Thread: OGDAK's ZJ sheetmetal removal 04/15/2012

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  1. #1 OGDAK's ZJ sheetmetal removal 04/15/2012 
    Senior Member Lifetime Supporter ogdak's Avatar
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    Hi,
    So it did take a while bud let's start a topic about my "project".
    The guide in this topic are the picture's i took in chronological order
    Therefore things might look a bit chaotic every now and then.
    As i get closer to the present time, things will get better documented, needless to say most off it will be common knowledge
    on this board. Since i have searched a lott on nagca and mallcrawlin.
    But now lets start with how this "crazy" hobby started when i bought our 1994 ZJ5.2LTD in October 2003 as a DD.
    These are the only pictures i have of our ZJ where it is stock, clean and polished










    November 2003

    The first event i went to do some offroading, it was held on a dirt bike track.














    And after this weekend the ZJ has never been clean.
    Along with it came the first costs
    General Ameri Trac TR 235/75*15TR


    I also found it necessary to take the pitman-arm off, why? I can't remember




    More to come
    Last edited by ogdak; 04-15-2012 at 04:49 PM. Reason: Title
    Jeep ZJ 5.2Ltd '94 "To much to do"
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  2. #2 Re: Ogdak's ZJ 
    Senior Member Lifetime Supporter ogdak's Avatar
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    A little jump to february 2004
    As far as i can see according to my jeep bills no problems what so ever this past winter.
    Bud I did buy the official FSM and owners manual an absolute must if you are a DIY person.
    Another very functional tool a "Schaarvetspuit".


    A recreational area nearby called the "posbank" near the city Arnhem, no offroading allowed however.




    My youngest fan in this picture 1 year old, now a days almost 3.


    Event on a dirt bike track in "Groesbeek" near the city Nijmegen, damages
    1 rear bumper reflector did cost me €18 by the stealership and
    1 head lamp glas, new unit went for €192.80 to be exact, have the invoice right here.
    Had a fun day though.


    Another event this month in "Overloon", offroading in the snow.
    No damages this time, only a tired son.




    By now the 4x4 virus(read as JEEP virus) really hit me, it is time for mod's
    So I ordered a BB, an ACOS kit and a set off BPE's in th US
    Waiting for the goods I started looking localy for wheels and tires.
    31" looked fine since this car was still our DD
    Succeeded with a set off US wheel "blade" 15x7 with 31"x10.5lt15 bf at's
    Since my BB was not in yet, I put the wheels on just for the looks and off course the pic's












    In the meantime the sound off the exhaust was becoming louder


    So the first time off electric welding to an exhaust.


    So got the first 6 months covered, more to come
    Last edited by ogdak; 12-13-2006 at 12:59 PM.
    Jeep ZJ 5.2Ltd '94 "To much to do"
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  3. #3 Re: Ogdak's ZJ 
    Senior Member Lifetime Supporter ogdak's Avatar
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    as promised march 2004

    In the meantime took care of some small repairs,
    Brakeshoe's for the emergency brake, oilseal rear DS and a torn CV-boot on the left
    Meanwhile the stuff I ordered arrived, took well over 1 month.
    So lets get on with it, first in the rear.


    2" BB in place.


    So some extra space in the wheelwell here with GT 235/75*15 which is almost equal to a 29" tire.


    Up Front


    Obviously these speak for themself, have the ACOS'ses on for a year and a half and no regrets what so ever.


    in detail


    here a half...


    and here the end result.



    And yes still on "small" tires, With an Arb bull-bar on the way it is kind off a waste to cut up a bumper.
    In the meanwhile changed diff oil and pimped the cover.
    bling-bling


    grounded


    green gehamerslagd(t)(wont know how to translate this, so learn dutch)


    and back in place.


    Time to start with the bull-bar.


    The thing itself


    All bits and pieces.


    Soon to be continued.
    Last edited by ogdak; 12-13-2006 at 01:47 PM.
    Jeep ZJ 5.2Ltd '94 "To much to do"
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  4. #4 Re: Ogdak's ZJ bullbar mounted 
    Senior Member Lifetime Supporter ogdak's Avatar
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    A magnum 8000 winch.


