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XJ Rail Sale!The Ruffstuff NOT Universal 4 Link Kit!Vanco Big Brake Kit Promotion!

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Unread 11-06-2014, 09:48 PM   #1
dillonjm
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Marshal's 03 Rubi

Just got back from deployment and it's time to start working on my Jeep. Everyone has build threads so I'm going to keep one for this too.

Here are my previous rigs:

EDIT: found some pictures of my first two Jeeps, the 99 was my first I got when I was 17, the CJ I bought for $500, stretched it on a 19 year old budget and beat the hell out of it. It was a piece of junk but fun, looking back I'm somewhat embarrassed by my fab work back then (apparently it CAN get worse than it is now)...taught myself to weld on that rig.

99 TJ on 4.5" RE and 33s:



78 CJ7 on Dakota leaves and 35s:



91 YJ on 35's:



01 WJ on 37's:




Here is the current rig as I got it:




And as it sits now (21 Nov 14):



List of parts in the garage:
Clayton arms
3" Currie Coils
Bilstein 5100s
Metalcloak Overlines/rockers/rear tube flares
New body mounts w/1" lift
UCF higher clearance skid
Brown Dog 1"MML
Genright plate rear bumper
New set of 35" MTRs
Allied Raceline 17" bead locks
ORFab rear tire carrier
Spare set of Ten Factory front and rear chromoly shafts

The overall plan is to lower the rig a little and keep it on 35's while changing out some of the POs build choices for ones I like better. Also going to be getting the preventative MX back up to speed as I go.

This TJ isn't going to be anywhere near as big of a build as my WJ was. Just going to keep it moderate and reliable. Eventually I'm going to swap out the factory lockers for ARBs as well but not sure I'll get around to that before I head to Korea for a year.

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03 Rubicon (Weekend Toy) Build thread

11 Ram 2500 - 6.7 Cummins (DD/Tow Rig)

05 Liberty Limited (Wife's): Minor mods, OME/JBA Suspension, 245 70/17 Duratracs
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Unread 11-06-2014, 10:46 PM   #2
gmc01redtj
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first: BIG! thank you for your service
second: sweet rigs
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Unread 11-07-2014, 10:54 AM   #3
dillonjm
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Quote:
Originally Posted by gmc01redtj View Post
first: BIG! thank you for your service
second: sweet rigs
Thanks!

In the interest of cleaning up some garage space and pulling my BFGs off for a buddy, I'm starting by mounting the tires to the wheels.

First one mounted up.


Also swapped the stinger onto my buddies YJ:
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03 Rubicon (Weekend Toy) Build thread

11 Ram 2500 - 6.7 Cummins (DD/Tow Rig)

05 Liberty Limited (Wife's): Minor mods, OME/JBA Suspension, 245 70/17 Duratracs
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Unread 11-07-2014, 05:57 PM   #4
dillonjm
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Finished the 4 I needed to pull my old wheels and tires:


Off go the old tires...think he needs another inch or two STS:


Then I pulled mine into the garage for suspension work.
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03 Rubicon (Weekend Toy) Build thread

11 Ram 2500 - 6.7 Cummins (DD/Tow Rig)

05 Liberty Limited (Wife's): Minor mods, OME/JBA Suspension, 245 70/17 Duratracs
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Unread 11-09-2014, 12:06 PM   #5
dillonjm
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Pulling the RE stuff off the rig, oh how I hate their design of the crossmember. Got the driver brackets off and now I'm starting to burn new control arm brackets in:

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03 Rubicon (Weekend Toy) Build thread

11 Ram 2500 - 6.7 Cummins (DD/Tow Rig)

05 Liberty Limited (Wife's): Minor mods, OME/JBA Suspension, 245 70/17 Duratracs
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Unread 11-09-2014, 03:39 PM   #6
dillonjm
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Finished burning in the driver side brackets. I started with Clayton brackets but I didn't like how little of the frame they actually welded to so I made some gussets out of some scrap 1/4" plate for inside the frame rail:



I also added some 1/4"x4" plates to the outside of the frame above the brackets for a little more reinforcement. I'm sure without the plates and gussets they would be fine but I feel better with them in there. Here they are burned in..ignore the missing body bolt, that's on the list too, have two that need repair:



One small hiccup. The rear upper Clayton arms that were on the Jeep (that I was hoping to reuse) have different size joints than the current design and they aren't double adjustable which I would like. So I'm either going to buy new rear upper arms or buy 4 new joints and build my own uppers. Will see how much new arms cost vs new joints and tube inserts tomorrow and decide which route to go.
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03 Rubicon (Weekend Toy) Build thread

11 Ram 2500 - 6.7 Cummins (DD/Tow Rig)

05 Liberty Limited (Wife's): Minor mods, OME/JBA Suspension, 245 70/17 Duratracs
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Unread 11-09-2014, 05:06 PM   #7
dillonjm
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Driver arms (sans rear upper) are in. They are a little shorter than the RE arms 34.5" front lower vs 38" for the RE and 31" vs 33.5" for the rear lowers which is good. I debated building my own mid arms at around 25-27" but I ran Clayton arms on my WJ and really liked them so went that route with the TJ too. Apples to Oranges but there it is. Plus having pre-built powder coated arms waiting for me when I got home was nice, with a 15mo old time is more valuable to me than the price difference. Been working on the TJ during nap times.

