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Unread 09-08-2010, 09:37 AM   #1
Allgood_73
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2004 TJ Wrangler 
 
Join Date: Sep 2010
Location: Nashville, Tennessee
Posts: 730
Project No Compromises

Latest picture:



On August 10, 2010, I flew up to Washington, IL to pick up my used 2004 Jeep Rubicon (manual) from a dealership (Uftring Chevy Saab) and drive it back down to Nashville, TN. At the time of pickup, it had 89,900 miles on it and I paid $14,410 plus my state's tax, tag, and title fees of $1,178.30.

Here's the first pic of the Jeep at the dealership:


Here's the first pic of the Jeep back in Nashville, TN (already removed the horrendous side steps):


Being that it was used and from the north, my first concern was getting it back to stock condition (i.e. - no rust, replace anything missing, perform any maintenance, etc.). The Jeep had horrible looking step sides, a moderately rusted back bumper, and some mild rust around the door hinges and on the top of the door where the upper windows sit. It was missing the hardtop mounting hardware and entry guards and the sliding upper windows did not securely lock. Therefore, I removed both the step sides and the rear bumper entirely, had all the rust spots and back tailgate professionally painted, replaced the locking mechanisms on the sliding windows, bought Lange Originals Kwick Kit Hardtop Hardware from Quadratec, bought OEM Mopar Door Entry Guards from Mopar Supercenter, and performed complete maintenance on the Jeep such as: differential cleaning and replacing of fluid, oil change w/ new filter, air filter, cleaned the throttle body, changed spark plugs, ran Sea Foam motor treatment, WD40 and / or PB Blaster on all accessible bolts or mildly rusted areas on bottom of Jeep, and repainted all rusted screws on body. The only thing left is changing my manual transmission fluid and replacing the fuel filter.

Here are pics after the initial work being done:









Feel free to post any questions or comments about the build. I'm learning all this as I go, so suggestions are welcomed. Luckily, I have a buddy that is a Jeep fanatic, so he's my "mechanic" when I need him (which is most of the time). All I ask is that you don't threadjack or spam on my thread.

I have created several posts below in order to "reserve" the space and keep my build within the first few pages.


Last edited by Allgood_73; 09-21-2010 at 02:39 PM..
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Unread 09-08-2010, 09:38 AM   #2
Allgood_73
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2004 TJ Wrangler 
 
Join Date: Sep 2010
Location: Nashville, Tennessee
Posts: 730
The following are my future plans of what my build will include. If I have already bought an item, I went ahead and put in the price of what I paid at the time... this is not to "show off" how much I have invested, but rather let new jeepers know what they are getting into when they start their build.

* = Prices obviously vary throughout time and some prices include discounts / promos / sales. No tax or shipping was counted in unless stated otherwise.

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Unread 09-08-2010, 09:39 AM   #3
Allgood_73
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2004 TJ Wrangler 
 
Join Date: Sep 2010
Location: Nashville, Tennessee
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****** On June 5th, 2011, I changed the build layout. The new layout will have 1 or 2 pictures of the end result... and if you would like to see the write ups and more details, just click the day's update link. This was done to prevent long loading time on slower network speeds and also to allow me to continue posting the build pics on the first page. ******
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Unread 09-08-2010, 09:39 AM   #4
Allgood_73
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2004 TJ Wrangler 
 
Join Date: Sep 2010
Location: Nashville, Tennessee
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Update 09/11/10 - (Click Here For All Pics)
Installed the new Alpine Head Unit:


Update 09/20/10 - (Click Here For All Pics)
Installed the Daystar 1" BL:

Before:


After:


Update 10/05/10 - (Click Here For All Pics)
Installed the Novak #SK3X-R Shifter Assembly:


Update 10/10/10 - (Click Here For All Pics)
Installed the CB system:


Update 10/13/10
Well, today is my birthday and I get to spend it taking apart the front driveshaft. While we were switching out the shifter linkage a few days ago, we noticed the rear u-joint was bad on the front driveshaft and I decided to replace them all. This is the first real maintenance item besides all the initial maintenance stuff like changing the spark plugs, cleaning the throttle body, changing the fluids, etc...

