Tearing YJ apart and rebuilding - Page 16 - JeepForum.com

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post #226 of 282 Old 05-29-2010, 05:34 PM Thread Starter
hotelconucc93
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Took the doors out of storage today to get them ready for repaint, etc.

I remembered that the door strap footman loop were torn out by PO, and he tried to redrill next to them and they pulled out also. Here is the footman holes torn out and broken off, twice.



Next I tried to take the OLD bolts out but no luck, so I cut them out to allow room to work.



Then cleaned area up for welding and took sheet metal and put 1/4-20 grade 8s on to the footman loop after givng the loop just enough benchgrinder touchup to allow hex 1/4-20 to turn on top and drilled the holes with a 1/4 drill to make them fit in. Little tiny footman mod...hardly noticable even when holding it.



Then welded nuts to the sheet metal when all together, then set and welded sheet metal.



Quick prime and paint to protect until I strip entire doors. Next took the $40 a pair ABS plastic door panels and didnt attach yet, but set them on to admire and plan final paint.






Axles and bolts and springs....Oh My!

My Build Thread --->>>
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Not my write up, but now one of my jeeps losing a BA and gaining an AX->
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post #227 of 282 Old 05-29-2010, 07:54 PM
KA24DET95
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keep up the good work!!!

If guns cause crime, all of mine are defective.
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post #228 of 282 Old 05-29-2010, 08:29 PM
samsonitesamson
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where'd you get those plastic door panels?

When thou walkest through the fire, thou shalt not be burned; neither shall the flame kindle upon thee ~ Isaiah 43:2 ~



Quote:
Originally Posted by Bnabb View Post
it bolted right up, except one bolt but i didn't need it anyway
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post #229 of 282 Old 05-30-2010, 06:55 AM Thread Starter
hotelconucc93
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ebay

NEW JEEP CJ7 WRANGLER YJ ABS Plastic Door Panels Doors: eBay Motors (item 350138486336 end time Jun-02-10 21:52:57 PDT)

Axles and bolts and springs....Oh My!

My Build Thread --->>>
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Not my write up, but now one of my jeeps losing a BA and gaining an AX->
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post #230 of 282 Old 06-02-2010, 03:37 PM Thread Starter
hotelconucc93
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LOL.

I figured I could do it, but I couldn't get the windshield glass out, in one piece.

Had to get to the frame to see if I could use POR15 on it, but it was TOO far gone. Holes x 100. My MIG would be a waste of time for the amount of metal needed.

Oconeeoffroad.com was cheapest for frame and glass even with all my coupons and ebates etc for other sites.

ALL I NEED TO DO IS PAINT AND I AM ON THE ROAD.

I gotta go get INS and REG done this week. Hopefully will be painted in the next week. I am ready and loosing patience fast. Want it done!!!!

Axles and bolts and springs....Oh My!

My Build Thread --->>>
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Not my write up, but now one of my jeeps losing a BA and gaining an AX->
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post #231 of 282 Old 06-02-2010, 08:14 PM Thread Starter
hotelconucc93
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Took it for about a mile drive today and xfer case test. I could NOT get the front axle to engage. Drove me nuts. I took the vac connect off and sprayed PB in the vacuum motor holes. Retried. No deal but found the light for 4wd was on during front axle in neutral. That's not supposed to be that way. So I farted around and figured that something must be wrong. Then I noticed that it went out in either front HI or LO. The switch was on in neutral I figured.

I knew the vac connection on the ATLAS was a keyed connection, IE it only goes on one way. I then took the front disconnect lines off and reversed them. The 4wd light went off in neutral and went on in gear. Then I applied tranny 1st gear and it worked!!!

Axles and bolts and springs....Oh My!

My Build Thread --->>>
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Not my write up, but now one of my jeeps losing a BA and gaining an AX->
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post #232 of 282 Old 06-02-2010, 09:24 PM
johnboy68
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It's great to see you're getting close! I got mine done before the holiday weekend and spent 3 days wheeling and camping. Had a great time.

After all the hard work it will feel wired when it's done (never done LOL) and you can just get in and enjoy it for a while.

I know your pain with the CAD. It took me a bit to get mine to work and had it working great on all my test drives. As soon as I got to the trail... put the t-case in 4 LOW and NO LIGHT! Got out my long vac hose so I could pull vacuum straight off the intake and still couldn't get it to engage so I gave up, hooked the lines up normally and went for it anyway. The Jeep did great and didn't spin a wheel even over a small rock garden. Come to find out it is engaging, my light just quit working. Always something to look into. Now I'm thinking up what I will work on next. I think it's going to be in the storage area as it's hard to get 3 people a dog and camping gear in the Jeep.

