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Unread 02-04-2013, 07:41 AM   #46
Que89YJ
Web Wheeler
1989 YJ Wrangler 
 
Join Date: Apr 2008
Location: Detroit, Michigan
Posts: 15,006
I think you need to dump that BA 10. That is way too much torque for it. Love the build!

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Unread 02-04-2013, 11:36 AM   #47
91BoD
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1991 YJ Wrangler 
 
Join Date: Apr 2010
Location: Marysville, WA
Posts: 644
Quote:
Originally Posted by Que89YJ View Post
I think you need to dump that BA 10. That is way too much torque for it. Love the build!
He is using an NV3550
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Unread 02-11-2013, 07:01 PM   #48
Homebrewed2
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1989 YJ Wrangler 
 
Join Date: Jul 2012
Location: Brighton, MO
Posts: 57
Bad News

I picked up a few more things on ebay one being a shifter for $75, it is set up for a bronco but I think it will work. I also got a new clutch kit for $50. I got my 8.8 with 3.55 ratio for $200 from a local salvage yard.
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I installed my sye from jb conversion, the insides looked good so I replaced a few seals and reassembled it.
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I mocked up the 8.8 and started setting my pinion angles. With the rear end pointed at the output shaft my angle is a little to steep for a cv shaft. I think I am going to drop the engine and transmission down 1-2 inches to help with the angles.
dscn1428.jpg
I will not have a flat skid plate but a couple inch drop is still better than stock. I don't think I am going to use a 1" body lift.
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Unread 02-11-2013, 07:28 PM   #49
140mower
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1989 YJ Wrangler 
 
Join Date: May 2009
Location: Lillooet, British Columbia
Posts: 220
Before you set your pinion angle I believe you should put some wheels on it and get it on the ground so the springs can sit at there "run" height. It's going to take some fiddling, so be patient. I'm sure if I'm wrong it'll soon be pointed out.
Looking forward to seeing how things work-out when finished, (also secretly looking forward to the demise of the wife's TDI VW so I can have a donor motor myself).
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Unread 02-12-2013, 07:14 PM   #50
Homebrewed2
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1989 YJ Wrangler 
 
Join Date: Jul 2012
Location: Brighton, MO
Posts: 57
I put some blocks under the springs and set the weight of the frame and body on them before I did set the angle. I might reuse a Cherokee front cv drive shaft but it didnt look like it had that much flex.
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Unread 02-24-2013, 05:32 PM   #51
Homebrewed2
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1989 YJ Wrangler 
 
Join Date: Jul 2012
Location: Brighton, MO
Posts: 57
No end in sight

I am a firm believer you get what you pay for. That being said I always wanted a plasma cutter but didn't want to spend $1000-1500 for one. That being said I found Simadre plasma cutters on ebay for going for $300. I looked into them and didnt find a whole lot of bad reviews so I decided to get one. It does have a few things that need changed, the air line is cheap and leaks and the ground clamp cable is super short. The thing actually works pretty good.
dscn1429.jpg
It made quick work of the old shock tower and I tacked on the new ford shock mounts.
dscn1430.jpg
I ended up cutting off the first set of motor mounts and remaking them out of 1/4" plate about 1 1/2" lower than the first.
dscn1431.jpg
I ended up dropping the transfer case mount a little over 2" inches. I need to gusset up the cut but I think they should work.
dscn1432.jpg
I pulled the tub off to finish welding all my mounts I have added.
dscn1433.jpg
And to fix the rust on the rear of the frame and skid plate bolts.
dscn1435.jpg
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Unread 03-10-2013, 07:59 PM   #52
Homebrewed2
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1989 YJ Wrangler 
 
Join Date: Jul 2012
Location: Brighton, MO
Posts: 57
Rust

The drivers side rear rail was rusted the worst. I cut off the rear bumper mount with the plasma cutter for access to the rails. The amount of rust inside the rails was amazing. The top of the frame rail was okay so I saved it but cut out the rest and welded in some new metal and welded in tubing for bigger bushings. I also burned in the shock tower, transmission cross member and shackle reversal bracket.
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The cross member above the rear axle has some rust around the body mount holes I need to repair the rest is about done. I have decided if if want to paint or powder coat the frame. Any ideas?
dscn1441.jpg
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Unread 03-10-2013, 09:09 PM   #53
amiller
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2005 TJ Wrangler 
 
Join Date: Jan 2006
Location: Omaha, Nebraska
Posts: 854
I'm really enjoying the build. Your Jeep is going to be awesome. Out of curiousity, how much is WFO paying you for all that advertising?
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Unread 03-11-2013, 04:13 PM   #54
Homebrewed2
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1989 YJ Wrangler 
 
