Project "YJ Unlimited" Build-Up - Page 8 -
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post #106 of 306 Old 02-13-2009, 11:27 PM
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1987 XJ Cherokee 
Join Date: Sep 2006
Location: 3rd rock from sun
Posts: 10,144
props man, hang with it. good thread!


"You can set my jeep on fire and roll it down a hill,
But I still wouldn't trade it for a Coupe DeVille."

COTY 2009

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post #107 of 306 Old 02-13-2009, 11:31 PM
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1992 YJ Wrangler 
Join Date: Sep 2007
Location: Pittsburgh, Pa
Posts: 3,698
looking great!!!!!!!!!!
-OD Green/Flat Black 92' 4" Rough Country Lift, tons of crap.
-Rio Red 1995 Ford Mustang- Daily Driver
Originally Posted by alfmoney
i see theres a bunch of toughguys on this forum or internet gangstas
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post #108 of 306 Old 02-14-2009, 09:28 PM
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1997 TJ Wrangler 
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Location: Ohio
Posts: 7
I love this thread, hang in there and good luck
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post #109 of 306 Old 02-14-2009, 09:29 PM
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1995 YJ Wrangler 
Join Date: Jul 2007
Location: Virginia
Posts: 352
What type of fiberglass fabric and resin are you using? Is it holding up pretty well?

1995 YJ Rio Grand - work in progress
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post #110 of 306 Old 02-14-2009, 11:05 PM
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1997 TJ Wrangler 
Join Date: Aug 2008
Posts: 145
AWESOME!! Nice work so far. Keep it up.
Can't wait for more

'97 BLACK TJ Sport
4.0L 5 speed Man.
4in lift
35"x13.5 Toyo Open Country M/T
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post #111 of 306 Old 02-17-2009, 10:16 PM
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2000 TJ Wrangler 
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Location: graham wa
Posts: 43
i know i've posted on here a couple of times
already but you doing great man keep it up
i'm so stoked to see this jeep finished
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post #112 of 306 Old 02-25-2009, 06:03 PM Thread Starter
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1988 YJ Wrangler 
Join Date: Mar 2007
Location: Utah
Posts: 669
So just a little update... things are a little better than they were before so now I can finally get working on the Jeep again. .

Some things that I've accumulated for the project since the last post-
-2nd frame (you'll see why shortly)
-My own MIG welder
-A pair of front racing seats
-Half doors
-A metal-cutting capable band saw
-Replacement body bushing mounts

And I've
-Cleaned up/stripped suspension related brackets/sandblasted/repainted both axles.
-Have gotten the body off of the trailer finally getting it all ready to go.

So now I will start work on the frame stretch. I know exactly how I'm going to do it and if all goes right and I do a good job, the joint will be seamless and very strong and only someone with an educated eye will be able to tell where I stretched it. Stay tuned! *sigh* glad to be working on the YJ again.

I'll post some small pics up of all the new parts.
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post #113 of 306 Old 02-27-2009, 09:13 AM
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1980 CJ7 
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Location: round rock, tx
Posts: 445
Welcome back, now post progress pictures!

In Process: 2002 4.0L and NV3550 Swap
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post #114 of 306 Old 02-27-2009, 01:32 PM
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1992 YJ Wrangler 
Join Date: Feb 2009
Location: colorado springs
Posts: 22
lol. always remember that jeeps eat speed bumps for breakfast. so when life becomes a speed bump you dont really have to worry too much. lol
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post #115 of 306 Old 03-01-2009, 03:14 PM
1992 renagade
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1992 YJ Wrangler 
Join Date: Nov 2005
Location: Chadds Ford Pa
Posts: 589
Keep up the good work man and post some update when you can. Project looks great and it seems like you have a plan that is working great for you.


