1 ton zj

[zjmartin]

I would like to start off with saying hello. My name is chad and I'm from Ohio. My rig is a 97 grand Cherokee limited. I got it in Feb of 2013 after selling my first trail jeep.

Build list
79 ford Dana 60 welded 5.38 gears
14 bolt welded 5.38 gears
231 sye case
Full frame reinforcement
Exo cage/bumpers
38x12.5x16 swampers
Rugged ridge winch
Tons of nickel and dime stuff

This build is on a local site when I started the build. Tried another Cherokee site but found out its directed mainly towards xj's. Here we go

The day I brought it home. Completely stock

[zjmartin]

Then the fun started

[zjmartin]

Started by pulling the stock axles. The front had a broken CV joint. But still was able to sell them. Then completely cleaned the frame of all the stock brackets and tabs. That was a job. Took forever. Pics of the rear





Then started on the stiffening plate templates.





I used ¼" thick angle on the outside and 3/16 plate on the inside

[zjmartin]

The middle section of the frame I used ¼" thick 4" box tube. I plasma cut the seam side off and blew holes in the side for plug welds. This piece went from behind the rear doors up past the cross member



Couple pics of the plates welded in





Once I got the frame finished up past the cross member I started the 4 link rear. All the link parts from Barnes 4x4. 1¼ heims at the frame and poly bushings at the axle ends

[zjmartin]

I have more pics from my old phone on the laptop if anyone is interested. Just ask and I'll get some more of whatever posted. Built the links out of 2" ¼ wall Dom for the lowers and 1¾" .120 wall dom for the uppers. The brackets from Barnes were great. Made it easy to mount everything.
The upper link mounts at the truss were homebrew





I stretched the rear 11" and the front 4½"

[zjmartin]

The offset brackets mount on the bottom of the frame and give me 4" of lift. It is sitting on the stock springs. Planning on a lot of cutting. That'd the look I like. Little lift and cut clearance.



Plating on the front went super smooth. I acquired a 4x8 sheet of 3/16 plate. If anyone is doing this this is definitely the way to do it. Templates transfered over to plate



Plasma cut out and cleaned up



I would mark the bends on the templates and grind ¾ of the way thru bend it the way it should go on and start fitting it

[zjmartin]

The outer frame well

[zjmartin]

Forgot to post a few more rear shots





Then work started on the driver side front



Was a little tricky with the motor mount bolts and the steering box plate. But going full hydro but gonna make the orbital mount plate work in the steering box location

[zjmartin]

Next I started on the spring mounts for the front. The frame was a little to narrow to run the Barnes brackets so I made my own out of ¼" plate.





Driver side



Links in and springs mounted

[zjmartin]

Next was the pan hard bar. I planned on running 1 1/4 heims to it but the brackets Barnes had wasn't wide enough for those. So I went with the ⅞ for it. Pic of the front brackets and 14 bolt disk brake brackets



Pan hard bar frame side



Test flex



At the oil pan

[zjmartin]

On its own weight





Test flex. Only about 20" up on the jack but it seemed very unstable on a jack under the tire



No more room on the rear but only about half way on the up travel



Me cheezen for height reference

[zjmartin]

Got the fenders cut last week. The rear is what I wanted. Front I haven't decided

[zjmartin]

Got the inner fenders to build in the rear and moving the air box and battery box for extra room in the front.

Got the 14 bolt disk brakes on and ready for brake lines





Took out the 249 and swapped out the front inputs and put it in the 231. To my surprise the guy I bought the 231 from had a 6 gear planetary already in it. :thumbup:





I couldn't get the studs out of the 249 so had to order new ones



Ready for driveshafts

[zjmartin]

Ordered a custom fuel cell from RCI on Thursday. Its a 30*12*9 but didn't need the pick ups and the sending unit. I bought this jeep sending unit adapter from genright. Should make putting it in a breeze. My pump and regulator are intank and this was the best solution I found since I wasn't able to use the stock tank





That is where I am at with the build. It is coming along great. Hope to have the rest of it done and ready by spring time.

Still to do list is
Driveshafts
Fuel lines
Brake lines
Power steering pump/Hydraulic lines
Paint
Exo cage/bumpers

[redneckrollercoaster]

Badass.


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[zjmartin]

Thanks. I had to build something that could take the whole family out. Once the baby was born I had to start a 5 seater

[redneckrollercoaster]

Looks like you are doing it right! Plated from end to end and all, love the coil buckets. Good work!


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[zjmartin]

I thought they ended up pretty nice. Started on filling in the inner fender from the cut. Here's a couple pics of the fender before I started.





Here's the piece I made to fit. Made a template and then a ton of fitting and grinding.



Didn't turn out to bad considering I have never worked sheet metal before. Got the door hole almost done but not ready for a pic yet

[ELLLLLIOTTTTT]

Nice work! Love to see new builds on here.

[pitbull78133]

Awesome build! Im working on the family trail rig also! Got a 6 month old wheeler in the making!

[polar_jeep_04]

Where in ohio and what local site? I'm in Columbus and wheel with empire off-road. I'm going to go out on a limb here and say cinnci area and core???

[zjmartin]

Thanks guys. I'm trying to do it right and only once. my littlest wheeler will be 2 in February. Maybe a few easy rides toward the end if summer for her. She is smaller than my son was at 2.
Sturdy limb. Hahaha I live south of Dayton. The site is core but not a member of that club yet. Plan to be once the jeeps done. I'm a current member of Miami valley four wheelers based out of middletown. Its a good club since we have private land to ride on.

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[Kraqa]

Sweet. Love the new build and the unibody plating. Keep the pics coming

[polar_jeep_04]

Thanks guys. I'm trying to do it right and only once. my littlest wheeler will be 2 in February. Maybe a few easy rides toward the end if summer for her. She is smaller than my son was at 2.
Sturdy limb. Hahaha I live south of Dayton. The site is core but not a member of that club yet. Plan to be once the jeeps done. I'm a current member of Miami valley four wheelers based out of middletown. Its a good club since we have private land to ride on.

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I'd love to wheel that land. Do they ever let non members come out to wheel it?

[zjmartin]

I'd love to wheel that land. Do they ever let non members come out to wheel it?

We can bring guests with us. One member rig per guest rig is the rule. Usually 4 or 5 members and 1 or 2 guest go in our group. When I get it done if you wanna make the drive you can come check it out and wheel with us.