Join Date: Jul 2012
Location: Brighton, MO
Posts: 57
I wish they were sponsoring me that would help a bunch.
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Unread 03-30-2013, 08:23 PM   #55
Homebrewed2
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1989 YJ Wrangler 
 
Join Date: Jul 2012
Location: Brighton, MO
Posts: 57
More rust

The cross member for the front of the tank was starting to rust out around the body mounts.
dscn1444.jpg
dscn1443.jpg
I thought about cutting out the rust and patching it or buying a replacement cross member bur I decided to make one instead.
dscn1446.jpg
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dscn1449.jpg

The frame around the skid plate mounting bolts was a chewed but so decided to cut it out and replace it. Looks like a mouse enjoyed living in the frame railed for a while.
dscn1452.jpg
I welded in some patch panels and installed new rivet nuts for the new skid plate.
dscn1453.jpg
I ordered a new rear cross member from gen right off road, once I get it I will post some more pics!
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Unread 04-21-2013, 05:47 PM   #56
Homebrewed2
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1989 YJ Wrangler 
 
Join Date: Jul 2012
Location: Brighton, MO
Posts: 57
Check frame repair off the list.

After a 11 pound spool of welding wire I finally have the frame ready to go to the sand blaster, if the weather holds I plan on taking it in on Friday and hopefully get the frame painted next weekend. Since I cut the rear cross member off to fix the rest I didn't want to reuse it since it was bent and rusted. I happen to stumble upon Gen Right's rear cross member. It is really designed to go over the original as a cap but it is nice and thick 3/16.
dscn1463.jpg
Since is was designed as a cap it didn't have a place to bolt up the fuel tank skid plate. I bent up a piece of 3/16 and drilled new holes.
dscn1464.jpg
I figured I will take the front axle and have it sand blasted with the frame, I didnt want to try and clean clean it with a wire wheel with all the irregular shapes.
dscn1461.jpg
It was quite a battle to get the ball joints out, the tops came out using a 3' breaker bar with a 2' pipe as a cheater. The bottoms where not so easy I had to make relief cuts in the them to get them to come out.
dscn1462.jpg
I got most of the parts in for my 8.8. looks like somebody forget to release the parking brake, both set are shot.
dscn1467.jpg
I installed the Aussie locker, welded up the spring perches, shock mounts, extended bump stops and also the tubes.
dscn1468.jpg
The diff cover is nice and thick. All I need is brake pads and shoes and to make up some brake lines and the rear should be ready to go.
dscn1469.jpg
Hopefully next weekend I will get the frame painted and start assembling it!
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Unread 04-28-2013, 06:13 PM   #57
Homebrewed2
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1989 YJ Wrangler 
 
Join Date: Jul 2012
Location: Brighton, MO
Posts: 57
And I thought I was done welding

Well it rained Friday so I didn't take the frame to the sand blaster but I got impatient and bought some flapper grinding disk and stripped the frame.
dscn1473.jpg
I thought the rear shock mounts were okay, they had some rust but didnt look to bad. Once I cleaned them out I found pin holes in the frame.
img_0218.jpg
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I planed on making new shock mounts but when i cut the old ones off they were in decent shape so I cleaned them and reused them with a little modification.
dscn1471.jpg
dscn1472.jpg

I sprayed the inside of the frame with Eastwoods Rust encapsulater for a little extra protection. I sprayed the outside with their 2k ceramic frame paint.
dscn1476.jpg
dscn1477.jpg
Finally I can start putting this thing together.
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Unread 04-28-2013, 07:24 PM   #58
Que89YJ
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1989 YJ Wrangler 
 
Join Date: Apr 2008
Location: Detroit, Michigan
Posts: 15,006
Its really coming along.
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Unread 04-29-2013, 08:09 AM   #59
aleh17
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1990 YJ Wrangler 
 
Join Date: May 2012
Location: San Jose, Costa Rica
Posts: 68
Nice work! keep it up, can't wait to see the finished product. And wow it really looks like a mouse lived there for a while, lol.
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Unread 04-30-2013, 10:26 AM   #60
jamesmc
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1989 YJ Wrangler 
 
Join Date: Oct 2011
Location: Sooke, BC, Canada
Posts: 17
Still following this thread. Since you started it I've moved from Portugal to Canada and brought my 1989 YJ 4.2 with us.... couldn't leave a family member behind
Keep the updates/pictures coming great work and a great read!!
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