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Unread 10-23-2012, 04:01 PM   #61
MallCrawling
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1997 TJ Wrangler 
 
Join Date: Feb 2012
Location: , Connecticut
Posts: 120
i'm so impressed at how you've completely transformed this jeep!!! keep the updates coming! subscribed

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Unread 10-23-2012, 05:15 PM   #62
sailsurf7713
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1999 TJ Wrangler 
 
Join Date: Jun 2008
Location: Rhode Island
Posts: 1,112
Quote:
Originally Posted by MallCrawling View Post
i'm so impressed at how you've completely transformed this jeep!!! keep the updates coming! subscribed
Thank you. Its definitely not the coolest rig here, but its come a long way on a minimal budget.
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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 10-23-2012, 06:22 PM   #63
MallCrawling
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1997 TJ Wrangler 
 
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Location: , Connecticut
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Quote:
Originally Posted by sailsurf7713 View Post
Thank you. Its definitely not the coolest rig here, but its come a long way on a minimal budget.
youre downplaying this build man. i was really impressed with your fab skills and the frame repair you did. i'm still doing my bolt on mods
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Unread 10-23-2012, 07:24 PM   #64
sailsurf7713
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1999 TJ Wrangler 
 
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Location: Rhode Island
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Frame repair was cake. First fabwork, so we'll see how it goes. I got tired of "normal" bolt on mods pretty quick after teaching myself how to weld. But nothing wrong with some carefully chosen or otherwise impossible to diy bolt ons.

Regearing, now that's a trip, but once you understand what's happening its very easy. I can't wait to build new axles for it.

Any good wheeling in Ct?
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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 10-23-2012, 08:21 PM   #65
sailsurf7713
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1999 TJ Wrangler 
 
Join Date: Jun 2008
Location: Rhode Island
Posts: 1,112
New lights. Gonna delete the license plate bracket thing as well and just secure it to the tub with some stainless steel button head fasteners and some bolts lights.

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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 10-24-2012, 02:49 PM   #66
MallCrawling
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1997 TJ Wrangler 
 
Join Date: Feb 2012
Location: , Connecticut
Posts: 120
Quote:
Originally Posted by sailsurf7713 View Post
Frame repair was cake. First fabwork, so we'll see how it goes. I got tired of "normal" bolt on mods pretty quick after teaching myself how to weld. But nothing wrong with some carefully chosen or otherwise impossible to diy bolt ons.

Regearing, now that's a trip, but once you understand what's happening its very easy. I can't wait to build new axles for it.

Any good wheeling in Ct?
not many really. not that i really have the equipment to really seriously offroad. Broke the spider gears in my dana 35 the other day, it was real fun replacing those and the side gears in my axle today. when i can afford it, dana 44 for sure
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Unread 10-24-2012, 04:50 PM   #67
sailsurf7713
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Quote:
Originally Posted by MallCrawling View Post
not many really. not that i really have the equipment to really seriously offroad. Broke the spider gears in my dana 35 the other day, it was real fun replacing those and the side gears in my axle today. when i can afford it, dana 44 for sure
Or buy my 35 I wheel pretty hard with mine. I no longer have the spiders though and I have chromo shafts...oh and 120 hp If you can find a 44, by all means, but an 8.8 with an Artec truss: Perfect.
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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 10-24-2012, 04:59 PM   #68
sailsurf7713
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1999 TJ Wrangler 
 
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Location: Rhode Island
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Alright some progress, albeit not very much:

Kept working on boxing it in:





I didn't get any feedback on how to fix this issue,





So, I took a guess at the correct solution and did this





Cut along the hitch tube with my handy craftsman battery powered sawzall:



Hit it with a hammer till I was satisfied and JUST tacked it in this time



And back to boxing it in:





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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 10-24-2012, 05:46 PM   #69
sailsurf7713
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I forgot my favorite mod of the day:



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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 10-25-2012, 03:30 PM   #70
sailsurf7713
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1999 TJ Wrangler 
 
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Did a lot more thinking than fabbing today. Getting to the stage where screwing up could be very aggravating.

But, finished boxing it in minus the bottom, because that has to be very accurately drilled for studs or welded nuts.



Mocked up "wings"



Body bolt access:





Project goes on hold for a few days. Gotta do a quick restoration on a 99 TJ.

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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 10-27-2012, 11:04 PM   #71
sailsurf7713
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1999 TJ Wrangler 
 
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Location: Rhode Island
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Well here's an idea of what is taking me away from my project



But this one might be getting some cool custom junk when its safe to drive again.
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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 10-28-2012, 08:20 AM   #72
contdevelop
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2003 TJ Wrangler 
 
Join Date: Dec 2008
Location: , Republic of Texas
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Gotta love the rust belt!
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Unread 10-28-2012, 08:55 AM   #73
G Beasley
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You have done a nice job teaching yourself to weld and fabricate . I have ran straight CO2 before , but I prefer a 75/25 mix. The weld still burns in and there is a lot less spatter . Might be something to consider next time you get a bottle filled . I feel bad for you guys up north and the rust , thats some aggravating stuff to deal with . Keep up the good work .
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Unread 10-28-2012, 10:17 AM   #74
sailsurf7713
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Quote:
Originally Posted by G Beasley View Post
You have done a nice job teaching yourself to weld and fabricate . I have ran straight CO2 before , but I prefer a 75/25 mix. The weld still burns in and there is a lot less spatter . Might be something to consider next time you get a bottle filled . I feel bad for you guys up north and the rust , thats some aggravating stuff to deal with . Keep up the good work .
I've welded with 75/25 and 90/10. I always go back to straight CO2 and my machine is small, just 180 so I like the extra penetration. Thank you for the recommendation though. Maybe when I go to a bigger machine I'll switch because I won't be as concerned about getting adaquete penetration.

Also, thank you for the compliment, I'm getting there and I'm having a really good time along the way.

I'll keep some pictures of that sahara with the hole in the side of it coming so this thread doesn't die down. Its getting some cool stuff. Gonna have a Safari sort of look to it when finished.
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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 10-29-2012, 01:14 AM   #75
tjsean0308
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1999 TJ Wrangler 
 
Join Date: Apr 2008
Location: Port Angeles, WA
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whats your plan for the middle body mount? I need to fix that too. My frame is ok because of my insane cleaning but I missed the torque box.
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frame repair , Frame rust , mce fenders , no lift , rear crossmember
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