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Rugged Ridge 8500lb Winch w/ Steel Cable $294.99 Shipped OSmittybilt Products at Oconee Off-Road!Building a Bumper?

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Unread 12-01-2008, 03:35 PM   #1
chocflip201
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1988 YJ Wrangler 
 
Join Date: Mar 2007
Location: Utah
Posts: 668
Project "YJ Unlimited" Build-Up (Lots of pics)

Well its begun. Many of you may have seen DukeGnarly's extended YJ build thread. This one is similar in the concept of stretching the YJ, but with a few changes to suit my choices. The TJ Unlimited has a wheel base of 103.5" while the regular TJ and YJ have a wheelbase of 93.5" so the unlimited has a stretch of 10". However they stretched the body nearly 15" versus the non-unlimited which leaves a nasty 5" extra overhang after the rear wheels, killing the departure angle.

Here are my objectives that I will try my hardest to keep in line with:
#1-STREET LEGAL!
As for my last build, it was nowhere near street legal, which forced me to trailer my Jeep from trail to trail, and not bein able to run errands with it.

#2- Somewhere around 8" of lift.
This will most likely be comprised of Six inches of suspension lift, and 2" of body lift. (The frame of the vehicle has to be no more than 24" off the ground (in between the wheels) to stay street legal.)

#4- *Run 40" tires.
So, I used to want to run 37" tires.. but I think I will be going with some 40's or 39.5's...

#4- Have a wheelbase of around 110".
Give or take 3 or 4 inches.

#5- Have Maximum Street-Legal Approach and Departure angles.
I will try to keep the edge of my tires just about 1 or 2 inches inside of the end of the bumpers, keeping it street legal without smacking my bumper on everything.

#6- Nice Quality Fabrication
My last build was kind of thrown together really cheaply and quickly, and yes I admit lacked in some safety aspects.


What components I have so far-
Ford 9" rear axle, 28 spline, locked, disc brake conv.-*Sold
Ford HP D44 Front (usable because its a '69)-*Sold
37" Worn out tires on 18" rims. -*Sold
*Ford D60-1979-High Pinion-King Pin
*GM 14Bolt-197?-Detroit Locker
1989 YJ
Hard top
4.0L from my 87 XJ
AW4 Auto Trans
NP 231 Xfer.
*Half Doors
*Racing Seats
*TJ Dash&Center Console


What I will need to buy still-
4 Coilovers. - *Most likely BallisticFabrication's...
New Tires. -*Most likely Nitto Mud Grappler- 40x17
A selectable locker for the front (most likely an ected or similar)
Tubing for roll cage
SYE - *Most likely JB Conversions "Super-Short SYE"
Control Arms/ suspension fab parts. - *Most Likely BallisticFabrication stuff
*Axle Trusses F&R
*5.38 Ring&Pinions - F&R
*8 Lug 17" Rims
*Guages
*Something along the lines of a fuel cell

*All items with a "*" are items as updated on 3-10-09


Well It's time to start the build up.

What I started out with- a $200 body complete with good windshield frame, good hood/grill/tub/tailgate. No rust!









Last edited by chocflip201; 03-10-2009 at 01:44 AM..
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Unread 12-01-2008, 04:01 PM   #2
chocflip201
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Location: Utah
Posts: 668
Cutting The Tub

After doing months of research after I had thought about the idea of stretching it, I found DukeGnarly's thread. I liked his idea about using a second tub to do the stretch. However he cut his tub right through the brace that the rear seat belts, and the body mounts tie into. I didnt like that so I moved my cut about 5" behind his so I could keep my support bar intact. So after lots and lots of measuring, double checking, and squaring, I masked out the line where I wanted to cut the body and I cut. DukeGnarly chose to use a Die Grinder with a cut-off wheel however I have found these awkward to handle, and lack in power. (I only have a 22 gallon compressor, can't quite keep up with the die grinder. So I chose to use a 4" grinder with a 1/16" cut off wheel. It worked wonders. Easy to handle, cut fast and straight, no air line needed.



To cut thin sheet metal, I usually mask out the line that I want cut, and stay about 1/8" away from the tape, and then go back with a Flapper disc and get right up against the edge of the tape, without touching the tape..



Nice Straight cut!




Good preparation turns out a good result.




