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Unread 04-14-2014, 12:50 PM   #1
fire6945
Registered User
2003 TJ Wrangler 
 
Join Date: Mar 2014
Location: jonesborough, tn
Posts: 7
Rubicon Rebuild

Well I bought a wrecked Rubicon to rebuild and will post as I get things fixed.

So far it all ready has a mix of Rubicon express/ teraflex lift 35" tires ect.
I am going to go over the front end install synergy ball joints, inner c gussets, a truss and go ahead and "3 link" it. Possibly do high steer.
I have a hood getting painted and have some tube fenders that will go on it. I am designing bumpers and sliders for it also.
Nothing spectacular, but something to keep me busy.
Here it is with the front tore down getting ready to rebuild.


screen shot

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Unread 04-16-2014, 07:16 PM   #2
fire6945
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2003 TJ Wrangler 
 
Join Date: Mar 2014
Location: jonesborough, tn
Posts: 7
Got bored waiting on parts to come in. So I smoothed out the rear. Added LED tail lights and reverse lights, removed the tag mount and installed my stubby bumper design that moves the tag to the center of the jeep.
Before:

image uploading

After:

photo uploading
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Unread 04-17-2014, 09:09 PM   #3
fire6945
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2003 TJ Wrangler 
 
Join Date: Mar 2014
Location: jonesborough, tn
Posts: 7
Got some of my designs back from the laser shop today. Front bumper and sliders.


post images

Decided to make a gusset for the stinger. Made it the ole fashioned way.

screenshot tool

Front bumper almost done.( it's not back all the way in the pic. Jack stands were in the way.

image hosting sites


host images
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Unread 04-20-2014, 05:44 PM   #4
fire6945
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2003 TJ Wrangler 
 
Join Date: Mar 2014
Location: jonesborough, tn
Posts: 7
I got to start on the D44 front. First thing is installing the Synergy axle sleeves. A few others sell the tubes also. Its pretty straight forward. Clean out the axle tubes drill some holes to plug weld and weld the tubes near the inner C. I did have to deburr the ends of the tubes and I also ground a chamfer on the end for a better weld.

To clean out the housing I cut and welded a washer to a rod so I could run it up the axle and pull out any trash that had got in it over the years. It also helps get the shavings out when the plug holes are drilled.


upload image free

Some sandy junk.

take a screenshot

Ends dedurred and chamfered

how to screenshot on windows 7

Plug welded and end welded

picture uploader


free upload image
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Unread 06-25-2014, 12:16 PM   #5
fire6945
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2003 TJ Wrangler 
 
Join Date: Mar 2014
Location: jonesborough, tn
Posts: 7
I have this posted on a few more forums. Couldn't keep it up to date on all of them. Here is a link to it.
http://www.pirate4x4.com/forum/jeep-...-w-3-link.html
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