Project Red Roof Inn

[Ken L]

Simple solution for you, Dave. Don't look at ZJs on Craigslist.

[FortCollinsZJ]

BUY THIS!!!! http://denver.craigslist.org/cto/3936069924.html

[BigDaveZJ]

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

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

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

[Kraqa]

well now that you have a shop.....get to work man.

[BigDaveZJ]

I just gotta finish the shop! Got one work bench done, 3 more to go, run the airlines, mount the compressor, and I'm sure some other stuff that will come up too.

[BigDaveZJ]

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



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[BigDaveZJ]

Old seats are out, cleaning up 15 years of gnarliness that was under the seats. Running with no doors and in the rain can certainly take its toll on an interior.



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



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

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[BigDaveZJ]

Seats are in.



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[JohnBoulderCO]

What would the new front axle choices be?

Edit: I just saw your CO4x4 wanted post.

[BigDaveZJ]

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

[fluxcap]

The 8.8 is stronger then a factory 9 unless you like spitting out pinions

[Stealth Crawler ZJ]

I have a good 8.8 with welded tubes a good truss, 4:10 gears, iron rock mounting kit and a ballistic 3/8 steel diff cover!
Give you a good price on it! 😉

[BigDaveZJ]

Already have an 8.8

[Stealth Crawler ZJ]

Well just sayin if you wanted to refresh you know just in case haha!

[ELLLLLIOTTTTT]

Since you know how to set up gears, I'd just replace them. 35's shouldn't be grinding teeth off like that, but we all know you don't take the easy lines.

[Ted_Z]

Nice thing about the d44 route is that you can convert to over the knuckle steering (among other things). Makes a huge difference on the street. If you pick up a some flat top knuckles, I can machine them for you probono (since you're such a nice guy and all) now that I know how to do it.

[Ted_Z]

https://denver.craigslist.org/pts/5311506605.html

[BigDaveZJ]

So if I did the HP44 . . .

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

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

[Ted_Z]

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

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

Add all the brackets to your list.

[K2]

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

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

[BigDaveZJ]

Keeping the HP30 for the time being, ordered up the gears today. Will probably start building a HP44/9 combo at some point, but for now that's money that can go towards a Typhoon!

[BigDaveZJ]

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

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

[ELLLLLIOTTTTT]

You have a rear bumper now?

[BigDaveZJ]

You have a rear bumper now?

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

[BigDaveZJ]

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

So far I'll be doing:

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

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