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Unread 08-15-2014, 11:52 AM   #1
jimmay
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1999 WJ 
 
Join Date: Feb 2013
Location: Chicago Ridge, IL
Posts: 62
Jimmays WJ Build Log

Alright, I've been saying I was going to do this for a while, and never got around to it. I bought the Jeep last year in Febuary. It had 123k on the odometer, and now she sits at 153k. I've done nearly all the work, bar the welding, which is what I'm trying to learn now. It has a 3 inch IRO lift, Bilstein 5100s, Trans go shift kit, 242HD swap, Akebono swap, factory armor, a set of Treadwright Claws. Ive replaced a ton of parts(radiator, bushings, steering gear box, balljoints, tierod ends and and links, hubs, pinion bearings, motor mounts(do yourself a favor and buy the mopar ones) you name it.)Basically the first couple of posts are going to be catch up from the last year and a half.

When i first brought her home


Ditched the crappy street tires for the Treadwrights and then went wheeling for the first time.

Highcentered, but I was able to free myself(This is at the Cliffs Insane Terrain)


Then I decided to crush my rocker panel


I was tired of the Claws rubbing on my front bumper, so i trimmed the fog lamps out.


Then I just took the bumper off completely(Still running it like this)( Badlands in Indiana)


This is from the last wheeling trip


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Unread 08-15-2014, 11:52 AM   #2
jimmay
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1999 WJ 
 
Join Date: Feb 2013
Location: Chicago Ridge, IL
Posts: 62
Floor board rust repair

I made the mistake of buying a WJ that has spend its entire life in Chicago. Sometimes I think the P.O. parked this thing in the ocean and let it sit there for a few weeks.

I a rust hole in my wheel well, which I cant find the pictures right now, but it was allowing water to pool on my drivers side floor board. So I pulled the interior out, and went to work.

Drivers floor board. Between wire wheeling and scraping, I was able to get it clean. I coated it in RustOleum rust converter, and then bedliner. We'll see how well it holds up.


When I got to the passenger side, I noticed a nice little rust bubble. So I did what most people would do, hit it with a hammer.


Hit it a few more times, and then the brace that ties the unibody rail to the rocker and also has the bolt on it for the seat, committed suicide.




So then I cut out the cancer


Cut a new piece and had it welded in


Then had the patch panel welded in


Boom, no more hole!
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Unread 08-15-2014, 11:53 AM   #3
jimmay
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1999 WJ 
 
Join Date: Feb 2013
Location: Chicago Ridge, IL
Posts: 62
Suspension

After replacing all the tierod ends, balljoints, and bushings, I still had clunk. I eventually narrowed it down to the front sway bar bushings.

Old vs New

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Unread 08-15-2014, 11:54 AM   #4
jimmay
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1999 WJ 
 
Join Date: Feb 2013
Location: Chicago Ridge, IL
Posts: 62
Quarter Panel rot repair

When i pulled my rear bumper off to replace my rotted gas tank skid, the jeep had another surprise for me. My quarters were rotted beyond belief. I covered the holes in duct tape to try and stop more water from getting into the cab. Now I need to fix them. Ive seen what a few members have done with the quarters, and Ill probably copy what they have done. But this is what im looking at now.

Completely gone


I hate salt


Why....
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Unread 08-15-2014, 12:07 PM   #5
jimmay
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1999 WJ 
 
Join Date: Feb 2013
Location: Chicago Ridge, IL
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Electronics/Audio

reserved
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Unread 08-15-2014, 12:15 PM   #6
mxjosh
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Did you extend your bump stops? I have similar set up, but with JK take offs and wheels spacers and a 3/4" spring spacer up front and haven't tried wheeling it yet, so just curious if you had any rubbing issues. Looks good!
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Unread 08-15-2014, 12:27 PM   #7
jimmay
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Location: Chicago Ridge, IL
Posts: 62
Quote:
Originally Posted by mxjosh View Post
Did you extend your bump stops? I have similar set up, but with JK take offs and wheels spacers and a 3/4" spring spacer up front and haven't tried wheeling it yet, so just curious if you had any rubbing issues. Looks good!
No, I have not. I massaged the front of the rocker with a mini sledge. The first time i disconnected the front sway bar i ripped the washer motors out of the bottle. In the rear the tires and the wheel well tried to become one. The wheel well ended up taking chunks out of the outer lugs. Im going to be cutting a lot back there soon, and Im going to open up the rear wheel wells.

Even if i wanted to extend my rear bump stops, they have rotted need to be cut out and replaced. Its on my to-do list, just haven't gotten around to it
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Unread 08-16-2014, 04:10 PM   #8
jimmay
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1999 WJ 
 
Join Date: Feb 2013
Location: Chicago Ridge, IL
Posts: 62
Rear frame rail crack

I also noticed this when I was under there.





Any ideas? What I think I'm going to do is, clean up as much rust as possible, fill in the crack with a welder, and then sleeve the rail( stitch welding, but should I also cut out some holes in the sleeves and have it plug welded?). Then paint it all.

Any thoughts or ideas are welcomed. I plan on fixing this when i raise the gas tank and get rid of the spare tire well. I figure there will be more room to work then.
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Unread 12-14-2014, 03:57 PM   #9
jimmay
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1999 WJ 
 
Join Date: Feb 2013
Location: Chicago Ridge, IL
Posts: 62
I havent been updating this regularly. Since my last post, ive repaired the rear quarter panels( no pics right now, but ill get some) installed some A-pillar lights, and cut out my rockers and trimmed the rear wheel wells.

The rockers were a bear, but I am pretty happy with how it came out. The jeep feels more solid now too. Im going to add some braces soon, and maybe a side bar( like the JKS rock sliders have)

Cutting the old rotted, and smashed rockers out.




I grinded what I could clean, and POR-15ed it


Mocked up


I ended up taking it to a welding shop near my house to have them welded on.


I will also have some more trimming to do in the spring.
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Unread 12-14-2014, 11:30 PM   #10
jimmay
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1999 WJ 
 
Join Date: Feb 2013
Location: Chicago Ridge, IL
Posts: 62
When I'd stuff the tire, it would catch on the wheel well right after the door. This bastard piece ended up cutting up all of the outside lugs on my tires. It was time for a new set, so before I mounted them, I trimmed it. I did it a bit differently than most. I didn't touch the top part, as I never had a problem there and I don't plan on running anything bigger than a 33( I have 32s now).

I pie cut the wheel well and i actually found that separating the inner and outer piece made the second side easier. Then I folded the inner flap, tacked it, folded the outer flap, and then tacked that. Then i went around and made sure it was welded together, grinded it clean, primmed it, and then covered it up with fiberglass. After a lot of sanding, and some body filler, I then primmed it a few more times, and painted it. This was the first time I've ever done any sort of body work. Overall, I'm happy with it.











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Unread 12-14-2014, 11:43 PM   #11
jimmay
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Location: Chicago Ridge, IL
Posts: 62
Here are the a-pillar lights. The brackets are from Farmer Johnson offroad. They are super stout. I ordered the lights off Amazon. Im satisfied as they only get occasional use only.







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