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Unread 12-30-2009, 11:03 PM   #1
mferrari
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Delmarva Offroad - Orange Peel - TJ Buggy Build

2011 SEASON REBUILD STARTS ON PAGE 16 HERE
2012 SEASON REBUILD STARTS ON PAGE 22 HERE

Figured it deserved its own thread... Here is the old thread of how I got to this point from a bone stock Jeep in 4 years I think.
http://www.jeepforum.com/forum/f9/sl...-build-540449/

Here is what I am starting with. 98 TJ. Stretched 2 inches, 44 and 30. Teralow. Locked Front and Rear with 36" iroks. 2" of lift in the front, no lift in the rear.



The build...
Double triangulated 4 link rear, 3 link w/ pan hard front. HP60, 14B. 5.38s. D300. 39.5" Rockers. Tube from the seats back and from the motor mounts forward.

Started with hacking the tub:


Lost the little axles:


HP60 with the truss on it:


Started to shave the bottom of the 14b:



Axles waiting:


Plasma cutter came in so I began chopping the frame:


Tubing arrived:


Took the "body" off to start on a tranny mount and finish cutting and capping the frame rails:



Capped the frame, then put the body back on to get final measurements for the chassis:


Start of the layout on the new chassis:



And that is where I leave you today. Tomorrow I need to finish the tranny mount, then going to start bending for the chassis!

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Unread 12-30-2009, 11:17 PM   #2
SnowYJ
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holy crap, look sgood
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Unread 12-30-2009, 11:20 PM   #3
mferrari
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Thanks, sorry for the mess in the shop. Working on a cage for one customer and axles for another along with my personal buggy. I need a bigger shop
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Thanks to our Sponsors:
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Unread 12-30-2009, 11:33 PM   #4
uvalax236
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Looks awesome! Keep up the great work!
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Unread 12-31-2009, 01:44 AM   #5
rs4race
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I finally get to see the beginning of one of these builds! One question tho. Why hack up everything? Looks like you have tons of material, besides the body why not make a new frame that you can bolt the body to?

Its just something Ive always wondered with these builds.
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Unread 12-31-2009, 08:21 AM   #6
00jeepsahara
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nice build. Like the new cage design. What are you planning for suspension?
Are you also using the stock d300 casing? Have you looked into STAKs replace a case. Works great when your flipping a 300.
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Unread 12-31-2009, 09:51 AM   #7
mferrari
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Quote:
Originally Posted by rs4race View Post
I finally get to see the beginning of one of these builds! One question tho. Why hack up everything? Looks like you have tons of material, besides the body why not make a new frame that you can bolt the body to?

Its just something Ive always wondered with these builds.
Originally I was planning on using more of the tub than I am going to end up using so I just decided to cut it all up. I also was thinking about selling the Jeep as a whole and starting from scratch but there was no way with the economy the way it is that the Jeep would have sold so I parted out what I wasn't using. Since I had the frame it made an easy starting point to work with. Plus now I can still say it's a Jeep
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Team 120 - DOR Racing - Racing for Operation Homefront
Operation Homefront (OHF) provides emergency financial and other assistance to the families of our service members and wounded warriors.
Thanks to our Sponsors:
Delmarva Offroad - F-O-A Shocks - BD Turnkey Engine - Under Cover Fab - Jer-C Transmissions - Quigley Driveshafts

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Unread 12-31-2009, 09:54 AM   #8
mferrari
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Quote:
Originally Posted by 00jeepsahara View Post
nice build. Like the new cage design. What are you planning for suspension?
Are you also using the stock d300 casing? Have you looked into STAKs replace a case. Works great when your flipping a 300.
Suspension will be double triangulated 4 link in the rear. Front will be a 3 link w/ pan hard (not going full hydro at this time). Both should sit on 14" air shocks but waiting to get the chassis sqaured away before I order them.

Right now I am still deciding on using the stock casting or using a Stak case for it. I am more leaning towards using the stock case because within a year or 2 I want to get a 3 speed case.




Going out to the shop to finish up some axles for a customer and then gonna spend osme time and start on the chassis today.
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Team 120 - DOR Racing - Racing for Operation Homefront
Operation Homefront (OHF) provides emergency financial and other assistance to the families of our service members and wounded warriors.
Thanks to our Sponsors:
Delmarva Offroad - F-O-A Shocks - BD Turnkey Engine - Under Cover Fab - Jer-C Transmissions - Quigley Driveshafts

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Unread 12-31-2009, 10:23 AM   #9
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Awesome! Thanks for posting.
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Unread 01-01-2010, 10:06 PM   #10
mferrari
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Spent some time today trying to figure out what to do with this D300. I broke out the bandsaw and cut down the old shifter crap:



Ok so now that made a little more clearance for the mount. But the next problem... The driveshaft and shifters. Looks like I am going to need a 2 piece shaft to fit around the transmission. Also may run into some trouble with clearance for the shifter but I may be able to work around that...


Shifter clearance:


Top View:


Back w/ "driveshaft":






Also while I had the D300 apart, I decided to grind the shift rail to allow me to use 2wd High in the Front with the rear in N.
Before (Marker is where you grind to):


Afer:



Also bent the first tubes for the chassis... The slider pieces to weld on the frame that will run right along the tub line.
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Team 120 - DOR Racing - Racing for Operation Homefront
Operation Homefront (OHF) provides emergency financial and other assistance to the families of our service members and wounded warriors.
Thanks to our Sponsors:
Delmarva Offroad - F-O-A Shocks - BD Turnkey Engine - Under Cover Fab - Jer-C Transmissions - Quigley Driveshafts

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You call it rolling, we call it R&D! 443-951-JEEP
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Unread 01-01-2010, 10:14 PM   #11
Unlimited04
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looks like you've got quite the shop there! how big? what kind fancy fab stuff you got?

nice work btw
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Unread 01-01-2010, 10:38 PM   #12
wrangler2007
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Looks nice
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Unread 01-01-2010, 10:42 PM   #13
MO2500
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Looking good
Can't wait to see it when you get some more of that chassis bent up!
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Unread 01-01-2010, 10:57 PM   #14
mferrari
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Thanks for the comments, feel free to ask questions on here as well and I can answer stuff as I go along.

As for the shop it our new 30x30 I just built a couple months ago but already way too small... And the fancy fab stuff? The basics; welders, plasma, bender, notcher, grinders, torches, myself

Most of the chassis is going to be on hold until I can get the the t-case and driveshaft sqaured away. Its alot easier to work on it right now with the body off, but I need to put the body back on to get the chassis fitted in and welded up.



I'm on the search for a Yota 2-piece shaft right now. Once I find that I am going to finish the mock up on the tcase and all. Should end up similar to this:
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Team 120 - DOR Racing - Racing for Operation Homefront
Operation Homefront (OHF) provides emergency financial and other assistance to the families of our service members and wounded warriors.
Thanks to our Sponsors:
Delmarva Offroad - F-O-A Shocks - BD Turnkey Engine - Under Cover Fab - Jer-C Transmissions - Quigley Driveshafts

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You call it rolling, we call it R&D! 443-951-JEEP
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Unread 01-02-2010, 11:04 AM   #15
97casteeltj
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this is awesome!
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