a sketch, the bends aren’t right, the nodes aren’t right, it’s just a general shape which needs hella more reinforcement. It’s not a blueprint.
http://www.bigassjeep.com/pics/phoenix/5.01.06.l.jpg

Figured out and measured out where all 4 seats are comfy. Since they won’t be adjustable, I’m trying to make it so a few different shapes of people can drive it. Back seats are definitely tight, but hey, it’s a buggy.
http://www.bigassjeep.com/pics/phoenix/5.01.06.m.jpg

http://www.bigassjeep.com/pics/phoenix/5.01.06.n.jpg

My dad and I spent the better part of a day reading up on tube bending and “how to” – eventually we really got the hang of it. Our first piece, the main hoop, came out to 1/100th of an inch of where we wanted it.

To bad it wasn’t until later that I realized “where we thought we wanted it” wasn’t where I really wanted it, and we measured a little to wide. Oh well, the fact we made what we were trying makes me very happy.
http://www.bigassjeep.com/pics/phoenix/5.01.06.o.jpg


http://www.bigassjeep.com/pics/phoenix/5.01.06.p.jpg


http://www.bigassjeep.com/pics/phoenix/5.01.06.q.jpg


http://www.bigassjeep.com/pics/phoenix/5.01.06.r.jpg


http://www.bigassjeep.com/pics/phoenix/5.01.06.s.jpg

Here you can see why the hoop sucks, it’s ½” too wide (see the fat top) and more so, they should be 84 degree bends instead of 90, so the top is closer to the stock/windshield line.
http://www.bigassjeep.com/pics/phoenix/5.01.06.t.jpg

I bent a second main hoop today, but totally wasn’t paying attention and over bent to 89 (again) instead of 84 on one of the two bends. After that happened, I realized that if I bent the other one to 89 as well, it’d make a perfect C hoop right above the rear passengers, just needs to be cut shorter and it’ll be much better. I can’t taper the C hoop like the main hoop, as it’s too close to the already tight rear passenger area. It’ll still be in 5-6” further than the front hoop, so it shouldn’t’ be a tree catcher.
http://www.bigassjeep.com/pics/phoenix/5.01.06.u.jpg


Time for bed, have some work to take care of throughout the day, but bending tube in-between the phone calls /whatnot.

Thanks to Ryan, I might have a flatbed to borrow, but I still need to buy a truck.

ILikeMud
05-02-2006, 12:18 AM
At least your making some progress bro.

nickzj08
05-02-2006, 01:02 AM
Looks awesome Matt! Glad to see it getting closer and closer to being done.

Kraqa
05-02-2006, 02:41 PM
nice shopping cart. lol

OverkillZJ
05-02-2006, 10:32 PM
We're having some tubing issues, I think they're going to occupy our time correcting for the next week or so, so don't bother checking back for updates.

Don't even ask about the 60 gears, we had some ARB "fitment" issues which almost left Dave Steve and I in the hospital.

And the Stak 3 speed case I want is backordered about 6 weeks, Advance Adapters Atlas 4 speed case is backordered 8 weeks, I think this build is just screwed.

JohnBoulderCO
05-02-2006, 10:47 PM
Matt, sorry to here about the recent issues. I was looking forward to seeing it. Take your time, do it right, get the T-case you want. Get your plane ticket to Denver! John

Cody
05-03-2006, 01:53 AM
No you can't sell it. You have to haul back the motor I am supposed to be bringing to you at GSW.

Chad
huh?

also, now you can appreciate the fact that my 'a' pillar tube had 5 bends on 4 planes....

good luck bro. toss a 231 in it to get it here. I have a bunch of spare 231 parts--input shaft--forks---etc etc. if you need them.

chadjans
05-03-2006, 02:37 AM
If you have 1.75 tube on top of the floor pans for the seat mounts your passenger compartment will need to be super tall and maybe would make the rig look out of proportion. Cut the oe seat mounts out. May give you more room to work.

Go get some chaulk and start marking up your driveway. Have you read the pirate bending 101? Get out your 90* and 45* templetes and mark your start of bends.

