'99 TJ Frame-Off: Rolled to Bold - JeepForum.com

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post #1 of 176 Old 04-22-2011, 06:17 PM Thread Starter
2000GrayTJ
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'99 TJ Frame-Off: Rolled to Bold

Well I figure its spring now and I should start a build thread to document my progress of a '99 TJ I picked up last fall. Its a black sport 4.0L 5-speed: Dana 30/35, hard top, 4.56 gears, 4" RC Series II lift, rear Lock-Right/Yukon shafts, Volant CAI, Edge Trailjammer, and possibly best of all a "brand new" rebuilt Gopher motor bored 0.030" over with less than 10K kms on it.

Shortly after doing all this work, the PO had flopped it on its side. After that happened he realized he was ready to move on so he found a used hard top and put it up for sale (it has a salvage title). I was able to pick it up for $3000, delivered

I currently drive a '00 TJ SE 4 banger with 2.5" SL/1.25" BL and 33s so my original plan was to swap my body onto the frame/drivetrain of the '99. However, after reading all the different salvage builds on here I decided that I will leave my '00 intact and build the '99 exactly how I want it . The body damage on the '99 isn't that bad at all plus I've always wanted a custom flat black or OD paint job that I don't have to worry about scratching up. I will be documenting the whole rebuild as much as possible, and hopefully end up with a capable DD on 33-35s that I can still beat up on the weekends


good from far, far from good.
'99 TJ frame-off rebuild: http://jeepforum.com/forum/f22/99-tj-frame-off-rolled-bold-1199954/
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post #2 of 176 Old 04-22-2011, 06:18 PM Thread Starter
2000GrayTJ
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Stage I: Rebuild from salvage title (almost complete)
Stage II:

good from far, far from good.
'99 TJ frame-off rebuild: http://jeepforum.com/forum/f22/99-tj-frame-off-rolled-bold-1199954/
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post #3 of 176 Old 04-22-2011, 06:19 PM Thread Starter
2000GrayTJ
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To start off here are a few pics of my current '00 TJ SE, the deal with my parents was they bought the '99 for me to work on as a project, and I don't have to pay them back if I can't provide another working vehicle for my sister to drive. As I mentioned before my original plan was to swap the bodies and eventually repair the '99 body/4cyl for my sister to drive. However, after looking at all the different builds on here I would prefer to start from scratch and build the '99/4.0 exactly how I want. Once I have it driveable I will give my sister my current TJ and be ready to rock the new one.

Here are a few pics of my current TJ, its a fairly mild build but a great DD/weekend wheeler. It has a 2.5" Skyjacker susp. lift, 1.25" Zone Offroad BL, and 33x10.50 BFG a/t's. Started off with 31 ProComp a/t's, then added the susp. and body lift, and finally the 33s within the past ~2 years. As much as I haven't minded the 4 banger around town, it has always sucked *** on the highway, I figure when I give it to my sister I'll drop the body lift and put a set of 31's on it to make it more practical for her as a DD/mild wheeler.




^^ btw that's my parking spot for the winter..
One thing I'm going to miss is the cheesy "if you can read this..." sticker, probably get the most compliments due to that than anything else...seriously

good from far, far from good.
'99 TJ frame-off rebuild: http://jeepforum.com/forum/f22/99-tj-frame-off-rolled-bold-1199954/
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post #4 of 176 Old 04-22-2011, 06:25 PM
WV_Boltman
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crawled
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post #5 of 176 Old 04-22-2011, 06:49 PM Thread Starter
2000GrayTJ
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Here are a few pics from last fall when the PO dropped the Jeep off, and I forgot to mention before, the Heep had a 3" BL man with ~7" lift those stock size tires look tiny..

The nice thing about this purchase was I was able to drive the Jeep and confirm the function of everything. Man that motor purrred

good from far, far from good.
'99 TJ frame-off rebuild: http://jeepforum.com/forum/f22/99-tj-frame-off-rolled-bold-1199954/
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post #6 of 176 Old 04-22-2011, 06:58 PM Thread Starter
2000GrayTJ
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I started out by lifting the body off of the frame, I originally thought I was going to be swapping the bodies/frames but either way I'm happy to be doing a frame-off so I can clean everything up underneath. Considering what it was used for (trail rig) there was minimal rust and damage.

I started by removing:
-wiring harness connecting motor to bulkhead harness
-steering linkage
-coolant lines, radiator, etc
-emergency brake cable
-all the emissions stuff
-removed hood and grill

May have been a few more things but thats what I can think of off the top of my head. Here are a few pics of actually raising the body, we jacked up the front and rear separately and places horses underneath to support the body when it was high enough off the frame:




pulling the frame out from underneath..