    Everything sorted out.


    Preparation


    It's dark and late.


    Winch mounted.


    The other side.


    Brackets and "evap canister" shield in place.


    Almost done, 31" on and some trimming on the inner fenders.


    Next day time to check the winch on a jeep event in "Zeumeren"




    Later that week, some flex pic's.




    Nice fit.






    So that was march 2004 more to come.
    Last edited by ogdak; 12-13-2006 at 01:49 PM.
    Jeep ZJ 5.2Ltd '94 "To much to do"
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  5. #5 Re: Ogdak's ZJ 
    just wondering why is there 8 slots in that Zj grille??????
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  6. #6 Re: Ogdak's ZJ 
    Member jeepnzj1's Avatar
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    wonder why the last post is all xxxx for me any one else
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  7. #7 Re: Ogdak's ZJ 
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    Quote Originally Posted by steves88vb
    just wondering why is there 8 slots in that Zj grille??????

    Same reason they all have 8.
    1998 ZJ wife's DD

    1990 XJ, budget built, Build total ~ $3,000
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  8. #8 Re: Ogdak's ZJ 
    Senior Member ATL ZJ's Avatar
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    Are those the foreign BFG ATs? all the ones I've seen don't look like that. Maybe retreads?
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  9. #9 Re: Ogdak's ZJ 
    Quote Originally Posted by 1996cc
    Same reason they all have 8.
    yeah YOUR right, my Zj is just a Reject model and has 7 slots
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  10. #10 Re: Ogdak's ZJ 
    Senior Member zj95's Avatar
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    Quote Originally Posted by steves88vb
    yeah YOUR right, my Zj is just a Reject model and has 7 slots
    93-95 have 8 slots and 96-98 have 7
    95 ZJ/ 5.2 / HD Dana 44 front / 14b rear / 5.5" CLAYTONS / 38'' Grooved TSL's / CLAYTONS belly skid / NP231 w/sye

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  11. #11 Re: Ogdak's ZJ 
    Senior Member Lifetime Supporter ogdak's Avatar
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    Quote Originally Posted by ATL ZJ
    Are those the foreign BFG ATs? all the ones I've seen don't look like that. Maybe retreads?
    I do not know wether there is a difference in US or European market.
    But the are not retreads.

    And for the number off "slots", 8 is indead stock for '93 through '95 models.
    Jeep ZJ 5.2Ltd '94 "To much to do"
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  12. #12 Re: Ogdak's ZJ 
    Member jeepnzj1's Avatar
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    ive seen those bfg's before they have them here this is an awsome write up its a trip to see how its done in other countrys
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  13. #13 Re: Ogdak's ZJ 
    The Oil Dude MallCrawlin Vendor
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    Nice write up.
    Your #1 Source for Amsoil Lubricants

    Lube it or Loose it!

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  14. #14 Re: Ogdak's ZJ 
    Senior Member Lifetime Supporter ogdak's Avatar
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    Quote Originally Posted by Cue-Ball
    Nice write up.
    Thnx,

    Here is some more.

    So after March comes April 2004.
    Did not do a lot this month, went to the "maaasvlakte" near the port of Rotterdam.
    Was fun due to good weather and company.
    So just some pic's




    Some people think you can swim with a SUV, fortunately Droopy was nearby






    from left to right
    Eelco, Jeeped, Droopy en Jeepee


    So afterall some maintenance issue's, leaky oilseal on the right rear axle.
    So time for fresh oil and a diff cover paintjob.
    An opened diff


    The leaking seal, €16,51 from the stealert.


    piece off iron


    nicer diff cover


    Famous mastershaft and c-clip


    new vs. old



    Cleaned


    All for now, latersz
    Last edited by ogdak; 12-13-2006 at 01:52 PM.
    Jeep ZJ 5.2Ltd '94 "To much to do"
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  15. #15 Re: Ogdak's ZJ 
    The Oil Dude MallCrawlin Vendor
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    Very nice detail in your posting. Awesome job.
    Your #1 Source for Amsoil Lubricants

    Lube it or Loose it!

