No stretch TJ build for the wife. - JeepForum.com
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post #1 of 25 Old 07-24-2014, 05:49 PM Thread Starter
LilViper95
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No stretch TJ build for the wife.

I picked up a 97 TJ with a 4" suspension lift to build for my wife. I got a really good deal on it through some trading. Needs some typical TJ frame repair and I'm going to paint it. It's currently a 4 cylinder 5 speed. Long term plan will involve an engine swap. Other than that we don't have really any direction planned yet.


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post #2 of 25 Old 07-24-2014, 08:39 PM Thread Starter
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More photos, the last one shows it next to the golf gti vr6 I traded for it.


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post #3 of 25 Old 07-31-2014, 05:05 PM Thread Starter
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So the home brew left over paint worked out so good on the stretched yj that I decided I would see what I could do for this one. She wants a pinkish color. This came out ok, sprayed a test panel on a paint can! I'm not sure if I will use it yet. I'm going to price out some "Pink Panther Pink" as I want something a little more high impact.



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post #4 of 25 Old 12-13-2014, 09:19 PM Thread Starter
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This build is still in progress, just very slow! I have been terrible at updating it!

I ditched the awful grill guard and swapped in some Harley Davidson headlights!



I replaced the worn out original tan soft top with a sailcloth top from a late model tj. I got the top free from a friend! The rear window has a very small crack. My plan is to pick up a set of tinted windows for it.

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post #5 of 25 Old 12-13-2014, 09:21 PM Thread Starter
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I removed the rusted out window frame and replaced it with a good used unit. Sadly this is the only picture I took of the swap!
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post #6 of 25 Old 12-13-2014, 09:23 PM Thread Starter
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I need a larger garage! I hate that they can't all be inside during the winter! I suppose if I got rid of the Demon and Trans Am we could fit them!
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post #7 of 25 Old 02-25-2015, 11:32 AM Thread Starter
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Fedex dropped off a present today! I picked up the the bumper builders mounting kit from A to Z fabrication. I plan on using it as a minimalist type bumper. I will likely add on a hoop of some sort and add on a fairlead mount.

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post #8 of 25 Old 07-16-2015, 07:44 PM Thread Starter
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I know this has been the world's slowest and most boring build. I'm still working on it in between building my flat fender and keeping up my stretched YJ.

Tonight I picked up a set of wheels and tires from a buddy. Tires are 31" super swamper truxus. Eventually I want to toss on a set of 33" BFG A/T tires that I have in the shop.

I'm going to get the frame work done this coming week and install a new exhaust so my wife can start driving it again. I would like to paint it as well but don't really have the extra time or cash right now.



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post #9 of 25 Old 07-21-2015, 07:48 AM Thread Starter
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Finally had a chance to get under this thing and scope out what it needs for repair work. The skid plate bolts had pulled through the skid on the pass side and the PO welded steel rod to the skid and the side of the frame to keep the skid up. I cut those off and lowered the skid. The frame really wasnt all that bad but the nutserts were broken free. I used some 3"x5"x.25" rectangle tube cut in half to repair the skid plate mounting area of the frame. This tube works great as it slides right up onto the frame with a snug fit. Prior to welding in place I drilled holes and welded in some nuts for the skid plate mounting. I used my shop vac to clean out all the rust scale and dirt from inside the frame while I had it cut open. I also used a blunt tip in my air hammer to free up as much rust scale from inside the frame before installing the patch. Once it is all done I am going to treat the inside of the frame with some Fluid Film.

Outside welded in place before paint.




Inside with some paint.




I also had to repair the upper control arm mounting area. I didn't snap any photos however.

Tonight I need to repeat this repair on the drivers side and install the new exhaust system.
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post #10 of 25 Old 07-22-2015, 06:16 AM Thread Starter
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Last night I put the new exhaust on the Jeep. The previous owner had removed the converter. I installed one I had in the shop.







I also began the rust repair on the drivers side of the frame.

cut the lower part of the frame off to patch in the skid plate mounts. This was the dirt that fell out when I removed this piece!



this is what the frame looked like opened up. I used a body hammer and long pry bar to remove all the rust flakes from inside the frame.



I used my shop vac to remove all the dirt and rust scale from inside the frame rails.





Tonight I am going to finish up the drivers side rust repairs. Then start prepping the frame for paint.
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post #11 of 25 Old 07-23-2015, 07:45 PM Thread Starter
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Last night I was too tired after work to go to the shop. I went down tonight and finished the repair of the skid plate mounting area. I would've done more work and completed the your control arm mount repair on the drivers side but I ran out of shielding gas for my mig welder. At least the jeep is driveable again. I'll pick up some more gas tomorrow. Then finish up the frame repairs. Once those are done I'm going to build a set of rocker protection tube sliders and likely install one of my warn 8274 winches on the front bumper.


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post #12 of 25 Old 07-24-2015, 08:20 PM Thread Starter
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Finished up the frame welding tonight. Forgot to take pictures.

I began building the rock sliders with tube steps. These are 3/16" plate steel that cover 6" up the side of the tub and 6" under the tub. They are mounted to the side and also to the torque box support under the floor.



Here is the tube I bent up for them.

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post #13 of 25 Old 07-24-2015, 09:01 PM Thread Starter
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I know this isn't innovative stuff, but is anyone reading this?
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post #14 of 25 Old 07-24-2015, 09:04 PM
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Nice work, I'm sure she'll be happy when it's all done!

Current: 99XJ 6.5 lift-Bought 2015
Sold: Patriot Blue 00 XJ.
'sploded: 01 stock-0331 head victim
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post #15 of 25 Old 07-26-2015, 08:33 AM
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Im reading it and it looks like a fun project. Judging from the pics it looks like you get the same amount of rust as we get here in Mi. I am starting a project on my 2000 TJ and will be removing the axles and gas tank shortly. Reading you article to see what I may be getting into with some of the repairs I might have to do. Im going to steal some of your angle iron frame repair ideas for mine so thanks for posting.
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