I'm very lucky to have my dad help me out with this project, he's been wrenchin' cars since he was 15, and still has his first car he ever owned, a '66 Mustang Coupe which has recently been restored (will post some pics of it later)

good from far, far from good.
'99 TJ frame-off rebuild: http://jeepforum.com/forum/f22/99-tj-frame-off-rolled-bold-1199954/
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post #7 of 176 Old 04-22-2011, 07:06 PM Thread Starter
2000GrayTJ
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We got the frame in the garage for the winter so I was able to do a little work while it was cold out. I will be wire wheeling/sanding the frame down and coating the whole thing in Chassis Saver. Everything appears to be perfectly straight so it shouldn't be a problem to get it inspected and insured.


Started off by removing the gas tank and transfer case skids, my plan is to mod the gas tank skid while I have it out (according to this thread http://www.jeepforum.com/forum/f9/st...arance-736901/).

Gas tank dropped:



T-case skid dropped:



There was TONS of dirt in the gas tank skid. Apparently the jeep had been sitting in a mud hole for a while..hence the reason for the rebuilt motor and axles:




Had a little helper while I was washing the skids out..

good from far, far from good.
'99 TJ frame-off rebuild: http://jeepforum.com/forum/f22/99-tj-frame-off-rolled-bold-1199954/
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post #8 of 176 Old 04-23-2011, 10:25 AM
Barrows
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Great job so far!
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post #9 of 176 Old 04-24-2011, 03:40 AM Thread Starter
2000GrayTJ
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Last Fall we pulled the tranny/transer case and split the bellhousing




The clutch appeared to be in decent shape


good from far, far from good.
'99 TJ frame-off rebuild: http://jeepforum.com/forum/f22/99-tj-frame-off-rolled-bold-1199954/
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post #10 of 176 Old 04-24-2011, 03:43 AM Thread Starter
2000GrayTJ
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good from far, far from good.
'99 TJ frame-off rebuild: http://jeepforum.com/forum/f22/99-tj-frame-off-rolled-bold-1199954/
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post #11 of 176 Old 04-24-2011, 03:49 AM Thread Starter
2000GrayTJ
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Removed the old RC Hydros today, just recently I purchased a set of 3 Bilstein 5100 shocks. The 4th one leaks so I have to buy another one. I got the 3 for $60 and they came off a show truck. Basically they are meant for a TJ 4" lift but they were put on a SEMA JK and eventually parted out. 3 out of the 4 are fine, so for ~$150 bucks I'm getting a nice set of new shocks to go with my RC lift.

Today I also replaced the clutch and re-installed the transmission/xfer case. I am hoping to get this frame painted asap so I can put the body back on

good from far, far from good.
'99 TJ frame-off rebuild: http://jeepforum.com/forum/f22/99-tj-frame-off-rolled-bold-1199954/
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post #12 of 176 Old 04-24-2011, 11:06 AM
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Looks like a lot of detailed hard work put into this so far... I'll be watching your progress I'll be restoring the frame on my jeep this summer as well since the rust build up has gotten out of control. I'm curious to see what you use for yours and how it turns out.

And this pic is priceless....



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post #13 of 176 Old 04-24-2011, 01:44 PM Thread Starter
2000GrayTJ
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^ haha lets just say it had some decent torque with those tires and 4.56s

good from far, far from good.
'99 TJ frame-off rebuild: http://jeepforum.com/forum/f22/99-tj-frame-off-rolled-bold-1199954/
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post #14 of 176 Old 04-24-2011, 05:13 PM Thread Starter
2000GrayTJ
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My plan is to paint the body of the Jeep John Deere Blitz Black with possibly an OD green hard top/accents. Does anyone know a place that is willing to ship a gallon of JD BB as well as the primer/reducer/hardener? The only local place so far quote me $45 for a gallon of paint (costs ~$25 in the US) and they didn't have any of the other things I need. It would probably be optimal to be able to order it from some place close to the border so shipping isn't too expensive.

good from far, far from good.
'99 TJ frame-off rebuild: http://jeepforum.com/forum/f22/99-tj-frame-off-rolled-bold-1199954/
2000GrayTJ is offline  
post #15 of 176 Old 05-08-2011, 06:05 PM Thread Starter
2000GrayTJ
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I've been doing some research and I've changed my plans a bit...with Monstaliner colours coming out soon, I think I've decided to coat the outside in red . I already have a gallon of black for the inside of my tub, so I figure I might as well coat the whole tub while the body is off.

I'm not a fan of all entirely bedlined Jeeps, but I think Monstaliner has a really nice texture and seems suitable for the task. Its 100% UV resistant and isn't as rough as most other DIY liners. I'm gonna have to wait and see how the phase 1 colours turn out as red isn't going to be released for a while..

good from far, far from good.
'99 TJ frame-off rebuild: http://jeepforum.com/forum/f22/99-tj-frame-off-rolled-bold-1199954/
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