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SPARTAN LOCKERS are on sale BIG TIME at ROCKRIDGE 4WD!FLASH SALE! Open thread to reveil the Newest Sale @ ROCKRIIntroducing MONSTALINER™ UV Permanent DIY Roll On Bed Line

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Unread 04-28-2014, 11:00 AM   #1
dpegasusm
Junior Member
1999 TJ Wrangler 
 
Join Date: Jun 2013
Location: Newport, RI
Posts: 37
99 TJ Sahara Build

I've been a lurker on here for a while making tweaks to my Jeep but I think its time to start a build thread as things begin to heat up on customization. I don't have any pictures of the car when it was stock, but it looked just like any other green 99 TJ Sahara. I bought it about 4 years ago and soon discovered the greatest perk of owning an older Jeep in the northeast: frame rot. Here is the most recent pic, about a year and a half post that story...

20141024_114013945_ios.jpg


Last edited by dpegasusm; 04-28-2014 at 11:27 AM..
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Unread 04-28-2014, 11:00 AM   #2
dpegasusm
Junior Member
1999 TJ Wrangler 
 
Join Date: Jun 2013
Location: Newport, RI
Posts: 37
And now for some frame rot:


Yes that is the frame... or whats left of it... i'm not sure how I didn't break in half...


The upper control arms had separated from the frame on both sides.


A lot of cutting... thanks @sailsurf7713 or this jeep would have been in a junkyard


The spring buckets fell off the axle when it was removed.


Repairing the frame and welding it back together.


Rusty's Offroad coil spring frame relocation bracket installed.


Axle back in.

A lot more and better pics here:
http://www.jeepforum.com/forum/f22/9...l#post14477499

Last edited by dpegasusm; 04-28-2014 at 02:12 PM..
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Unread 04-28-2014, 01:55 PM   #3
dpegasusm
Junior Member
1999 TJ Wrangler 
 
Join Date: Jun 2013
Location: Newport, RI
Posts: 37
ARB Compressor Install

A far more recent upgrade from this past weekend: ARB Compressor Install.

Step 1:
In order to make room, the horn was relocated to the passenger side of the engine compartment. The white/red wire that feeds the horn is split just underneath the charcoal canister so i opened up the harness and extended the wire from there following the existing part of the harness that runs along the underside of the top of the grill for the lights. it was split and then rewired over on the other side.



Step 2:
The ARB backing plate was used as a bracket and mounted to the fender flare where the horn used to be. One of the horn holes was reused and only one hole was drilled. For added strength the bracket was welded into place but this could have been done without welding by putting some oversized washers on the backside.









Step 3:
Compressor was bolted onto the bracket. One of the bolts needed a little bit of trimming as it was too long for the fender flare as well as one of the bolts on the backside of the grill that holds in the headlights was sticking about an inch into the engine bay.



A quick test to make sure that it is working. and it looks like it is made to fit there with easy access to the compressor for switching tire inflation and hopefully room for the locker hoses to come soon...

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Unread 05-25-2014, 01:25 PM   #4
dpegasusm
Junior Member
1999 TJ Wrangler 
 
Join Date: Jun 2013
Location: Newport, RI
Posts: 37
Just picked up a D44 rear axle and an HP D30 front both with 3.73 gears this weekend and learned that you can successfully fit both inside of a Jeep...



The D44 has disc brakes too which was an added plus. Yes the rear brakes do not provide a lot of stopping power but discs are easier to service than drums and although i probably would have not done the conversion myself it was a nice added bonus.

Unfortunately however the D44 has blown spider gears in the Trac-Loc. Does anyone have a set that they took out during a locker install and are willing to part with?
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Unread 01-02-2015, 02:31 PM   #5
dpegasusm
Junior Member
1999 TJ Wrangler 
 
Join Date: Jun 2013
Location: Newport, RI
Posts: 37
Axle project update 2:

It's probably time for an update on the axle project, seeing now that it is nearing completion. But first more updates brought to you by rust. It's the northeast; the struggle is real.

Brake knuckles on the axle about to be removed. the twelve point bolt has become almost unrecognizable. It is also difficult to see in this picture but the rust has scaled so bad inside the tone ring on the axle shaft that it cracked the ring and the ring has now been worn down on the sensor (you can see it just to the bottom left of the bolt in the center of the pic)
2015-01-02-11.36.50.jpg

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Unread 01-02-2015, 02:51 PM   #6
dpegasusm
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1999 TJ Wrangler 
 
Join Date: Jun 2013
Location: Newport, RI
Posts: 37
Grinding and painting

First thing that was done was stripping the entire axle shaft back to bare metal.
2014-06-08-15.41.51.jpg

2014-06-08-17.27.43.jpg

2014-06-08-13.12.23.jpg

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Unread 01-02-2015, 02:53 PM   #7
dpegasusm
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1999 TJ Wrangler 
 
Join Date: Jun 2013
Location: Newport, RI
Posts: 37
Painting

Then both were painted to black
2014-06-01-22.14.09.jpg

2014-06-08-19.39.12.jpg

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Unread 01-02-2015, 03:00 PM   #8
dpegasusm
Junior Member
1999 TJ Wrangler 
 
Join Date: Jun 2013
Location: Newport, RI
Posts: 37
TracLoc Rebuild

The Dana 44 had blown spider gears in the TracLoc, so the gears were replaced along with the rest of the clutches. This was a relatively simple process and used a few nuts and some threaded rod purchased from Lowes.