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  16. #16 Re: Ogdak's ZJ 
    Senior Member Lifetime Supporter ogdak's Avatar
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    May 2004

    So got a few things done like longer shocks, adj. TB's, did not make tha many pic's.
    After getting my rocker panels dented, I desided to get some protection.
    Liked these a lot.
    So went to a friend who is very good on a drawing board and with iron.
    He came up with this




    So after one day, the unpainted result


    So the next day went offroading with some www.jeepforum.nl guys/girls in "veldhoven". Sorry no pic's

    So 1 week later, got the SB off to get powder coated, and went playing








    flex-out


    flex-in



    So meanwhile it is june 2004
    The SB are ready and mounted




    detail


    more detailed


    Also notice the spots where I dented my rockers


    Topview


    So all for now, enjoy
    Last edited by ogdak; 12-13-2006 at 01:54 PM.
    Jeep ZJ 5.2Ltd '94 "To much to do"
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  17. #17 Re: Ogdak's ZJ 
    Pinch Yo Sack Pimp MallCrawlin Vendor
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    not to be a bitch but in the pic of your rear BB install the coil isolator go's between the coil spacer and the spring. not between the coil spacer and the coil bucket.
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  18. #18 Re: Ogdak's ZJ 
    Senior Member Lifetime Supporter ogdak's Avatar
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    I agree to do it that way, makes more sense.
    However, it was a nicer fit this way as a remember.
    That was over a year ago, they are already long gone.
    Jeep ZJ 5.2Ltd '94 "To much to do"
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  19. #19 Re: Ogdak's ZJ 
    Junior Member Jeepxtrem's Avatar
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    Great zj Ogdak. I want put a from ARB bumper, but is not very heavy?
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  20. #20 Re: Ogdak's ZJ 
    Senior Member Lifetime Supporter ogdak's Avatar
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    If I remember correct about 40~45Kg without the winch.
    Jeep ZJ 5.2Ltd '94 "To much to do"
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  21. #21 Re: Ogdak's ZJ 
    Senior Member Lifetime Supporter ogdak's Avatar
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    So Left off last time with the SB's
    So here is one more.


    Nice thing off those heavy duty custom SB's is, is that you can put a jack underneath and lift up half the ZJ


    Just one single pic off a weekend offroading in "schaijk"


    So now time for a real job, we are planning to go to Sclayn in Belgium early next month.
    Bud with 3 kids in the backseat it is nice to have a working CC.
    So had a change to get the system put under pressure to determine what caused the CC not to work, at a
    local german dealership. Happens to be one off the mechanics used to work for our well known stealerships.
    He told me 90% off not working CC's in Grand's are caused by leaky evaporator's.
    So went to a local airco specialist for a "track & trace", they did confirm on the 90% rule.
    So the T&T did cost me €160, left me with a working CC for about 1 week.
    So went back to them to have one of the mech's go over, under and in the ZJ with a UV-light and yellow goggles on.
    And finally, looking through a very small hole in the heater-a/c unit found the leak, the predicted evaporator core.
    They gave me a quote for approx €1000 to fix it, the evaporator is only €140 bud it is a time consuming repair
    because the have to get the dash off and the complete heater-a/c unit out to change the evaporator core.
    So I decided to do it myself and save like €800, went home with the new evaporator core.
    Grabbed the FSM and started removing the dash, also took out the right chair for some extra space to work in.




    Obvious the "black box" is the heater-a/c unit, with the evaporator core in it.
    Goes from the right side right up to the steering column.
    Consist off a top and bottom half, copper pipe's on top is from and to the heater core.






    The dash


    heater-a/c unit out


    and opened
    On the left, blower motor.
    In the middle, evaporator core.
    On the right, heater core.


    The leakage is on the right side cant be seen with the bare eye. Normally for proper operation the system would be on 12 bar
    so you don't need that big off a hole. On this side there was a lot off dirt and leafs.
    So made a filter, from a panty off my .... on the outside right on top off the firewall where the air comes in.


