1995 YJ to CJ / Flat fender rebuild - JeepForum.com
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post #1 of 46 Old 03-15-2017, 09:05 PM Thread Starter
Firefyteremt
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1991 YJ Wrangler 
 
Join Date: Mar 2017
Posts: 45
1995 YJ to CJ / Flat fender rebuild

I have been working on my all original paint, 95 YJ over the winter and thought I would share photos of the build. I am a big fan of the CJ front clip, but decided to go with a set of flat tube fenders for this build to gain wheel clearance over the CJ style flares. I have 5/8"boom shackles and the 1" body mount lift to help the CJ front. If I went to the CJ flares, I would have to lift it at least 2" just to clear the 31's that are on it now.

To this point I have replaced the front floor pans and replaced the rockers with custom 16ga steel. I had to hand fab the front pillars, and been building the tube fender kit just the way I want them. I have installed the CJ grille along with a new hood and repaired the rust on the tailgate.

When replacing the floors I tied in the roll cage to the frame and sandblasted the inside floor pan. The cage is more of an extension to the factory bar than a real cage, but it is in mainly to allow me to drop the windshield in the summer. The cage allows me to keep a rear view mirror as it is on the cage, and honestly.. a YJ with a family cage just looks bad with the front bars removed and the windshield folded. (it's an odd look that my 91 with the slant back roll bar did not have. The square shape is too far back and looks odd with the family cage) The cage is mounted much like a factory body mount. I used some left over poly bushings and added some round stock to the bottom of the cage tubing. It will bolt with 1/2" grade 8 bolts through the floor and to the frame brackets. The frame mounts also wrap the top of the frame and are fully welded on.

The inside will get a sprayed in Spice Monstaliner and the outside repainted in that dark 95 YJ green.... I plan to keep the full interior and carpet (My Jeep is more of a daily driver than a wheeling rig) but I wanted to color key the interior more with the color matched liner kit, and protect it against rust and water.

So onto some photos!

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Last edited by Firefyteremt; 03-15-2017 at 10:50 PM.
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post #2 of 46 Old 03-15-2017, 09:46 PM Thread Starter
Firefyteremt
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1991 YJ Wrangler 
 
Join Date: Mar 2017
Posts: 45
More tub work... I will spare photos of the drivers side as it's exactly the same as the other. I replaced the full rocker on both sides even though it only had the small rot holes at the a-pillar. I went back to the flange on the B-pillar so that it looks original on the inside. I did drop the Jeep stamping and debated long an hard about sectioning in the plates I cut out, butiIn the end, I will just apply the decal on the body side like a newer Jeep. It just was not worth all the work to make it look good inside and out.

You can see that I converted the fuel filler to the TJ style filler and took the time to weld up the old hole (although 99.5% of it is covered perfectly with a TJ style plate holder.

The rear floor was just starting to bubble out with rust, so cut out the corners of the rear floor and decided to shape the plate to match the curve of the front floor. No real reason, just my preference. I still have to pull out the seam sealer along the wheel wells and sandblast the seams. Once that is done, I can seam seal all the floor and rocker seams and spray in the bed liner. I also plan to spray a light coat of black bed liner under the rear metal flares, the sliders, the inside tube fender wheel wells and maybe the underside of the floor pan. I may look for a more traditional style under body coating to spray seeing how I bought the gun for it. (not using the spray can crap)
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Last edited by Firefyteremt; 03-15-2017 at 11:00 PM.
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post #3 of 46 Old 03-15-2017, 10:08 PM Thread Starter
Firefyteremt
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Now onto the front... The tub still needs to be skim-coated with a thin poly putty and epoxy primed, but i am waiting for a little warmer weather first. The grill needed to be modified a bit and the lower corners modified. I ended up sectioning on the YJ corners onto the CJ grille. I then had to remove the old grille any build a new frame mount.

I did break down and bought a new hood, the green one has a couple pin holes from rust spots on the underside. However, that made me push the hood forward buy 1/2"... which caused me to cut apart the tube fender grill brackets and make new ones....
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post #4 of 46 Old 03-15-2017, 10:32 PM Thread Starter
Firefyteremt
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1991 YJ Wrangler 
 
Join Date: Mar 2017
Posts: 45
The fenders are a kit from C&C Fab made for a CJ, but heavily modified using the YJ inner fenders and i made new side plates that wrap the mount flange at the tub and the top tube to be more fender like than tube fender, These are close to being done, but I need to finish the top plates and weld them on. I also have matching rear flares on the way and have talked to them about making custom sliders that I can trim to fit their rear flares and the curve of the lower tube fender shape. I also want them to only come half way up the rocker for personal preference.