I have heard that these don't get too much stress put on them, so there is no need to go crazy expensive on U-Joints in that section at this time... therefore, I went with Advance Auto Part's Brute Force U-Joints:



Update 11/05/10
My battery died on me while attending a company event. Luckily I was able to roll start it down a hill.... twice... thank goodness for the manual transmission! I just ran up to Advance Auto Parts and picked up their Gold series battery. I will most likely put this is my wife's jeep down the road and grab a pair of Optima yellow tops for my Jeep once I get the dual battery setup. I'll need it due the pull of the winch, lights, stereo, etc.

Update 11/21/10 - (Click Here For All Pics)
Installed TeraFlex CB Mount and ran wiring through tail light housing:


Update 11/22/10 - (Click Here For All Pics)
Installed Front & Rear Warn Bumpers and Warn Winch:




Update 12/11/10 - (Click Here For All Pics)
Removed the antennae for daily driving and made a custom bolt to keep trash out:


Update 12/31/10 - (Click Here For All Pics)
Installed the Brown Dog MML:


Update 01/04/11 - (Click Here For All Pics)
Got the first part of my Under Cover Fab order in.... and got it primed and painted:


Update 01/12/11 - (Click Here For All Pics)
Got the Under Cover Fabrication's Ultra High Clearance Skid System Installed:


Removed the Rear Drive Shaft:


Mounted Up The Old Skid As A Souvenir:


Update 01/17/11 - (Click Here For All Pics)
Got 12VoltGuy's In Cab Winch Controller Installed:


Update 01/24/11 - (Click Here For All Pics)
Extended my CB wire and installed the mount:


Update 01/29/11 - (Click Here For All Pics)
Got the Trail Ready beadlocks cleaned up:


Got the 35" MTR tires in and started mounting them up:


Update 02/01/11 - (Click Here For All Pics)
Got the Spidertrax adapters installed:
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Unread 09-08-2010, 09:40 AM   #5
Allgood_73
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2004 TJ Wrangler 
 
Join Date: Sep 2010
Location: Nashville, Tennessee
Posts: 730
Update 02/05/11 - (Click Here For All Pics)
Removed Front Flares:


Update 02/12/11 - (Click Here For All Pics)
Rubicon Locker Pump Relocation:


Removed Rear Inner and Outer Flares:


Switched to Mobil 1 Full Synthetic Extended Performance:


Update 03/08/11 - (Click Here For All Pics)
Clayton Long Arm Lift Installed:


Got the PIAA Lights on:




Update 04/24/11 - (Click Here For All Pics)

Alright, so it has been a month and a half since my last update... but I finally am getting some things done. I bought a trailer (hello trailer queen!), the exhaust was installed by Master Muffler (highly recommended), then the T.W. rear drive shaft went in, then afterwards it was a VERY long and painful process of getting the alignment performed, then some transfer case issues were resolved, then the Currie Anti-Rock sway bars were installed, then PIAA windshield lights were fully wired up to a factory switch, then a few minor tasks were completed, and all that brought me to my most recent project that I just finished this weekend... a home-made garage hoist for the hard top.

Here's some pics (and links) in the order of which they were done:

Trailer:
(Accidentally deleted pics of trailer) :-\

Exhaust:


Sorry, but no pics of T.W. rear drive shaft.

- Transfer Case seal replacement:
See my the issue I was having and how it was resolved by clicking here.



- Currie Anti-Rock install:


- PIAA Windshield Light Switch Install:
IMPORTANT - See my other thread for wiring information to factory switch and how my issues were resolved.... click here.



- Misc. small projects:
Picked up a MaxOut fire extinguisher and Drake's quick release mount:


Medical kit and a Hi-Lift holder:





- Garage Hoist for Hard Top:
Just so you know... my object was NOT to save money by not buying a kit from Quadratec or some other place... it was to do it right and have it exactly how I want it. That being said, it still ended up costing me half of the amount of one of the pre-fabbed kits.



Update 05/6/11 - (Click Here For All Pics)

Got the Jeep back from Line-X today... I love the way it turned out:


The SpiderWebShade SW1 had also arrived today, so once the jeep was back, I got that installed:


Update 05/27/11 - (Click Here For All Pics)

I got the fire extinguisher installed and the riddler diff covers painted:


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Unread 09-08-2010, 09:40 AM   #6
Allgood_73
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Join Date: Sep 2010
Location: Nashville, Tennessee
Posts: 730
Got the system installed by DRIVEN Nashville:


Update 06/1/11 - (Click Here For All Pics)
Replaced broken radiator with CSF 3 core all metal radiator:


Repaired bent sway bar axle mount:


Installed Riddler diff covers:


Bought & installed Rusty's radiator skid plate:


Update 06/19/11 - (Click Here For All Pics)

Installed the Metal Cloak Fenders, Corner Armor, and Rockers:


Update 09/06/11 - (Click Here For All Pics)

Removed my rubicon dana 44 axles, Bilstein shocks, Clayton coils, and control arm mounts.


