MoonyJohn's 2004 WJ "Project Rocky" - JeepForum.com
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post #1 of 88 Old 07-28-2015, 11:19 PM Thread Starter
MoonyJohn
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2004 WJ 
 
Join Date: Feb 2008
Location: West Linn
Posts: 7,393
MoonyJohn's 2004 WJ "Project Rocky"

Making a build thread in this section, grand section is pretty dull lately from what ive noticed. Ill copy and paste what I have so far

I picked up a gem. 2004 WJ 4.- Rocky Mountain Edition with 91k miles. Two owner, with being towed behind a motor home at times. Its a 9.5 out of 10. Interior is practically new, and the exterior has minor things. Doesnt have a tow package so I got to get that still, but slowly Ill get there. All Ive done is drive it, and I got some husky floor mats in today too. Plans are to be mild. Not a big lift, but well equipped. Heres the day I brought it home, pretty basic





Did some small things here and there, got new rims, projector headlights, tinted windows, sound system, sound deaded the floor and doors, husky floor mats, cb radio.. my photobucket isnt working right now so ill skip ahead to my current setup..

Right now Ive got a 2" BB with bilsteins, MOOG SS, JKS HD front track bar, and 265/70/R17 duratracs with some Ultra Motorsport 198's.



Set up with my home made trailer color matched





I then picked up a welding project for myself to learn how to weld. My dad is teaching me how, been welding for 40+ years. Its a flatland4x4 bumper design, and a nearby fabricator cuts the prints out for a DIY kit so I picked a set up.





Heres my dad and his safety gear, tequila had nothing to do with this..



Bumper tacked together







Right now I have the bumper welded up, just need to grind it down to get ready for paint. I am buying some color matched graphite metallic clear for the bumpers, and future sliders. Should look nice and clean.

Also have a Warn VR8000 to be installed, with some Warn fog lights and a Masterpull orange synthetic winch line to be installed in the winch.

Thats all I got! More to come the next couple days hopefully


"Water covers 3/4 of the earth, Jeep covers the rest"
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post #2 of 88 Old 07-29-2015, 05:41 AM
grandboost98
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1989 YJ Wrangler 
 
Join Date: Aug 2010
Location: Essex
Posts: 4,210
Garage
I was actually thinking the same thing. Was going to ask a Mod or Admin if they could just move it.

Either way, love the way your WJs coming out. The bumper is lookin sweet!

89 Wrangler-3.5" HD BDS lift,M.O.R.E HD 5/8" booms on 35" KM2s
99 Cherokee-2 door,5" lift on 35" KM2s
04 Grand Cherokee Overland
72 Chevy Nova-in progress

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post #3 of 88 Old 07-29-2015, 01:00 PM
Jay8five
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2001 WJ 
 
Join Date: Aug 2012
Location: wichita
Posts: 11
Nice find, i can't wait to see the front end.
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post #4 of 88 Old 07-29-2015, 09:37 PM Thread Starter
MoonyJohn
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2004 WJ 
 
Join Date: Feb 2008
Location: West Linn
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Quote:
Originally Posted by grandboost98 View Post
I was actually thinking the same thing. Was going to ask a Mod or Admin if they could just move it.

Either way, love the way your WJs coming out. The bumper is lookin sweet!
Thanks man! I was part of the grand section a few years ago and it was alot more active, dont know why its not as busy over there. I guess I'm an attention whore

Quote:
Originally Posted by Jay8five View Post
Nice find, i can't wait to see the front end.
Thankyou sir!

I just got inside from a grinding spree. Got everything welded up, I missed a couple spots so I had to go back and add a weld to fill a hole. Other than that for a beginner fab project, I think I did good. The corners arent perfectly smooth, there are some imperfections.. but Im hoping that some good coats of primer and paint will cover it up. Anyways, heres the pictures

One side ready for primer and paint



Process of adding some welds :/



Added a light bracket because the angle that is provided wont work for my fog lights I'm mounting. Just cut some flat stock and tacked it up.



Fairlead holes drilled



Drilled for the light



Measuring out for the winch



3/8" holes drilled, bored a little for some extra play room just incase



Winch set in and checking for gaps, sits in nice!



Now I'm just messing around and wanted to see everything on it minus the fairlead



Hope to get it to paint tomorrow! Sucks having to work when I have this at home..

"Water covers 3/4 of the earth, Jeep covers the rest"
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post #5 of 88 Old 08-03-2015, 06:45 PM Thread Starter
MoonyJohn
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Join Date: Feb 2008
Location: West Linn
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Completed the bumper the other day! Spray 4 coats of color, and about 4 coats of clear this morning. Thankfully since its already warmed up it dried in no time. Threw it on the jeep and got everything hooked up besides running some wire from the factory fogs to the warn fog lights. Easy step, just need to go get some wire loom to hide it all and then ill hook those up and it will be complete! Very, happy with the results minus my fabrication skill is on the low side so in some areas its not the cleanest.. but the paint hides alot of the imperfections. Overall very satisfied

Front setup all includes:

