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04Overland47 08-14-2012 07:50 PM

04Overland47's WJ Build Thread
 
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Okay, so I have been contemplating making a build thread and have finally decided to do it! Kind of regretted not doing it with my red Overland (Jenny) so I'm going to do it for my gray one (Kelly).

I don't plan to do too much to her (mainly because I don't have the money after recently purchasing a 98 ZJ niner), just minor fixes and modifications that make her look/sound nice!

Here she is the day I picked her up:
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Notice the 02-03 Overland leather center console lid! She came with a black Laredo/Limited mesh one so I had to swap that out quickly :2thumbsup:

04Overland47 08-14-2012 08:01 PM

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Here is Kelly with the recently purchased niner, still thinking of a name for her
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04Overland47 08-14-2012 08:02 PM

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Of course one of the first things I had to do was detail the engine bay...who doesn't like a clean engine??
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04Overland47 08-14-2012 08:06 PM

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Next was a Powerstick muffler to give the 4.7 a nice throaty sound. Muffler was a medium length Powerstick 2.5" in/outlet 3.5" body diameter. Highly recommended!!
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04Overland47 08-14-2012 08:10 PM

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Now for the dirty bits...changed the transfer case fluid and the differential fluids:
Transfer case was beyond BLACK :( New fluid in cup for comparison.
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The diff fluid wasn't much better, but definitely not as bad. Fluid used was Redline 75w-140 for both diffs. No additional friction modifier needed for the Variloks
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04Overland47 08-14-2012 08:13 PM

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Got some new lights for her. Really nice at night, no yellow haze like the factory lights Attachment 452959 Attachment 452960

04Overland47 08-14-2012 08:15 PM

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Got a t-shirt made in Wildwood for her, pretty self-explanitory haha
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04Overland47 08-14-2012 08:17 PM

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First time off-roading!! Flexing the stock suspension, pretty good if you ask me!
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04Overland47 08-14-2012 08:20 PM

Currently in the process of restoring the Overland rock rails. Will post a step-by-step procedure on how to remove, clean, prep, and paint them once finished.

snobrdrkid07 08-15-2012 08:31 PM

Yes, first post haha! I am glad you made one, its fun to keep track of what you have done to your Jeep. Also, to share it with everyone! That transfer case fluid was horrid dude.

04Overland47 08-15-2012 08:54 PM

Quote:

Originally Posted by snobrdrkid07 (Post 14027013)
Yes, first post haha! I am glad you made one, its fun to keep track of what you have done to your Jeep. Also, to share it with everyone! That transfer case fluid was horrid dude.

Thanks man, really appreciate it! Yeah, it was pretty bad, but I've replaced the fluid once more since then in hopes of cleaning it out.

snobrdrkid07 08-15-2012 10:07 PM

Oh you are welcome! I can't wait to see where it goes. Sometimes a slow start but keeps going and going!

04Overland47 08-15-2012 11:29 PM

Quote:

Originally Posted by snobrdrkid07
Oh you are welcome! I can't wait to see where it goes. Sometimes a slow start but keeps going and going!

As evident with yours haha. Don't have any BIG plans in the near future, but perhaps a lift down the road :thumbsup:

snobrdrkid07 08-17-2012 12:16 AM

Perhaps! But everyone loves pictures! Awaiting the rock rails when you get them done!

04Overland47 08-17-2012 04:56 PM

Overland Rock Rail Restoration!
 
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This will be a step-by-step “restoration” process for the factory rock rails on my Overland. I will show how to remove them from the frame, disassembly, preparation for painting/rust removing, and using Duplicolor Truck Bedliner to paint them black. It’s a good project to take on if your rails are sun faded, rusted, or you just want to give them a different look! Takes about 2-3 days to do it right. Shout out to Compcrasher86 for the idea and great advice:thumbsup:

Things you will need:
” socket
5/16th socket
PB blaster
Purple Power degreaser
1 can of Rustoleum “Rust Reformer” (depending on how much rust you have)
2 cans of Duplicolor Truck Bedliner

Removing the rails from the frame of the Jeep is a very easy process. There are 6 bolts holding each rail (3 on each end) to the frame. Spray some PB blaster on the bolts and let it soak for a little, then remove each of the bolts using the 1/2” socket.
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Once the rails are removed from the frame, note the bolts holding the mounting bracket to the rail itself, these are also ”. Next, note the 2 screws holding the end caps to the rail, these are 5/16th.
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To apply the bedliner to all the parts, it would be best to disassemble everything and paint each piece individually. I attempted to do so, but broke the head off one of the bolts that holds the mounting bracket to the rail (pictured below).
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Therefore, I just removed the end caps, leaving the mounting brackets attached to the rails.
At this point, I noticed a good amount of rust where the end caps meet the rail.
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This is where the Rust Reformer comes in. This product is made to bond to the rust and “reform” or “transform” it into a paintable surface while preventing future rust. First, I sanded the major rust spots using 150-grit sandpaper. After a few minutes of sanding, I noticed that the rust didn’t penetrate the metal too far which was good! Next, I sprayed the whole rail with Purple Power and wiped it down with a microfiber cloth to get rid of the fine dust and grease. Finally, I sprayed one coat of the Rust Reformer on the areas I sanded down. (Some people might want to spray the entire rail with this product if the whole rail is compromised with rust) Let this dry over night to ensure a good bond.
After taking care of the rust on the rails, I still had a good chunk of the day left so I decided to clean/sand/paint the end caps. I followed this process: degrease, sand, degrease, paint. Four easy steps that make a big difference! First, wiped down all the caps to get rid of grease and dirt, then sanded them using 150-grit sandpaper, degreased again, and finally painted using the Duplicolor Truck Bedliner. Now, I did decided to tape off the inner portion of the caps (pictured below) since each cap indicates it’s placement on the rails (FR, FL, RR, RF) and the bedliner would cover that. This part is of course, optional.
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Finally, I decided to do 3 coats because A) I liked the texture and B) it would provide more protection since the caps are just plastic.
Attachment 454718 That wrapped up day 1!:highfive:


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