It turned out really well, and took about 2 minutes to cut from start to finish. And about 5 minutes of fine detail work with a flapper disc to clean up the edge. The last picture shows what good measuring will turn out. This was a blind corner and so I wasn't able to measure this to make sure it would turn out in the same spot, but good measuring and double checking shows that they found the exact same location!
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Unread 12-01-2008, 04:08 PM   #3
chocflip201
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Floor cut

This picture shows how I didn't cut through the body mount support bar, so only one layer of sheet metal, versus DukeGnarly cutting through both.

Mine-

DukeGnarly's-
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Unread 12-01-2008, 04:09 PM   #4
luc
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Keep the pics comming... I love this type of build - you know the kind that start with cutting a jeep in half!
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Unread 12-01-2008, 04:14 PM   #5
chocflip201
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Donor Tub

I bought this tub a few months ago for $300. However the person would only sell it to me if I took the entire Jeep. Frame (no good), Axles (stock), Hood, fenders, Roll Cage (won't use) etc.. . I'll plan on cutting this one tomorrow (12/2/08) and get them welded up during the week. (not working right now)
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Unread 12-01-2008, 04:24 PM   #6
chocflip201
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Quote:
Originally Posted by luc View Post
Keep the pics comming... I love this type of build - you know the kind that start with cutting a jeep in half!
Ha yeah me too. People have called mods like this "Jeep and a half" haha
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Unread 12-01-2008, 07:08 PM   #7
UBOHICA
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WOW, cool man I can't wait to see this thing done
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Unread 12-02-2008, 06:32 PM   #8
chocflip201
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Donor Tub

Well I got the 2nd tub cut apart today. It didnt go quite as fast as cutting the first tub because this body was still on the frame but it still turned out well. Here are a few pics, sorry about the flash it was dark outside. Plan is to weld it up Thursday (12-4-08.) Thanks For looking!





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Unread 12-02-2008, 08:50 PM   #9
JEEP97TJ
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Awesome job so far, I like these two builds going on at the same time. Good luck.
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Unread 12-02-2008, 09:41 PM   #10
chocflip201
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Quote:
Originally Posted by JEEP97TJ View Post
Awesome job so far, I like these two builds going on at the same time. Good luck.
Yep thanks. Ha yeah its pretty nice having someone a step ahead of you so you know what works and what doesn't. But other than what I have done already ( after I weld it up) our threads will start looking pretty different. Other than the fact that he has a nice cozy shop to work in haha.
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Unread 12-02-2008, 09:43 PM   #11
chocflip201
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Nice TJ btw. Just read ur build thread.
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Unread 12-02-2008, 10:04 PM   #12
Turner
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Crawled! Looks good. When you say hardtop what top will you be using a scrambler top, yj hard top, or an unlimited top? I have wanted to do this for about a year now... lucky... will be watching daily!
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Unread 12-02-2008, 10:10 PM   #13
chocflip201
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Quote:
Originally Posted by Turner View Post
Crawled! Looks good. When you say hardtop what top will you be using a scrambler top, yj hard top, or an unlimited top? I have wanted to do this for about a year now... lucky... will be watching daily!
I will be stretching the stock YJ hardtop. And that will be why DukeGnarly's thread and mine will start to differ after this week because he is starting working on his rollcage, suspension etc, but before I can do that I have to get something to keep the snow out before it gets here! (don't want to use just a tarp. Plus I'd rather get it done and out of the way now so that I don't put it off later and end up never doing it. So after I get the body welded together, I will start on the hardtop stretch! I'm also doing this to save up some money over the winter so that I can afford all the coil-overs and other suspension components. And thanks for bein my first crawl!
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Unread 12-03-2008, 12:10 AM   #14
dukegnarley
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looking good. the only thing i regret so far is not cutting my tub 1" farther back, but it looks like you got that taken care of
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Unread 12-03-2008, 01:16 AM   #15
chocflip201
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Quote:
Originally Posted by dukegnarley View Post
looking good. the only thing i regret so far is not cutting my tub 1" farther back, but it looks like you got that taken care of
Yep it comin along pretty easy. btw i used your pic, but you already knew that ha I've been pondering for quite a while now on how I'm going to stretch the hard top and I think I've came up with a way to still be cost efficient, be strong and still look good. what I didn't figure in, I might as well have just bought an LJ hard top and made it work. (between time and cost, one just sold online for 1,200, and was in mint condition) but Oh well thats why jeeps are "built not bought" right ha.
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