1992 black Renegade
4.0L 5spd. 4:10 gears 33x12.50 BFG KM 2's A to Z fabrication front and rear bumpers and cage
1994 YJ Sahara Project Bean
2000 Jeep Cherokee Stock
AtoZ Fabrications
Blue Mountain Jeep Alliance
Delaware jeep Association
Originally Posted by Imped View Post
Screw the HOA. More guys just need to start doing man things in the garage.
Originally Posted by aw12345 View Post
Jeeps are like mistresses, they take all your money, but boy what a ride!
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post #116 of 306 Old 03-10-2009, 09:02 PM
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1993 XJ Cherokee 
Join Date: Mar 2009
Location: Seattle
Posts: 89
Thats a crazy undertaking. I once cut 13.8 inches out of a chevy shortbed and put my body up on a K10 chassis. I was about 17 at the time too. You're bringing back some great memories. Keep up the work.
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post #117 of 306 Old 03-16-2009, 10:30 AM
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1992 YJ Wrangler 
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Location: Bullville, NY
Posts: 22
where's the updates?
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post #118 of 306 Old 03-16-2009, 11:23 AM
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1974 CJ5 
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Location: Baltimore
Posts: 26
Yea i want more

Take it out and play with it!
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post #119 of 306 Old 03-16-2009, 06:29 PM Thread Starter
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1988 YJ Wrangler 
Join Date: Mar 2007
Location: Utah
Posts: 669
Getting ready to file mutiny are we?

__________________________________________________ ______

Well I'll fill you in some.... When I was taking the black section of the body off (Jeep #2) I broke off one of the body mount bolts (at the very back of the tub).. IT KICKED MY @$$ for hours.. I ended up breaking: 2 drill bits, and and easy out... then I ended up cutting out the "Body Mount Retainer" (the threaded steel block that sits inside the tub).. .Then I tried everything to get the bolt out and ended up breaking another drill bit, and dulled 2 more... so I went to the stealership and ordered a new one... ($9 ) and then I remembered that I had another one (from the part of the red tub that I cut off) and so I canceled my order, then went and hacked the other one out of the tub... wrestled that bolt out......

Bought the right body mount bushing set finally... (other ones didn't work) and sandblasted both sections of frame... there was some decent rust underneath the rear upper shock mounts on both sides so I'm in the middle of fixing that (I'm doing a write up on "Seamless frame rust repair") .. hopefully tomorrow or wednesday I will conjoin the two frames and will have some pics for you guys!

Oh also my gasket kit came finally from SummitRacing so when I get my frame all done up I can rebuild the engine...
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post #120 of 306 Old 03-18-2009, 03:11 AM Thread Starter
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1988 YJ Wrangler 
Join Date: Mar 2007
Location: Utah
Posts: 669
K well I decided not to do a write up on the frame repair because its just my way of doing it and you may have another way... but I will post step by step pics of what I did....

Phase 1- Destruction
So when I cut off my rear shock mount brackets, I noticed that underneath was rusted pretty badly... and after sandblasting the frame I was able to knock a hole in one side with a screwdriver... (this was the only spot that was rusty... everywhere else was fine and rust free)... so I decided it was best to just replace that section... so I sprayed the frame down with some rustoleum primer to prevent the newly sandblasted frame from rusting, then I grabbed the angle grinder with the wire wheel attachment and scrubbed off where I wanted to cut out...

Side-1 (passengers)

Side-2 (drivers)


Then I figured out where the edges of the rust damage was, and using my handy-dandy square and some masking tape, I marked the areas of where I wanted to remove... (even though one side was a little worse than the other... I cut out identical peices)


Now I wanted to remove any possiblites of stress risers by having a sharp corner where the frame could end up cracking...and so I wanted nice rounded corners... so I marked in 1/4" each way on each corner with a dummy punch...


And then drilled a 3/16" pilot hole....


And then followed with a 1/2" drill bit...


And finally played connect a dots!... With a cutoff wheel on an angle grinder...(my fav tool to cut with.. makes a nice straight clean cut.)

In all reality I probably could have gotten away with doing it another way... but I didn't want to risk any chances of having thin material there and end up cracking...

This is just one way to do it.. and its the way that I liked best and the way that I chose....

I had to do a lot of running around today (grr... had to pay another speeding ticket I wasn't able to get much more finished as I wanted to... but tomorrow it should all be back together and then I can conjoin the frames!... Just to let everyone know before hand.... I will reinforce this area to eliminate a weak link in the frame...
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