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Unread 01-27-2012, 06:13 AM   #1
Danno6102
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Danno's DD TJ Build

Going to start in Index here, so if anyone is looking for anything it'll be easier to find.

Index:

Outboard Rear Shocks = Post #16
Start of the Ford 8.8 Swap = Post #32
LED Tail light wiring info = Post #204
Ford Windstar Cowl Intake Mod = Post #230
Ford front shock towers = Post #282
Removing the Charcoal Canister = Post #308
Trimming Rear Flares = Post #574
Start of Cage Design & Install = Post #1081
RCI 2162 Install in a Late Model TJ = Post #1292




I started this build thread over on IndyORV, but things have been slow & boring here at work & I'm always lurking the build threads here, so I figure I'd start one here to, what the hell right?

I bought this '03 Sport Easter weekend 2011. It was bone stock except for a 4" RC suspension lift. Here she is in the dealer parking lot the day I got it.


It came with the hardtop obviously & one of those half top tonneau cover thingys that I dislike & could not use because of kids & needing the back seat, so first purchase was a Supertop NX. Then some misc stuff like a new passenger door seal & the correct speedo gear.

Here's a list of upgrades so far in chronological order:

Supertop NX
Smitty SRC Classic Front bumper, plan to turn this into a stubby someday
XRC-8 Winch
CB Radio Uniden Pro510XL with 4' Firestik
Skid Row Engine Skid & Steering Box skid
B&M Tranny Cooler
Poison spider Hood Louver
Savvy/Currie Front Lower & Rear Upper Control Arms
Fumoto Oil Drain Valve
Riddler Cover for the D30
Aussie Locker for the D30
Rugged Ridge Mirrors
ZJ tie rod upgrade & replaced drag link because it was bent
Currie 4" progressives in the front with a 3/4" spacer
Currie Adjustable front track bar (CE-9120TJJ)
Installed a stock pitman arm. PO had a drop on it.
JB Conversions SYE with cut down XJ shaft
RE Adjustable rear track bar with JKS CV bracket
T&T Custom rear cross member with 2" receiver. Still need to get this one on, my welder is busy with some **** called a "pumpkinator"
Novak shifter cable
Rokmen Mercenary sliders with no tube, I think I'm the only one...

That's what's done so far & this is how she sat a month ago. The Novak & Rokmen's are going ont his weekend.


One of my better wheeling picks. Red trail at The Badlands. My passenger mirror fell victim to that tree that day.


I've also removed the rear tire carrier & DD without a spare. It gets loaded into the tub when we hit the trail. I'm working on a rack to go above it to mount tools & spares. Something that will resemble this.


Next big project on the list is a Ford 8.8. I picked up one from a 1998 Mercury Mountaineer with 3.73 gears to match the front, & limited slip, but I just got a good deal on a set of 4.88 for the D30, so it will get re-geared to match before it goes in. I was also going to 4-link it, but am putting that on hold due to cash flow & I also want to challenge myself a little so I can learn more about line selection, how the Jeep handles, etc. So, we're going with stock bracket kit & I will move the upper frame coil buckets back when we install the 8.8 to get rid of a the arch.

I also have plans to tummy tuck a little. Originally was going to go with UCF UHC skid, but just picked up a 2'x4' piece of 1/4" plate from work, for free. I probably won't go completely flat, but plan on getting the UCF Lo-pro & going as flat as easily possible for now & go from there.

There you have it. I'll try to update with Novak & Slider install this weekend.

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Unread 01-27-2012, 08:33 PM   #2
BlueRubiconrich
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The Ford 8.8 L/S's are junk.waste of time. I'd add a c clip e kit and locker
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Unread 01-27-2012, 09:21 PM   #3
Danno6102
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You buying? An arb is in the plan just don't have a grand to drop on a locker right now, so an $80 LSD rebuild will have to do.

In other news, broke 3 out of 4 rear upper shock bolts tonight. will be fun getting those out tomorrow...
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Unread 01-28-2012, 06:52 AM   #4
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Last nights work.

Novak
forumrunner_20120128_084746.jpg

Bedlined behind the sliders. They will get mounted today.
forumrunner_20120128_084914.jpg

Someone missed the Target when they installed this shock.

