OD TJ ~~ 56K beware

[ODTJ]

Hello Everyone,

I thought i woudl post up a thread of my TJ here so all to see.  I bought it late 2008 with the sole intention of completely tearing it down and rebuilding it from the ground up in 3 stages.  

Stage I was to be the actual body/structure with some modifications to get it to it's final stage.  This was accomplished from December 2008 to August 2009.  I was able to get it out for a few trail runs, however it was then stored away for the impending winter.  For a full breakdown of the build, (http://www.jeepkings.ca/forums/showthread.php?t=85078  // http://picasaweb.google.com/offroadin)

Stage II is to address the drivetrain. This being upgrading the axles, regear, lockers, going to a long arm system, upgraded steering, discs in the rear, belly up, tera 4:1.  I have acquired the Clayton LA system and a set of axles (HPD44/8.8 with 5.13's and ARB's) as i try and get my parts in order for stage II

Stage III is to address the motor, however this will only occur once the 2.5 fails me.

[ODTJ]

[ODTJ]

[ODTJ]

[Jesse-James]

Impressive! 

[Jeffy]

Very nice.  I never understood why the factory cheapened out and didn't bother painting the dash frame.  This goes back to the CJ though.

Did you ever think about moving the engine forward a but to give you additional drive length?  Are you going to consider stretching the wheelbase any with the new axles?

[sharpxmen]

that is awesome work 

the military paint and the black looks great btw, great choice.

[95yjman]

very cool! I like the look!

[stan98tj]

i really like the color...id often considered army green, but i have those black diamond plate covers on the side and fenders..dont think it would look so great with that.

[jagular7]

Yes, very nice. Seems you had a plan and pretty much stuck with it. Now, there are the pics, how about some tech, afterthoughts, should have and have nots, etc. Whose truss is on the new axles? They are surely quite different for the setup.

Lastly, Stage 3, would that come sooner than you think with all the hardware you've built in?

[ODTJ]

Did you ever think about moving the engine forward a but to give you additional drive length?  Are you going to consider stretching the wheelbase any with the new axles?

Not really.  If i do, it would be by streching the rear  but with that comes new sides, relocating/replacing gas tank,etc..... While I would love to do so at this stage as well as outboard the rear shocks and go coilovers Fr / Rear, my discretionary spending (READ: Wife) will just not allow it 

So, i will stick with the axle upgrade and keep everything else as is for now and wheel it for a year and see how it handles....

[ODTJ]

Yes, very nice. Seems you had a plan and pretty much stuck with it. Now, there are the pics, how about some tech, afterthoughts, should have and have nots, etc. Whose truss is on the new axles? They are surely quite different for the setup.

Yup, i pretty much did right from the start.  I do have included links to the full buildup on another forum as well as a complete photo file of the work done, however in a nutshell.

• 1997 TJ 5 spd
• Complete Frame off restoration.
           * Frame / all connected parts sandblasted and sealed with POR15, body completely rust free/painted OD Green.
           * All parts sandblasted/cleaned and repainted.
           * Most bolts replace with gr8's / Stainless steels
• Engine completely torn down, all gaskets replaced, every single part was degreased and painted/cleaned up.
• 2000 TJ Sahara interior.
• All interior panels sanded and painted OD Green and matte black
• 4.5" RE Superflex lift
• Quick disconnects
• D30/D5 with 4.10's and a locker in the rear
• 35"X12.5" Mickey Thompson Baja's / Procomp wheels with Beadlocks
• 1" Energy body lift
• All bushings replaced with Energy bushings (Sway bar, track bar, coil isolators,etc...)
• Poison Spyder Rear Corner guards, PS 3" Front Flat Fenders, PSRicochet Side Rails
• Genright 3" Rear Tube Flares, Full LED light replacements (Front and rear), Relocated LED Licence plate bracket/light, Hood Louvers
• Warn Gas Tank Skid Plate, Warn Power Steering Skid plate
• AA SYE with Tom Woods Driveshaft
• 10000 lb Titan winch
• Novac TC Shift Kit
• Stainless Steel exhaust
• Custom Built front shorty bumper with integrated hitch
• Custom Built rear bumper with hitch and tire carrier

Recently acquired:
• Clayton 5.5" Long Arm System
• 1976 Ford HP D44 Front Axle, narrowed to ~62 inches. It has Rubicon express mounts along with some JRC bracing. It uses stock rubicon 44 width shafts, so its easy to buy replacements. The inner shafts are alloy USA evolution series shafts, the outers are stock and it has mile marker lockouts. It has 5.13 gears and a ARB air locker. Trussed with TNT bracketry.  Brand new u joints / bearings / dust seals / carrier bearings and pinion bearings / ball joints, all the seals, and the brakes, nothing is more than 1000 miles old.
• Rear is a 98 ford 8.8, matching 5.13s and a ARB air locker. It has treks off-road u bolt eliminators (1 inch lift ones I believe) and high clearance shock mounts. It also has a custom truss and the tubes have been welded to the housing. All brake components are brand new as the previous owner bought the setup without brakes. All the bearings and seals have about 1000 miles on them. Comes with a set of spidertrac wheel adapters than set it out at the same width as the front and make it 5on 5.5 bolt pattern like the front.
• JRC one ton steering. It is set up under the knuckle and reamed out pitman arm. The trac bar was custom made by JCR. The mount is very heavy duty and it used a adjustable hiem joint on the axle side and a bushing on the frame side.

Lastly, Stage 3, would that come sooner than you think with all the hardware you've built in?

It'll only come once something brakes.  Honestly, i don't really need a rip-snorting setup.  Just as long as it allows me to offroad with consistency, i am happy.  After using it a few times this summer, i knew that i had to re-gear.  So, rather than re-gear the D30/D35, i felt it was an opportune time to upgrade the axles...  

Cheers,

[aw12345]

Sweet setup. you like the gearing, might want to think about chromoly stub shafts though the stock ones aren't much stronger than stock dana 30 outer shafts

[Tsd]

Great work!!!

[jagular7]

.....snip.....• Rear is a 98 ford 8.8, matching 5.13s and a ARB air locker. It has treks off-road u bolt eliminators (1 inch lift ones I believe) and high clearance shock mounts. It also has a custom truss and the tubes have been welded to the housing. All brake components are brand new as the previous owner bought the setup without brakes. All the bearings and seals have about 1000 miles on them. Comes with a set of spidertrac wheel adapters than set it out at the same width as the front and make it 5on 5.5 bolt pattern like the front.

ubolt eliminators represent leaf sprung. Since they look like they are on top, it should be a plate that is welded to the diff with 4 holes. Then another plate goes on top with the leafs between them. Leafs are secured to the base plate with 4 bolts. Going to go leafs or the LA you recently got?