Can't wait to see your finished project!!

-John-

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post #233 of 282 Old 06-08-2010, 11:06 AM Thread Starter
hotelconucc93
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Did some more test drives and finally with the help of an electrician friend was able to get the break away and RV brake system operational, without constant drain on the battery even when off.

I have an EVENBRAKE system under the dash that wires to a break away under the bumper and ties into the brake switch under the pedal. Long story, but it was spliced in by the installer in such a way that it was ON all the time as it is for towing but it wasnt needen on and draining all the time when not towing. I needed a stock wiring jumper and a powered towing connection.



We mounted and wired a jumper under the hood by the coolant overflow. When the stock plug is in, it emulates stock wiring under the dash and brake system. When the plug is in that says TOW it gives dash power when key is out powering brake switch, lighter plug and brake computer.



Then today I mounted the XENON flat flares for test fit. I need to drill some new holes. The flares should line up for the money but they don't 100%, but they are sharp. They now come with support kit for the front flares to keep them from drooping in hot weather. Glad they fixed that.

After I drill the new holes they are coming off and the garage is being turned into a paint booth for Duplicolor Paint Shop Lacquer. I think its the worst stuff I could shoot, but I am not skilled at auto paint so if it lasts a few years, I will be happy and ready for the next round. The price is right, but I am not ready for AU or AE paint yet I don't think for the money needed to screw it up for my first paint job.








Axles and bolts and springs....Oh My!

My Build Thread --->>>
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Not my write up, but now one of my jeeps losing a BA and gaining an AX->
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post #234 of 282 Old 06-08-2010, 11:59 AM
8nine-sahara
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looks great

89 yj
06 lj
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post #235 of 282 Old 06-23-2010, 07:06 PM Thread Starter
hotelconucc93
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Got the main body painted, as well as hood and tail gate. Doors will come next. Got front bumper on as well as smitty winch plate. Added JEEP logo in red...nice...

Paint Booth in Garage



Primed



Hood and gate



Painted, 4.0 sticker, rear Xenon flares bolted on for good.



Added and tested lights. Added bumper, smitty plate, and plate.



JEEP FTW


Axles and bolts and springs....Oh My!

My Build Thread --->>>
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Not my write up, but now one of my jeeps losing a BA and gaining an AX->
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post #236 of 282 Old 06-24-2010, 05:50 AM
Mr.ThunderMakeR
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Looks great man!

Just curious, you have any sort of estimate on how much you've spent on this rebuild? I'm considering doing a complete rebuild of my 91 but I'm starting to think it might make more sense financially to buy a late model TJ that's in good condition and start from there.
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post #237 of 282 Old 06-24-2010, 07:05 AM Thread Starter
hotelconucc93
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Thanks. It's around 10K, but I have done more than a basic rebuild, so assume that to be on the high end.

I have a 2010 Jeep here, with square headlights....Squares float my boat....

Axles and bolts and springs....Oh My!

My Build Thread --->>>
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Not my write up, but now one of my jeeps losing a BA and gaining an AX->
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post #238 of 282 Old 06-26-2010, 11:51 PM
jakechristina
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Quote:
Originally Posted by hotelconucc93 View Post
Took the doors out of storage today to get them ready for repaint, etc.

I remembered that the door strap footman loop were torn out by PO, and he tried to redrill next to them and they pulled out also. Here is the footman holes torn out and broken off, twice.



Next I tried to take the OLD bolts out but no luck, so I cut them out to allow room to work.



Then cleaned area up for welding and took sheet metal and put 1/4-20 grade 8s on to the footman loop after givng the loop just enough benchgrinder touchup to allow hex 1/4-20 to turn on top and drilled the holes with a 1/4 drill to make them fit in. Little tiny footman mod...hardly noticable even when holding it.



Then welded nuts to the sheet metal when all together, then set and welded sheet metal.



Quick prime and paint to protect until I strip entire doors. Next took the $40 a pair ABS plastic door panels and didnt attach yet, but set them on to admire and plan final paint.



This is exactly what i have to do to both of my doors.Great job!
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post #239 of 282 Old 07-05-2010, 05:29 PM Thread Starter
hotelconucc93
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Well, other than painting and hanging the doors...here she is.

She now has 200 miles on the new powetrain.







Tune in next time for the doors...and front axle seal replacement.

Axles and bolts and springs....Oh My!

My Build Thread --->>>
To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.


Not my write up, but now one of my jeeps losing a BA and gaining an AX->
To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
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post #240 of 282 Old 07-05-2010, 08:43 PM
JasonRumler
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Man, I gotta tell you that it looks awesome. I can't wait til I can do that with my YJ. Hoping to start that in Dec-Jan. Looks awesome, good job!
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