We'll hopefully get those broken bolts out & finish up the Currie shock extenders & get the rokmen slides mounted today.
forumrunner_20120128_085030.jpg  
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Unread 01-28-2012, 08:13 AM   #5
Ferrachi
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I like the back rack design.
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Unread 01-28-2012, 02:34 PM   #6
Danno6102
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Couldn't get the damn shock bolts out. Looks like we outboard sooner than expected. Aw shucks...
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Unread 01-28-2012, 03:07 PM   #7
Irongrave
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I've been working on ideas for a rack like that myself. the hard part is comming up with a way to strap the tire in place so it can't go any where.
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Unread 01-28-2012, 05:17 PM   #8
Nosights
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Having the Glock in the back is just plain silly. Should be sitting stong side between 1 and 4...but that is just my opinion
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"Fender flairs"? Really? I'll let a combination of my sawzall, plasma cutter and hammer take care of the clearancing.
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Unread 01-28-2012, 07:44 PM   #9
Danno6102
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Quote:
Originally Posted by Nosights
Having the Glock in the back is just plain silly. Should be sitting stong side between 1 and 4...but that is just my opinion
Lol! Yea usually sitting at IWB at about 4. Found a G19 block for sketchup so I had to use it.
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Unread 01-28-2012, 07:50 PM   #10
Nosights
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Quote:
Originally Posted by Danno6102 View Post
Lol! Yea usually sitting at IWB at about 4. Found a G19 block for sketchup so I had to use it.
Glad to hear it
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"Fender flairs"? Really? I'll let a combination of my sawzall, plasma cutter and hammer take care of the clearancing.
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Unread 01-29-2012, 03:57 PM   #11
Danno6102
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Ok, going to order some Bilstein 5125's from Shockwarehouse tomorrow & need some help figuring out what shock length I need to get. Don't have access to a garage tonight & it's too damn cold & windy to go do this in the driveway or I would just go flex out the axle, but I think I can get close just want some opinions. I need to order them tomorrow so they are here before Friday so I can get these in this weekend.

Sitting at ride height I have 8" to bump. When I jack up the back of the jeep until the wheels come off the ground (springs are loose but still seated) it extends another 3", so that says to me 11" of total travel right? So should I order the 11" travel or get some cushion & get the 11.94 travel? What would be the down side to ordering too long of a shock? As long as I locate the top mount point on the ford towers at full bump I should have an extra .94" of travel "wasted" at full droop.

Any help would be greatly appreciated!
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Unread 01-31-2012, 08:22 AM   #12
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Well, the rack is in redesign mode. I cut the base plywood to size & tried to get it in the Jeep with the top up last night & couldn't even get it in. It's cut at 56" wide to set on the fender wells. Not going to happen. I'd like to be able to cut it down to 46" wide so it will fit easily between the B pillars to get it in. Might figure up some mounting method to attach it to the B & C pillars. I thought about just setting it on the spare & strapping it & the spare to the floor, but don't really want to remove this rack just to get the spare out, so I would like it suspended 1" or so above the spare so I could just slide it out.

Might get a piece of angle iron & U bolt it to both the B & C pillars & then bolt the rack to the top of the angle. Might need to tack weld some tiny pieces to the pillars so the U bolts don't slide down from the weight.

Stay tuned...

In other news, shocks have been ordered, 12" travel, ford towers ordered & brackets from Poly have been ordered. Hopefully all will be here by friday.
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Unread 02-01-2012, 04:36 PM   #13
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Finally got pics of the rokmens.


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Unread 02-01-2012, 05:33 PM   #14
camjeep3
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nice jeep buddy. I love some bfgs on a jeep... maybe Iam biased though
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Unread 02-02-2012, 04:19 AM   #15
Danno6102
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Quote:
Originally Posted by camjeep3 View Post
nice jeep buddy. I love some bfgs on a jeep... maybe Iam biased though
Thanks! They are a pretty good tire. I'm happy with their performance so far. I air them down to 15psi on the trail. I can't wait until it's more of a dedicated trail rig & maybe get some crawlers.
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caliper flip , ford 8.8 , indyorv , outboard , tube fenders

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