That brings me up to date pretty much, I plan to have it done by the time its warm enough to drive with the top down.
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Last edited by Firefyteremt; 03-15-2017 at 11:14 PM.
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post #5 of 46 Old 03-16-2017, 07:23 AM
93YJfan
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1993 YJ Wrangler 
 
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Location: Lansing
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Very nice work, subscribed.
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post #6 of 46 Old 03-16-2017, 08:12 AM
en480c4
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Join Date: Apr 2004
Location: York, ME
Posts: 262
Looks great. Excellent work. I'm surprised with the CJ conversion that you didn't go with a CJ tailgate to complete the look. I love having the tailgate on my LJ, though admittedly it makes the spare tire a challenge.
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post #7 of 46 Old 03-16-2017, 12:02 PM Thread Starter
Firefyteremt
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Quote:
Originally Posted by en480c4 View Post
Looks great. Excellent work. I'm surprised with the CJ conversion that you didn't go with a CJ tailgate to complete the look. I love having the tailgate on my LJ, though admittedly it makes the spare tire a challenge.
Thank you! This is my 2nd "CJ clone" and I did the tailgate on the last one. The biggest pain is that my hard top does not have the early style "outside handle". With the YJ hardtop on the Jeep, it's a real pain to open the tailgate. Even more so because this Jeep has the factory "trunk" that would be in the way. You have to shut the lift gate first, then catch the gate shut. This would be pretty much impossible with the factory trunk insert. Plus, like you said... then you have the spare tire to deal with.

Last edited by Firefyteremt; 03-16-2017 at 07:52 PM.
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post #8 of 46 Old 03-24-2017, 06:20 PM
RufBoy
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Great work! Can't wait to see more.
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post #9 of 46 Old 03-27-2017, 11:43 AM Thread Starter
Firefyteremt
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I got the rear flares in and test fit. I will add filler plates in the wheel well so that they fit the factory arch and cover the holes from the old flares. Right now I have 7" on the front and 8" on the rear (with no interior)
I also "liberated" a power steering can from a 90's Subaru. The holes were welded up in the bottom and all the brackets cleaned off. I added a 5/8" hose barb to the side and used the bracket and clamp strap from the same cars fuel filter as a mounting bracket. It needs paint, but there are no leaks and it works mint.
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post #10 of 46 Old 03-29-2017, 10:17 AM
Ynotayj
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Man, I envy you guys who do great body work. I love the look of the fresh metal. The tube fenders are cool as well!

Matt Miller
So y not a yj?
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post #11 of 46 Old 05-12-2017, 12:45 PM Thread Starter
Firefyteremt
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1991 YJ Wrangler 
 
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Posts: 45
A major milestone... my spice tan Monstiner has been sprayed in the tub. This stuff is awesome! If anyone plans to do this though, I HIGHLY recommend buying the Walcom shutz gun like they sell on their site. I did buy mine from Amazon for about $30. This is a wash given the fact that the liner only kit is about $30 less. However, the finish product is 100x better than the roller job, faster, and cleaner.
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post #12 of 46 Old 05-12-2017, 12:47 PM Thread Starter
Firefyteremt
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Just to note.... the liner was still wet in the photo and did flatten out when it was dry.
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post #13 of 46 Old 05-16-2017, 05:03 AM
GermanyChris
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1999 TJ Wrangler 
 
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Very nice!

I'm generally a very pragmatic person: that which works, works. -- Linus Torvalds
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post #14 of 46 Old 05-16-2017, 10:13 AM
kbarwall
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1992 YJ Wrangler 
 
Join Date: Jul 2008
Location: Cincinnati
Posts: 815
Nice Work! Very Nice work. I totally respect you for this. I restored my 85 CJ7 a couple years back and I remember cursing body work. Its both a skill and an art.
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post #15 of 46 Old 05-17-2017, 09:34 AM Thread Starter
Firefyteremt
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1991 YJ Wrangler 
 
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Posts: 45
Quote:
Originally Posted by kbarwall View Post
Nice Work! Very Nice work. I totally respect you for this. I restored my 85 CJ7 a couple years back and I remember cursing body work. Its both a skill and an art.
Thank you very much..
I do tend to go overbroad on stuff like this, but it's fine the way I like it. Things like spraying the whole firewall will not be seen often, but whenever I work under the dash and see it, I will smile!
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