My 1997 Military TJ build :) - JeepForum.com

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post #1 of 217 Old 07-06-2009, 12:01 PM Thread Starter
gecko5
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My 1997 Military TJ build :)

I thought i would add this to the forum of my rebuild of a 1997 TJ. I started this last December after acquiring a 1997 TJ bone stock with a 2.5L and Standard in God awful teal....

The goal is to transform this from it's current state to something that will get me out and on the trails with my son as my co-pilot. He has an amazing love for jeeps or trucks and i hope that this will take us to all sorts of new places.... The planned end result:

BODY/INTERIOR:

* Full Body Dissassemble from the frame ~~ DONE
* Strip down completely all the body parts,~~ DONE
* Sandblast underside of tub ~~ DONE
* Repair any surface rust~~ DONE
* Repaint in Military Green OR Copper Orange~~ DONE - Went with Olive Drab Green
* Full rollcage tied to the frame ~~ DONE. Custom Built cage with BTF A pillars and Poly Perf Cage/Frame Tie ins
* CJ tailgate conversion~~ Decided against this for this build iteration.
* YJ half door conversion ~~ DONE - Picked up a set of TJ half doors
* Flush LED rear lights ~~ DONE
* Front Flat Fenders ~~ DONE
* Full replacement TAN interior ~~ DONE
* 5pt Harness~~ DONE - Bought Corbeau's, just need to bend the cross bars for the shoulder mounts
* Some nice 5pt seats front and rear. ~~ DONE - Corbeau ultras in the front and Beard rear seat in the back.

UNDERSIDE:

* Completely strip the frame, removing everything~~ DONE
* Full frame sandblast ~~ DONE
* POR15 the complete frame~~ DONE
* Completely strip the engine down ~~ DONE
o Degrease and repaint~~ DONE
o Install all new Gaskets~~ DONE
o Degrease all components ~~ DONE
o Upgrade to 4.0 TB
o Install Headers
* SA / LA 5.5" or possibly 7" suspension system~~ DONE - Clayton 5.5" Long Arm System
* SYE KIT~~ DONE
* New Rear Driveshaft
* POSSIBLY swap out the axles for meatier ones..... If not, stick with the 30/35's for now and re-gear to 4.88~~ DONE - '76 HPD44, 5.13's, ARB, Alloys, Trussed, Solid Diff Cover Front ~~~~ '98 8.8, 5.13's, ARB, Trussed, Gussetted, Solid Diff Cover rear
* 35X14.5 MT's ~~ DONE - went with 37X14X16 Irok's.. Beadlocks to come!!.

THE TRAIL ARMOUR:

* Welded in Front bumper with Stinger~~ DONE - Bolt on beef
* Welded in Rear bumper with Swing Away tire carrier~~ DONE - Genright Rear Tire Carrier
* Side rails with steps~~ DONE - Bolt on beef
* Winch


Some pics of the start:














Last edited by gecko5; 07-21-2010 at 07:55 PM.
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post #2 of 217 Old 07-06-2009, 12:02 PM Thread Starter
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Continuation of the tear down:









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post #3 of 217 Old 07-06-2009, 12:04 PM Thread Starter
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Tub and body parts finally off!!!











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post #4 of 217 Old 07-06-2009, 12:06 PM Thread Starter
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Engine has been completely degreased, cleaned and completely dissassembled. Now being re-assembled, new gaskets, worn parts replaced, yada-yada-yada. Current status:






Got the tub outside and sandblasted the underside of all the dirt, grime and grease. It is now ready for paint:








With the frame, it has been completely sandblasted and cleaned right now. Began the process of sealing it all up with POR15:



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post #5 of 217 Old 07-06-2009, 12:08 PM Thread Starter
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I finally was ready and able to reconnect the drivetrain to the frame and button everything up. I had one heck of a time with the tranny to the engine. ****, i just couldn't get it to line up (Guess it does make a difference to have a tranny stand!!!). Then a note to all...... MAKE SURE you have the bottom splash plate correctly in place BEFORE you torque down the bolts securing the tranny to the engine. I learnt the hard way that this is required...

In any event, some photos of the results so far. Frame is completeley POR'ed, SYE is in place, everythings degreased sanded and/or repainted, all new gaskets and everythings connected back up. I had to grind off the rivnuts for the skid plate and insert new ones as the existings all spun loose. I then tack welded them in place so it should hold nicely. Next steps are to get the axles finished, then hook up the suspension and then get the wheels on!!










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post #6 of 217 Old 07-06-2009, 12:10 PM Thread Starter
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Got all the suspension in place and was able to hook up the Tires. My RE front track bar's frame side mount would not fit to the track bar mount on the frame. The bolt was just too big. I had to drill it out to 5/8" for it to fit. Strange that RE would do this as it is nowhere in the manuals.... In any event, i ended up ****ing up the threads on the bolt and the nut. Was able to sawzall the bad threads but could not locate a 5/8" nut fine thread in my area so...









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post #7 of 217 Old 07-06-2009, 12:11 PM
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nice...i think this is the first frame off tj resto on here.....
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post #8 of 217 Old 07-06-2009, 12:12 PM Thread Starter
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* Got the holes fixed on the jeep tub
* started priming parts
* Finalized the color that i want to paint everything
* Got my bumpers made and are ready to be sealed/painted.













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post #9 of 217 Old 07-06-2009, 12:14 PM Thread Starter
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Update as of June 23rd:

* Warn Gas Tank Skid Plate in and tank back in place
* Front and rear bumpers prepped, POR'd, painted and installed
* Front PS skid plate installed
* Sway bars installed.
* Tub prepped and primered
* Tub was then lined inside with Herculiner
* Tub was then painted
* GenRight flares POR'd, prepped and painted
* Tub was then installed (Added a 1" body lift)
* Added a set of Poison Spyder Ricochet Side Rails
* Added a set of Poison Spyder Rear corner guards
* Installed the rear flares
* Installed the front grill (Cut out and installed a set of 2" LED signal lights)
* Installed the 2" rear LED lights (These are real slick from Genright)


I decided to paint the TJ myself with rattle cans. I have a feeling it won't be as hard as i was hoping but we'll see. Worst that can happen is i pull it all off next year and get it coated with a better paint. So far i am in about 19 cans of the Krylon Cammo paint. I still have the hood to do, the front flat fenders and the 1/2 and full doors.












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post #10 of 217 Old 07-06-2009, 12:18 PM
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Arrr Awesome!

This is great to see! Keep up the great work!
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post #11 of 217 Old 07-06-2009, 12:19 PM Thread Starter
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Update as of July 5th:














Last edited by gecko5; 07-06-2009 at 01:47 PM.
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post #12 of 217 Old 07-06-2009, 12:39 PM
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what prep did you do for painting the body?

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2000 XJ, 3.5" lift, 32s, Locked
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post #13 of 217 Old 07-06-2009, 12:59 PM Thread Starter
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Quote:
Originally Posted by AlTheKiller View Post
what prep did you do for painting the body?
Not a heck of allot really. Sanded down any deep scratches, patched up the new sheet metal, gave the body parts two coats of Red Oxide primer and then gave the parts two coats of paint. I also lined the inside of the tub with Herculiner before paint so that once i have ruined the carpet i can just yank it out and all is good
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post #14 of 217 Old 07-06-2009, 01:17 PM
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cool its looking great! wish i would have been able to tear mine down the way you did with yours

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post #15 of 217 Old 07-06-2009, 01:21 PM Thread Starter
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My only concern is how hard the paint will be. Only time will tell I guess. Touch ups will be a breeze though!!!
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