Warn VR8000 Winch
MasterPull 5/16 100' orange synthetic rope
Warn W350F Fog Lights
Bestop D ring 3/4" Shackles
Smittybilt License Plate Clip










"Water covers 3/4 of the earth, Jeep covers the rest"
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post #6 of 88 Old 08-18-2015, 07:55 PM Thread Starter
MoonyJohn
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Location: West Linn
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Well, I dove into the rock slider project. Picked up some material today, thinking it was going to be more than what I paid for. $126 bucks for all the metal and then about 12 bucks for hardware. Im building these identical to the JCR sliders (measurements courtesy of Bama_WJ ) Heres a list of material I picked up

66" long 2x3" rectangular 3/16" tubing
60" 1 1/4" flat bar 3/16"
1x2" rectangular tubing 1/8" thick (didnt have 3/16)
3x4" 3/16" flat bar for the frame brackets
1 1/2" 3/16" round tubing

Heres some progree/write-up pictures

Pre-drilled all the mounting brackets before getting them up on the body



Using some 1/4" self tapping screws, worked good



Next I clamped up the flat bar and measured out equal spacing for the (6) 3/8" 1" bolts





While waiting for my 18v battery to charge, I clamped up where the brackets are going to be



Just 2 screws to hold it up, and then I screwed the top holes for when I will install them when its painted.



3 brackets up



Flat bar drilled and bolted in for tacking the mounting bars





And thats where I left off, going to do the welding tomorrow, should have a good chunk done by the end of the day tomorrow.. as long as no one asks to see if I'm free to hang out lol

"Water covers 3/4 of the earth, Jeep covers the rest"
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post #7 of 88 Old 08-20-2015, 09:08 AM
Irongrave
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1992 YJ Wrangler 
 
Join Date: Apr 2005
Location: Flroence
Posts: 1,666
Nice work and I like the color

Current
2002 WJ 2wd DD
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post #8 of 88 Old 08-20-2015, 07:59 PM
thevanillaninja
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2002 WJ 
 
Join Date: Mar 2014
Location: Base Kodiak
Posts: 216
Good looking jeep and quality work, too!

02 Overland 3"/31s
Tows a 21' TT
SOLD - 89 XJ 3", 32's, & cut
MK2 USCG
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post #9 of 88 Old 08-23-2015, 10:09 AM Thread Starter
MoonyJohn
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Location: West Linn
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Quote:
Originally Posted by Irongrave View Post
Nice work and I like the color
Thankyou I love the inferno red

Quote:
Originally Posted by thevanillaninja View Post
Good looking jeep and quality work, too!
Thankyou! Im trying to make it nice and do it right.

Got the slider tacked up, need to get the tube bent somewhere and get that tacked on also. Lookin pretty familiar like my other set!








"Water covers 3/4 of the earth, Jeep covers the rest"
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post #10 of 88 Old 09-01-2015, 10:39 PM Thread Starter
MoonyJohn
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Join Date: Feb 2008
Location: West Linn
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Ordered the RC 4" LA kit! I am eventually going to get some JKS bar pin eliminators and some better shocks if I dont like the RC shocks. Also got some .75" spacers to level the front out with the bumper. Cant wait for it to get here!

"Water covers 3/4 of the earth, Jeep covers the rest"
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post #11 of 88 Old 09-12-2015, 06:09 PM Thread Starter
MoonyJohn
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2004 WJ 
 
Join Date: Feb 2008
Location: West Linn
Posts: 7,393
Got the lift put on, also added some IRO spring posts and some bar pin eliminators.











Links were noisy, so I added a thick washer to keep them playing around and making noise!



Then found a rola roof rack on craigslist for cheap w/ the extension




"Water covers 3/4 of the earth, Jeep covers the rest"
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post #12 of 88 Old 09-14-2015, 09:35 AM
drgonzo92
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2003 WJ 
 
Join Date: Jun 2009
Location: Worcester
Posts: 84
Looks awesome. How are you liking the lift? Any issues?
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post #13 of 88 Old 09-14-2015, 01:18 PM Thread Starter
MoonyJohn
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Join Date: Feb 2008
Location: West Linn
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Quote:
Originally Posted by drgonzo92 View Post
Looks awesome. How are you liking the lift? Any issues?
Thankyou! The only issues I can think of are the bushings are squeaking already, and the coils seem to be hitting something when I go over any speed bump or hard pot hole. Other than that it rides good, and the pieces went together good

"Water covers 3/4 of the earth, Jeep covers the rest"
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post #14 of 88 Old 09-19-2015, 04:40 PM Thread Starter
MoonyJohn
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2004 WJ 
 
Join Date: Feb 2008
Location: West Linn
Posts: 7,393
ZJ washer bottle mod




"Water covers 3/4 of the earth, Jeep covers the rest"
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post #15 of 88 Old 10-04-2015, 03:20 PM Thread Starter
MoonyJohn
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2004 WJ 
 
Join Date: Feb 2008
Location: West Linn
Posts: 7,393
Welded up the rest of the sliders, still have to get the tube bent and get that on, then its ready for paint. Hate being busy.. ruins my jeep fun lol




"Water covers 3/4 of the earth, Jeep covers the rest"
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