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03 Rubicon (Weekend Toy) Build thread

11 Ram 2500 - 6.7 Cummins (DD/Tow Rig)

05 Liberty Limited (Wife's): Minor mods, OME/JBA Suspension, 245 70/17 Duratracs
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Unread 11-09-2014, 05:56 PM   #8
grogie
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Looks like some good progress during nap time.

Thanks as well for your service. Enjoy!
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Unread 11-10-2014, 05:09 PM   #9
dillonjm
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Thanks, I will be enjoying my time off before getting back to the grind.

Wife had some work calls today so in an effort to keep the noise down I started on the front fenders this afternoon. Pain in the butt to get to the firewall bolts but it's off. Looks naked.



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03 Rubicon (Weekend Toy) Build thread

11 Ram 2500 - 6.7 Cummins (DD/Tow Rig)

05 Liberty Limited (Wife's): Minor mods, OME/JBA Suspension, 245 70/17 Duratracs
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Unread 11-10-2014, 06:39 PM   #10
dillonjm
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Not aligned or tightened yet but got the passenger fender on before dinner.



And a couple hours later...passenger side done:



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03 Rubicon (Weekend Toy) Build thread

11 Ram 2500 - 6.7 Cummins (DD/Tow Rig)

05 Liberty Limited (Wife's): Minor mods, OME/JBA Suspension, 245 70/17 Duratracs
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Unread 11-11-2014, 06:11 PM   #11
dillonjm
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Didn't get much time with the Jeep today, did mount up the driver side fender.

All done:


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03 Rubicon (Weekend Toy) Build thread

11 Ram 2500 - 6.7 Cummins (DD/Tow Rig)

05 Liberty Limited (Wife's): Minor mods, OME/JBA Suspension, 245 70/17 Duratracs
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Unread 11-11-2014, 06:19 PM   #12
LeeMasterGT
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Definitely going to be keeping track of this build! Your parts list has a lot of the same stuff mine did. Interested in your opinion on how everything works together. Looks great so far!
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Unread 11-11-2014, 06:44 PM   #13
dillonjm
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Thanks!

The parts I needed to redo my rear upper arms came in today so I should have most of this wrapped up this weekend assuming I get motivated enough. I'll let you know what I think once I get it together.
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03 Rubicon (Weekend Toy) Build thread

11 Ram 2500 - 6.7 Cummins (DD/Tow Rig)

05 Liberty Limited (Wife's): Minor mods, OME/JBA Suspension, 245 70/17 Duratracs
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Unread 11-11-2014, 07:06 PM   #14
billiebob
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Nice work. Love the high line MetalCloaks.
And really like the extra gussets you added. Yours would be one of the few modified Jeeps I would not hesitate to buy... if it was fer sale.

Yer buddies white YJ is sweet. Makes me wish I never sold mine.
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Unread 11-12-2014, 06:15 PM   #15
dillonjm
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Removed the last of the RE brackets and welded in the passenger side suspension brackets. Didn't take pictures of that, it's just a mirror of what I did on the driver side with the exception that I had to replace two of the frame nuts where the skid plate attaches, they had rusted to where they stripped out.

My technique for repairing those if you don't have new nutserts is to cut off the head of the existing nutsert, tap out the old sleeve, drill out the hole to accept a new nut/washer that I've welded together (or you can use a flange nut) then weld the new one to the frame. Easy fix assuming the frame itself is in good shape.

As for the rear upper arms, here was my remedy for the wrong size joints on the frame side:





Cut off the old smaller Johnny joints and about 3.5" off the length of the arm to accommodate adjustment. Then welded in new tube inserts that will work with the larger joints. The second picture is a finished picture of the modified arm (on the left). I didn't replace/rebuild the axle side joint as it was already the larger 2.5" joint and seems in good shape still.
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03 Rubicon (Weekend Toy) Build thread

11 Ram 2500 - 6.7 Cummins (DD/Tow Rig)

05 Liberty Limited (Wife's): Minor mods, OME/JBA Suspension, 245 70/17 Duratracs
dillonjm is online now   Reply With Quote Quick reply to this message
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