I've bought my new axles and cut off the old mounts:
2003 F-350 Superduty Front HP Dana 60, 5.38 gears, trussed, Solid diff cover, Nitro Chomo 35 spline axles, 35 spline RPM drive flanges, disc brakes


2003 F-350 Superduty Rear Sterling 10.5, 5.38 gears, trussed, Solid diff cover, disc brakes


Removed my Metal Cloak extended corner guards.
Started installing the new Metal Cloak extended stretch corner guards.


Got the Just4Effect sub box in and placed into the jeep.


Bought my 40" MTR tires.


Update 09/16/11 - (Click Here For All Pics)

Made the following order with Gen-Right:
LED Recessed Tail Lights
LED Back Up Lights
5pc Black Hood Louver Set
Bumper Plate for Swing Down Tire Carrier
Inner Reinforcement Plate
Outboard rear frame brackets
Also purchased the following:
Complete front bumper system from MetalCloak
Used Gen-Right Crawler ALIEN Gas Tank
Bought a new trailer:


Removed front and rear bumpers.


Modified emissions charcoal canister:


Removed rear stock coil buckets from frame and removed about 2-3' off the end of the exhaust pipe.


Update 09/24/11 - (Click Here For All Pics)
Installed MetalCloak front bumper.


Fixed rear tailgate tightness.

Bought Delrin door bushings. While waiting on them to arrive, I removed the stock door bushings.


Prepared Gen-Right gas tank for install.


Update 11/21/11 - (Click Here For All Pics)
Installed GenRight hood louvers.
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Unread 09-08-2010, 09:41 AM   #7
Allgood_73
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2004 TJ Wrangler 
 
Join Date: Sep 2010
Location: Nashville, Tennessee
Posts: 730
Installed MetalCloak rear stretched corners.


Installed GenRight flush mount LED lights & drilled out holes in cross member for GenRight flush mount back up lights once my bumper is installed.


Did the initial install of the GenRight rear bumper, but am now waiting on it to get powder coated before final install.


Removed Delrin bushings and installed Kentrol lower hinges. Need to still file out / fix the upper hinges or replace them with Kentrol.

Removed all wiring done by Driven Nashville and correctly re-wired the entire stereo system myself.


I was replacing the locking mechanisms on my upper windows... then my wife busted out one of the windows... so I no longer have uppers on my half doors....


Update 01/04/12 - (Click Here For All Pics)

Grille bezels painted black.


Rear bumper powder coated and installed, gas tank fully installed, and rear LEDs put in.


Odyssey battery installed and big 3 electrical upgrade finished.


New door hardware installed.


Jeep loaded up and ready to head to EOR.


Update 06/09/12 - (Click Here For All Pics)

Received jeep back from EOR with the following completed: Dana 60 front, Sterling 10.5 / 10.25 rear, full hydro steering, custom cage, King 2.5" IBP coilovers, 40's, 5 pt harnesses & Corbeau seats, ARB lockers, OBA, custom Switch Panel, custom backhalf & bumper, 17" TrailReady HD beadlocks, quick disconnect Grant steering wheel, stretched wheelbase, and custom double triangulated 4 links front and rear. Even with all that said, I'm sure I'm missing some stuff.







Professional Pics Coming Soon!
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Unread 09-08-2010, 09:42 AM   #8
Allgood_73
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Unread 09-08-2010, 09:42 AM   #9
Allgood_73
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Unread 09-08-2010, 09:43 AM   #10
Allgood_73
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Unread 09-08-2010, 09:43 AM   #11
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Unread 09-08-2010, 09:44 AM   #12
Allgood_73
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Location: Nashville, Tennessee
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Unread 09-08-2010, 09:44 AM   #13
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Unread 10-13-2010, 06:49 AM   #14
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Unread 10-13-2010, 07:00 AM   #15
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