The diff was set up on one of the axle shafts that was bolted to the countertop and the threaded rod was inserted into the other end with a few large washers and a nut on the top and balanced on a steel plate on the bottom. the clutches and gears were in on the top and bottom at this point and it was just the side gears and the rod that had to be inserted. The side gears were carefully lined up on the sides and then using the center rod from the diff the entire assembly was spun until the side spider gears lined up the entire rod could be pushed through. The hardest part was determining the correct tension to put on the threaded rod to spread the top and bottom gears and still allow for the entire diff to spin.
2014-07-19-15.53.23-hdr.jpg

2014-07-19-16.13.11.jpg

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Unread 01-02-2015, 03:01 PM   #9
dpegasusm
Junior Member
1999 TJ Wrangler 
 
Join Date: Jun 2013
Location: Newport, RI
Posts: 37
Dana 44 finally done:
2014-09-20-16.47.50.jpg

2014-09-20-19.17.14.jpg

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Unread 01-02-2015, 10:49 PM   #10
dpegasusm
Junior Member
1999 TJ Wrangler 
 
Join Date: Jun 2013
Location: Newport, RI
Posts: 37
Rear Axle Install

And finally the rear axle is installed. It was a pretty simple and straightforward swap, unbolt everything, remove the old D35 and then slide the D44 underneath and bolt everything up. At the same time i replaced all of the control arms with MetalCloak control arms.
20141013_151952593_ios.jpg

20141013_170757500_ios.jpg

20141013_170806945_ios.jpg

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Unread 01-02-2015, 10:51 PM   #11
dpegasusm
Junior Member
1999 TJ Wrangler 
 
Join Date: Jun 2013
Location: Newport, RI
Posts: 37
And Tires

At the same time of the rear axle install a friend of mine was getting rid of his JK rubicon rims and tires so i picked those up off of him and mounted them on the TJ using spacer adapters.
2014-08-16-17.01.23.jpg

20141014_023002122_ios.jpg

20141017_225832603_ios.jpg

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Unread 01-02-2015, 11:00 PM   #12
dpegasusm
Junior Member
1999 TJ Wrangler 
 
Join Date: Jun 2013
Location: Newport, RI
Posts: 37
Detour project: stereo

I was tired of the stock jeep stereo and fell in love with the Apple CarPlay when it came out so i decided to get the Pioneer AVIC-8000NEX for the car play and to help drive the new speakers for the car.

Installing it involved cutting apart the dash bezel to make room and fabricating two custom brackets (16 gauge steel) that bolted deep into dash to hold it.
2014-07-26-13.01.10-hdr.jpg

2014-07-26-13.15.55-hdr.jpg

2014-07-27-19.49.10.jpg

2014-08-03-19.30.25-hdr.jpg

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Unread 01-02-2015, 11:02 PM   #13
dpegasusm
Junior Member
1999 TJ Wrangler 
 
Join Date: Jun 2013
Location: Newport, RI
Posts: 37
Another Detour: Light Bars

And another detour from the axle project. Added light bars to the Jeep. Both are from Delta.
20141024_114013945_ios.jpg

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Unread 01-15-2015, 01:20 PM   #14
dpegasusm
Junior Member
1999 TJ Wrangler 
 
Join Date: Jun 2013
Location: Newport, RI
Posts: 37
Light bar install

And the light bar install:

The top and bottom bar were purchased at a closeout tent sale. They were open box items so I got an awesome discount on them and everything was there. That being said I would NOT purchase these at full price. They have a slew of quality issues (see my post here: http://www.jeepforum.com/forum/f217/...d-bar-2927881/) I ended up throwing out the hardware and going with rocker switches and my own fused relay box.

For the wiring, i cut the Delta harnesses apart and built my own fused relay box and bracket to hold it in place. The box is Bussman and has 5 fused relays and 5 fuse slots. I can provide instructions and source for everything to build it if people are interested. It costs about $60 to build. The 5 relays of the light bars filled all of the slots and kept it very clean and organized. I also ran a constant hot outlet into the cab using one of the non relayed fuses.

The bracket I custom built from a piece of 16 gauge steel and mounted it underneath the existing fuse box bracket using the same bolt holes. it fits right behind the stock air box and leaves everything exposed.

There are 5 switches for the light bars the first three are for the front ground bar and the top two are for the top light bar. The zombie lights is because the shop didn't have a 5th different switch icon so i had to choose a duplicate or something silly.

Overall I'm happy with the look except for the huge delta logo on the top bar which i plan on blacking out. It was a good mod but if you had to buy the light bars at full price and then scrap the wiring it would get expensive very quickly.
20141018_010603000_ios.jpg

2014-11-27-19.54.36.jpg

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2014-11-27-20.00.28.jpg

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2014-12-26-22.22.11.jpg

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