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95YamJam 05-23-2013 07:55 PM

The 95' Yam project
I had a 00' Tj with 31's that i loved but got rid of to pay off bills. I always missed it and wanted another jeep but wanted to do it all cash.

I decided YJ's were in my budget becuse i wanted a DD/ part time trail rig.

I found a decent little candidate on CL. 2.5L 5spd, had 180k on the clock but ran and rove great.

So ere she is about a week after i got it just over 2 years ago.

So what now?

Well, I took off the stock front bumper to make room for my yet to be determined custom bumper. I did get some 3/4" d ring shakles for the front tow points.

I also determined that I have a pinion seal leak, and an axel seal leak.

I just ordered a new diff cover to get rid of the stock "plug" cover, and a spartan locker for the d35.( Bad idea I know but it worked out great.

I yanked the rear end apart and change the seals, install the locker, install the diff cover and change/check all the rear brake hardware as well.

I thought someday maybe a lift and some bigger tires than the 30's that are on it.

First time with the top down....

Front bumper off. I cut out the bottom captured nuts as one broke out already. Leave the holes for drains. Welded angle brakets on the sides of the rails to mount my new bumper to. Also still use the factory top bolt as well. This way I should be able to put the factory bumper back if I ever choose to. I doubt I will but...

I also got some of the frame tub under coated on the passenger side. The before pic is the driver side but the passenger looked the same.

Wire brush, cleaned a lot, more wire brush, rust inhibiting primer, and truck bed line spray.

Alot more to do but...


Oh, BTW i did know the front booms were backwards. PO on that one.

95YamJam 05-23-2013 07:59 PM

So I ot the shackles fixed, turned around and a center support welded in. Also a fender flare trim.


Those tires look really small now.....

Well i started working on the rear end and other general maint issues. Did some more cleaning on the frame and axel and more undercoating. New diff cover too. Thanks to Tony at Baseline 4x4. Also painted the rear drums with high temp ceramic caliper paint.

Now to get my bumpers done and try this thing out in the dirt.

I got a good start on the front bumper. Just for info. All 1/4 wall steel, bolt holes are sleeved, bolts are grade 8. It should not go anywhere. :)

95YamJam 05-23-2013 08:03 PM

So I decided to look at craigslist for more parts and.... it started... tires...

They fit way better than I thought. I still needed a lift but they were more than driveable the way they were. I jacked the front tire til the other one lifted off. No rubbing at all in the front and only slight rubbing in the rear. Honestly a small lift shackle would fix it. :rolleyes:

I am debated a 2.5" lift and 1" body lift.
Anyway.. I had to test them out. Didn't play long becuse I was by myself in a bad area and it was really soupy with no recovery vehicle.

So anyway i got the front bumper done.

Front Bumper done for now. I may add a "stinger" of some sort later IF I get a winch.

Now time for some fun....
Bored after work. Mostly poser pics but I did do some wheeling. Scary at night but she did great!

95YamJam 05-23-2013 08:06 PM

So now it was time for a rear bumper.

So if figureing out the rear bumper mouting i ran into this. grrrr....

Frame rust:

Not to fear!!!!!!!!!

Plates for repair:


95YamJam 05-23-2013 08:09 PM

While the gas tank was out i decided to do some as tank skid reapir and slight up grades: :) Doubled the thickness of it too!

Also decided to make some other goodies!

cb mount:

Fuel filter protector:

So after a wheeling trip to the badlands in Attica IN, with the 32's i had some rubbing issues and decided that a 2.5" SUA lift, 1" body lift, and some 1" boom shackles for the rear would do the trick.

Pics from the trip...

Random, and my son "helping" on the new spension. LOL

Who says old yjsprings are worthless.?

95YamJam 05-23-2013 08:21 PM

In the meantime I had also done some rust repair here and there on the body and some other random things. I cut out and raised the front and rear flares over an inch to get more room, steering stops as not to rub the tires. Also so me 1 inch spacers to get more wide.

Plus some pieces of flair! LOL!
New, old *** polished sparkley 70's shift knob for the trans, and badass holmes wrecker winch disengagement knob for the 4wd. :)

So now that the list was done and frame was fixed i could do the final bumper work, some of the skid plate repairs, and some wheeling to test things out. All tests performed as planned! YAY!

95YamJam 05-23-2013 08:22 PM

Short Vid:


95YamJam 05-23-2013 08:28 PM

So now more wheeling!!!!!!!!

95YamJam 05-23-2013 08:34 PM

I built some rock guards/ side steps and fixed some sheet metal from not having rock guards. lol

Also started on my custom tool box.

Sidestep stuff:

95YamJam 05-23-2013 08:37 PM

Tool box done: YAY!

Also got some newish seats.

95YamJam 05-23-2013 08:41 PM

My steering was getting pretty bad so i did this.

Here is what the factory steering looked like:

The kit that I purchaced from Baseline 4x4 outfitters was this one:

So onto flipping it to the top of the knuckle.[/url]

I ordered 2. When I got them they are a quality unit.

So now it's time to drill a 3/4 inch hole in the factory knuckle to install the flip bushings. I made this to try to make sure that the bit stayed centered and did not walk or waller the hole out.

95YamJam 05-23-2013 08:44 PM

I ran into issues with the kit so i modified it. Now becuse I am extra anal I decided to make the bushing differently. It's sets the drag link connection about 3/16" futher out to gain more clearence.

This is what I did:

So now that I got the bushing made I welded it in and cleaned it up and repainted it.

So now I get to finally install everything YAY!

I have a flipped hd steering now, I have ran over 5k miles on it plus a few wheeling trips and it's been great!

95YamJam 05-23-2013 08:47 PM

I decided to get some lights on for an upcoming night run but did not want to spend big$

Specs are GE4509(napa equivalent) 100w @13v.
Trucklight Rubber housings(napa part # to be added)

Mounts, Wireing, and 30 A relay by me.

Lights on with headlight low beams.

Just for ref:
Low beams headlights


highbeams with new lights:

I need to get some night shots. They are stupid bright for less than $50. :)

95YamJam 05-23-2013 08:52 PM

So basically i wheeled and DD for about a year. Doing basic maint but about 6 months ago i couldn't pass up a deal and decided to get nasty.

36" tsl super swampers and rims for $500. :)

What to do with the d 35? 8.8 time.

Hood pins installed cause I won't have fenders to tie the side latches to.

8.8 work begins, got it stripped, tubes and other stuff welded up too. Plus a pile of parts to throw on it.

Also started working on my "fenders".

Some of the fender work.

Got the fender skinned. Some little finish work and time for paint

95YamJam 05-23-2013 08:55 PM

Final fender work, plus my new paint shceme on zee wheels.

So the fenders got tied up, rears got some "work too", led rear lights, 8.8 lsd got buttoned up and in, with custome shock mount bar. Also did a flat skid and trans mount. Electic fan. And about a million other little things.

couple bs pics cleaning out the garage

The time now is 12:32 AM.

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