Needs more nodes. :cheer2:

Chad

JohnBoulderCO
05-03-2006, 09:33 AM
toss a 231 in it to get it here Good point!

jeep4x4nut
05-03-2006, 02:24 PM
CHeck pirate and JU for a Atlas...i know they are out there. Just gotta find one! Good luck man, Cant wait to see it done!

Kraqa
05-03-2006, 03:37 PM
hmm matt dont; you remember a telephone conversation with me tellign you not to sell off your driveline components till after the build. and you;r liek NAWWW it will PAY for the build.


well here is go;s



I TOLD YOU SO!

OverkillZJ
05-04-2006, 11:10 PM
Some of you called BS on us giving up on the buggy, and, well… You were right. However, I’m not going to say how it’s going, or post pictures of the progress yet, you’ll just have to sit there wondering what the hell we’re up to over here until we show up with it in Moab at Grand Slam West 2006 in June, on time, with a functional ZJ buggy.

Until I feel like letting the cat out of the bag, have some teaser pics :D

http://www.bigassjeep.com/pics/phoenix/5.04.06.a.jpg


http://www.bigassjeep.com/pics/phoenix/5.04.06.b.jpg


http://www.bigassjeep.com/pics/phoenix/5.04.06.c.jpg


http://www.bigassjeep.com/pics/phoenix/5.04.06.d.jpg


http://www.bigassjeep.com/pics/phoenix/5.04.06.e.jpg


http://www.bigassjeep.com/pics/phoenix/5.04.06.f.jpg


http://www.bigassjeep.com/pics/phoenix/5.04.06.g.jpg


http://www.bigassjeep.com/pics/phoenix/5.04.06.h.jpg

http://www.bigassjeep.com/pics/phoenix/5.04.06.i.jpg


http://www.bigassjeep.com/pics/phoenix/5.04.06.j.jpg


http://www.bigassjeep.com/pics/phoenix/5.04.06.k.jpg


http://www.bigassjeep.com/pics/phoenix/5.04.06.l.jpg


http://www.bigassjeep.com/pics/phoenix/5.04.06.m.jpg

http://www.bigassjeep.com/pics/phoenix/5.04.06.n.jpg


http://www.bigassjeep.com/pics/phoenix/5.04.06.o.jpg


http://www.bigassjeep.com/pics/phoenix/5.04.06.p.jpg


http://www.bigassjeep.com/pics/phoenix/5.04.06.q.jpg


http://www.bigassjeep.com/pics/phoenix/5.04.06.r.jpg


http://www.bigassjeep.com/pics/phoenix/5.04.06.s.jpg


http://www.bigassjeep.com/pics/phoenix/5.04.06.t.jpg


http://www.bigassjeep.com/pics/phoenix/5.04.06.u.jpg
I guess I didn’t really show you much, huh? Guess you’ll just have to wait.

HA!

MUDDTRACKS
05-04-2006, 11:58 PM
your so mean:finga:

Good luck with the rest of the build

ILikeMud
05-05-2006, 12:42 AM
Good luck Matt...I think you'll need it lol :p

Kraqa
05-05-2006, 01:14 AM
Those arn't matts pics. those were spy shots taken fro a real shop that have peopel workign that actually knwo what they are doing. :flipoff2:

good luck matt. if i coudl fly out to help you i woudl but unfortunatly i dont' think i will have time.

althoguh if all go's well MY buggy shoudl be finished in 2 weeks.

ATL ZJ
05-05-2006, 08:06 PM
LAAAAAME, those pics are boooooringggg....

I like how you mix fractions and decimals in your main hoop design calculations to make it easy on yourself :yawinkle:

OverkillZJ
05-05-2006, 09:08 PM
well I can't really remember .875 as a fraction easily, so ya, decimal! What's the difference, it's all just measurement.

OverkillZJ
05-05-2006, 10:08 PM
IT'S BUGGY DE MAYO

http://bigassjeep.com/pics/phoenix/party.jpg

That's right, we're getting shit done.

bburgi
05-06-2006, 12:17 AM
lol, that's awesome.

ATL ZJ
05-06-2006, 12:27 AM
well I can't really remember .875 as a fraction easily, so ya, decimal! What's the difference, it's all just measurement.

