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Unread 08-27-2012, 09:10 AM   #16
sailsurf7713
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1999 TJ Wrangler 
 
Join Date: Jun 2008
Location: Rhode Island
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I think I've inadvertanely created the least interesting build thread ever

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'99 SE: The "It could be worse..." jeep

Quote:
Originally Posted by 97flexy View Post
...I say don't lift but CUT. :)
My Rusty Revival
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Unread 08-27-2012, 07:27 PM   #17
GreenTJ04
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2004 TJ Wrangler 
 
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Jeep looks awsome bud keep up the good work I like the jk seat swap might have to try that
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Unread 08-28-2012, 09:46 AM   #18
sailsurf7713
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Quote:
Originally Posted by GreenTJ04 View Post
Jeep looks awsome bud keep up the good work I like the jk seat swap might have to try that
Thank you. I'll post up the details on the swap soon.
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'99 SE: The "It could be worse..." jeep

Quote:
Originally Posted by 97flexy View Post
...I say don't lift but CUT. :)
My Rusty Revival
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Unread 08-28-2012, 10:09 AM   #19
gst95dsm
Chop, Wheel and Rebuild..
 
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2002 TJ Wrangler 
 
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Location: Fresno CA
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Quote:
Originally Posted by sailsurf7713 View Post
I think I've inadvertanely created the least interesting build thread ever
On the contrary man, you're doing some great work bringing it back. Congrats on the re-gear, that's a big accomplishment in itself, now welding up your frame..... not much that'll be out of your reach with those skills in hand.
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Unread 08-30-2012, 09:57 AM   #20
sailsurf7713
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Saying Goodbye to a bit more rust.

My fenders had started to rust...not surprised. Bearing in mind that I have a 120 hp engine, I didn't want to go with anything too heavy and I didn't want to shell out the cash for Genright aluminum. The MCE Gen II 3" fenders fit the bill. Excellent guys to deal with and a top notch product with excellent instructions. Took about 5 hours, with a whole lot of slacking off, eating and drinking beer. So I'd say 2 hours of actual work.

Rust:




Damaged passenger side fender:



1st step, cut:





2nd step, fit and drill:



3rd step, look like an idiot:





4th step, complete installation:





5th step, install two wire LEDs which you neglected to understand wouldn't work properly.

6th step, make adapters, because you neglected the LED issue:



7th step, figure out why your adapters don't work .


Alright. Here's an updated shot. I'll post some more detail on the seat installs and the fender install soon.

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'99 SE: The "It could be worse..." jeep

Quote:
Originally Posted by 97flexy View Post
...I say don't lift but CUT. :)
My Rusty Revival
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Unread 08-30-2012, 03:54 PM   #21
GreenTJ04
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The fenders look great I've been considering mce for awhile I think u just pushed me over the edge to buy then this weekend as for the bumper I agree it would look good with a little trimming
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Unread 08-30-2012, 06:45 PM   #22
NBBacon
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good work on the rebuild man. but may I ask why on the JK seats? I had a JK for a year and I found them horribly uncomfortable. I found they have even less lumbar support than my TJ.
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99 TJ on 33's

It is an expensive mud slogging, sand throwing, snowmobile with a heater, convertable toy that as a bonus happens to provide daily transportation.
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Unread 08-31-2012, 08:24 PM   #23
sailsurf7713
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Thanks for the feedback and compliments!

The JK seats I find pretty comfortable. They're not perfect, but I paid very little for them and the existing seat was for lack of a better word, catastrophic. It was destroyed. I needed something even decent. I was gonna order seats, but had no means of sitting in them first. Ran by a local dealership to check out the JK seats and they weren't bad so I grabbed them.

Tried to get my running lights working today to no avail. Got psycho blinker issue fixed with an LED relay. Gonna have to strip back to harness and intergrate both into one.

Think I'm gonna box off the front bumper right at the frame. Should look pretty good.
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'99 SE: The "It could be worse..." jeep

Quote:
Originally Posted by 97flexy View Post
...I say don't lift but CUT. :)
My Rusty Revival
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Unread 09-03-2012, 11:12 AM   #24
sailsurf7713
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Integrated all of the lights into the same circuit with 470 ohm resistors which work well for the smaller LEDs, bright enough running lights and the blinkers stand out well when on.
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'99 SE: The "It could be worse..." jeep

Quote:
Originally Posted by 97flexy View Post
...I say don't lift but CUT. :)
My Rusty Revival
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Unread 09-08-2012, 05:14 PM   #25
sailsurf7713
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03-06 Mirrors installed. So much better.