    Evaporator core out, on the right top I had to cut my coolant lines to/from the heater core


    heater-a/c unit installed


    So went back to the airco shop to get the system filled again, did not have to pay for the R134A the second time around
    Excellent service. So off for a nice ride to "Sclayn".
    Last edited by ogdak; 12-13-2006 at 01:58 PM.
    Jeep ZJ 5.2Ltd '94 "To much to do"
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  22. #22 Re: Ogdak's ZJ Updated 14th-dec 
    Senior Member Lifetime Supporter ogdak's Avatar
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    July 2004

    Like mentioned before we are planning a trip to "Sclayn" in Belgium.
    It is also going to be our first time camping with our kids.
    So the day before leaving came to the conclusion that we did not have enough lugage space. So went for a skibox.
    Good thing to buy one of these in de summertime, plenty choice and nothing "out off stock".
    So for de trip to sclayn put the small ones on again.
    I know, not the best pictures but al I had




    Due to bad waether the weekend was not to succesfull for the wife and kids,
    but I had a GREAT time.

    August 2004

    This months mod's
    -F>R spring swap
    -3" longer front spring's
    -Adjustable CA's

    F>R swap does not need further explaining.
    Combined with the BB's about 5" lift in the rear.
    Upfront 3" longer skycrapper's combined with the ACOS is about 6"
    Nice flexxin


    Upfront

    Bottom


    Like mentioned above, Adj. CA.
    Tape with line around the tire is to get things roughly allignt


    This months end result.
    Personally I think it is sitting to high for a set of 31"






    Pro to that is that the tires move up into the wheelwell very nice and easy.
    Downside is that the Skycrapper coils can not take that much flex.
    This is how the came off in january 2005.
    I know I should have known.



    So meanwhile it is september 2004
    So things need to get tested and we are only 1 week away of The First Annual Dutch Jeepcamp
    As said as done, went testing in "Ressen".
    The pic's speak for them self.








    Just checking the extended brake lines.


    Former front coil now in the rear and almost fully compressed.


    Little rubbing on the rear, needs some adjusting.


    From below.


    And the last one.


    Sooooooooo all for now.

    p.s. test went well.
    Last edited by ogdak; 12-13-2006 at 02:06 PM.
    Jeep ZJ 5.2Ltd '94 "To much to do"
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  23. #23 Re: Ogdak's ZJ Updated 14th-dec 
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    cut off those shock boots all they will do for you is trap mud and sludge. Eventually that stuff will score the shaft and yoru shock will leak.
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  24. #24 Re: Ogdak's ZJ Updated 14th-dec 
    Senior Member Lifetime Supporter ogdak's Avatar
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    Quote Originally Posted by Kraqa
    cut off those shock boots all they will do for you is trap mud and sludge. Eventually that stuff will score the shaft and yoru shock will leak.


    That is why I left them loose at the bottom.
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  25. #25 Re: Ogdak's ZJ Updated 20th-dec 
    Senior Member Lifetime Supporter ogdak's Avatar
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    September 2004
    So time for Dutch Jeep Camp
    Also in 2004 lot's off poison ivy.




    The camp site
    Thought it would be nice to put some 33" on MT wheels on.
    So just some "poser" pic's.






    Lady's from my most favourites list.


    So saturday in a nice piece off forrest.










    So last day, sunday.




    So that was jeepcamp 2004, till next year.

    So later that same month we had the FOC trophy in Belgium http://www.4ft.be/eng/index.htm
    But I wanted o go on 33". So made a deal with Mav and went to work to make things fit.
    So the adj. CA's turned out to be very usefull again. Finally had to grind half the head off the SS bolt off.
    Also the sway-bar had to go. Which made driving on the highway fun, especcially on the fly over's.
    So first night on the camping site with some rain.


    Signin went very well, considering there where over a thousend 4x4's over the weekend.


    Saturday had a flat tire after being pulled out by a traktor.
    Did catch dirt between de tire en the rim.
    BUt with som crow-bar's and lots off water managed to get things airtide again.


    So sunday we went into a rather small piece off forest which was very swampy.
    So got stuck in a ditch.


    Don't think it has been this dirty before.




    And this was the last time I wheeled it.
    Time for a HP30, 8.8 and LA's
    Stay tuned.
    Last edited by ogdak; 12-13-2006 at 02:09 PM.
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