Just giving you a hard time, looks like it worked :D

death-mobile
05-10-2006, 06:59 PM
IT'S BUGGY DE MAYO

http://bigassjeep.com/pics/phoenix/party.jpg

That's right, we're getting shit done.

HAHAHAHAHAHA

2jeepsforus
05-11-2006, 12:15 AM
http://www.bigassjeep.com/pics/phoenix/5.04.06.o.jpg


Is it a flux capacitor?? :-D

OverkillZJ
05-11-2006, 12:58 AM
Just a few more teaser pics.

I guess I need a new vice, what the hell were we building to break that thing? Of course since it involved half inch plate when I say “we” I meant “Steve.”

http://www.bigassjeep.com/pics/phoenix/5.11.06.a.jpg


http://www.bigassjeep.com/pics/phoenix/5.11.06.b.jpg


http://www.bigassjeep.com/pics/phoenix/5.11.06.c.jpg


http://www.bigassjeep.com/pics/phoenix/5.11.06.d.jpg


http://www.bigassjeep.com/pics/phoenix/5.11.06.e.jpg


http://www.bigassjeep.com/pics/phoenix/5.11.06.f.jpg


http://www.bigassjeep.com/pics/phoenix/5.11.06.g.jpg


http://www.bigassjeep.com/pics/phoenix/5.11.06.h.jpg

http://www.bigassjeep.com/pics/phoenix/5.11.06.i.jpg


http://www.bigassjeep.com/pics/phoenix/5.11.06.j.jpg


http://www.bigassjeep.com/pics/phoenix/5.11.06.k.jpg

Cody
05-11-2006, 02:56 AM
well I can't really remember .875 as a fraction easily, so ya, decimal! What's the difference, it's all just measurement.

7/8 ;)

OverkillZJ
05-11-2006, 06:43 PM
Yep, but when you measure with a micrometer and come out with .875, I bet you don't know it off hand.

jclaudii
05-12-2006, 04:07 PM
looks like that diff protector would stop a 50 Cal! Are you sure your not building the army a new vehicle, it really looks like it will take some abuse!

OverkillZJ
05-12-2006, 04:32 PM
Diff pretector?

It's an axle trus with a steering ram mount.

The diff cover / protector just arrived from Rockcrusher, it's no smaller...

violatedppl
05-13-2006, 01:47 AM
those welds are so pretty

black box renegade
05-14-2006, 06:15 PM
those welds are so pretty

thanks!

zjeepin
05-15-2006, 01:19 PM
how'd that housing spreader work out for ya?

OverkillZJ
05-15-2006, 11:35 PM
how'd that housing spreader work out for ya?

Actually, REALLY WELL!

We needed it "now", didn't know where to get one... so ya, it actually worked pretty well for a 45 minute crap-fab job.

We may need to reinforce it a little to spread it a couple more thousandth's for the final set with more load on the bearings, but it's made it a lot easier.

OverkillZJ
05-15-2006, 11:37 PM
those welds are so pretty

Which usually means I didn't lay them and steve was bored :smt033

chadjans
05-15-2006, 11:46 PM
What size cell you end up going with?

Chad

OverkillZJ
05-15-2006, 11:48 PM
15 gallon, only about 12 of which is usable since the stock pump is shorter than the cell. I'll figure out how to extend it eventually, but I didn't want to waste time right now, I'll just keep it full for now.

chadjans
05-16-2006, 01:59 AM
Could one get away with a 19" height cell? Even with the use of the threaded ring?

Chad

OverkillZJ
05-16-2006, 08:54 AM
You'd only be able to pickup about 12" of fuel, unless you figure out a way to extend the scren/pickup...

chadjans
05-16-2006, 12:36 PM
Ooops mistyped. 19"=10"

Chad

OverkillZJ
05-16-2006, 01:02 PM
oh ya I can't remember off hand what the stock pump height was, but i think it extended from like 10-12", so if you got that BTF ring on top it'd probably be perfect, and use all the fuel in the tank. I'd measure your stock pump though, I've found a lot of crazy litle differences between the gen 1 and 2 zj's lately