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'99 SE: The "It could be worse..." jeep

Quote:
Originally Posted by 97flexy View Post
...I say don't lift but CUT. :)
My Rusty Revival
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Unread 09-08-2012, 06:21 PM   #26
Jachi101
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Nice build man! Hey what kind of tires are those?
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Unread 09-08-2012, 09:03 PM   #27
sailsurf7713
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Kelly Safari TSRs, mentioned earlier in the thread

Thank you.
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'99 SE: The "It could be worse..." jeep

Quote:
Originally Posted by 97flexy View Post
...I say don't lift but CUT. :)
My Rusty Revival
sailsurf7713 is offline   Reply With Quote Quick reply to this message
Unread 09-08-2012, 10:27 PM   #28
sailsurf7713
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Location: Rhode Island
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Lighting is 100% street legal now. Here's an idea of the finished wiring looks. Tried to keep it looking OEM.



If anyone wants any help on this project, just let me know.
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'99 SE: The "It could be worse..." jeep

Quote:
Originally Posted by 97flexy View Post
...I say don't lift but CUT. :)
My Rusty Revival
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Unread 09-09-2012, 09:37 AM   #29
sailsurf7713
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Now that this lighting junk is wrapped up, I'll be focusing on getting ready to go wheeling this coming weekend. Transmission oil, oil change, new outer axleshafts/ujoints, rubber bushings to replace the poly in my motor mounts, etc.

Next objective is to get the tummy up a bit. There is no low profile mount for the AX-5, so a crossmember (possibly genright's) will go in and a UndercoverFab T.C. skid, aluminum of course to keep weight down, will go in. Also some low profile amid-jeep body mounts will likely go in as well. I still need to put the new frame side coil buckets in, which will go nicely with a rear shock outboard.

Front control arms will need replacing. And the JKS disconnects will get swapped out for an antirock.

Pretty sure I'm going to truss the 35 as I'll probably stick with it. I appreciate its ample ground clearance. Its weakness seems to be mostly related to how much it flexes. I will also TIG the tubes. Polishing a turd, yeah yeah, but its served me well so far and my wheeling style combined with the decent stock suspension doesn't allow for much wheel hop.

I still plan to do the AX-15 swap and the 1.9 TDi, but that's going to be a heavy investment.

I do have a buddy who may be getting rid of an AX-15 though, so we'll all be getting an education in rebuilding one.

This won't be happening quickly, but stay tuned.
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'99 SE: The "It could be worse..." jeep

Quote:
Originally Posted by 97flexy View Post
...I say don't lift but CUT. :)
My Rusty Revival
sailsurf7713 is offline   Reply With Quote Quick reply to this message
Unread 09-20-2012, 01:15 PM   #30
sailsurf7713
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Location: Rhode Island
Posts: 1,117
Some pictures and observations from wheeling this past weekend.

Getting there:





Getting to the trail:



Only poser shots on the trail:








The buggies got up so I figured I could :


Think its time to rebuild my power steering pump

Overall, everything performed better than I expected. The rear johnny joints, although in stock orientation, seemed to limit wheel hop substantially. The front will get them as soon as funds allow.

The truetrac never struggled even a bit. It provided ample amounts of traction and didn't decide to assist either of the rear Superior Discovery axle shafts in failing.

I was more than impressed with the Kelly TSRs. On the street they were quiet and handled in the corners just fine. On the trail, they stick to everything. They were good in the dirt, in the Northeast mud, on the rocks, and on the roots. I could see them struggling in southern mud. They do take a little revving to clean out. Others got a little wary when I told them I aired down to 12 psi on the 16" rims, but no issues. They allowed for a 20 mpg average throughout the weekend to top it off.

Front traction, front wheel hop, and breakover were the Jeep's downfalls. I expected this. An aussie will be added soon to improve traction and johnny joint control arms and an antirock to keep unsprung weight in better control than simply pulling the disconnects will be a huge improvement.

As mentioned before, an aluminum TC skid will be added as well as a genright crossmember to keep driveline angles in check. If necessary I will add a SYE and CV driveshaft, but at the moment the pinion angle is still too steep even with the upper control arms shortened completely.

In the mean time, I'm out of jeep money . However, I won some Warn fog lamps at this event, and my buddy gave me an ARB style snorkel head, so a cowl intake/sort of hummer style intake is in the works. Also smashed both my rear corners a little so I'm on the hunt for some aluminum corner guards and both tail lights will be replaced with LED 4" flush mounts. I emailed rokmen, and hopefully they'll be able to make some TJ ones. As they currently make LJ ones. Although, I could just get those and cut them to fit. Also need to repair two body mounts . So the thread shouldn't die out.

I also can say that the Brown Dog motor mounts weren't the best idea. They are extremely tough, but the vibrations even with the rubber bushings are annoying. I would definitely recommend spacers and stock mounts. I would love to have their engine brackets though.
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'99 SE: The "It could be worse..." jeep

Quote:
Originally Posted by 97flexy View Post
...I say don't lift but CUT. :)
My Rusty Revival
sailsurf7713 is offline   Reply With Quote Quick reply to this message
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frame repair , Frame rust , mce fenders , no lift , rear crossmember

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