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TallyZJ 06-13-2011 06:58 PM

Tally ZJ's 1996 ZJ Laredo build
Wow, I have had this Jeep since 2007 now and its almost too late to post a build thread but I haven't done so much to it that I can't go ahead and start one.

This Jeep was given to me. It was a one owner Jeep purchased in Pensacola Florida. The owners had an accident, it was hit in the left rear wheel well, and bent the axle tube flange. They attempted to pull the axle out to change it but were unsuccessful. :confused:

Anyway, they left it on jack stands in their back yard for five years. Imet them at a mudding event and they offered it to me for a couple hundred bucks. I was interested but had no money. A few months later I ran into them again and they told me just to come get it.

I got to their house and I was horrified. It had weeds and twigs grown up all over it, over the roof, up the antenna and was pretty pathetic looking.

Little did I know that the weeds that covered it actually saved it! There was no sun damage anywhere and the interior was mint!

The only damage was the wreck damage to the axle, a little bit of fender damage to the rear quarter and a family of squirrels had made a home under the hood and chewed the engine harness up real good.

Got ait home, removed the fuel tank, completely cleaned it out and dried it, installed a new fuel pump assembly, new engine harness from Pick-N-Pull, new plugs, fluids and filters, serp belt and plugs and a new battery. It fired right up! Has ran ever since.

Snatched a free Dana 35 ZJ axle from Pick-N-Pull (I worked there at the time so it was free) and installed it. Did some minor work to the rear quarter panel and cleaned it up real good with a buff job and wax job.

Other than the Moab rims, it looked just like this pic below when it was completed and running. Moabs were added a few months later.

In the pics below you can see the square tubing on the roof for the rock slider build.

TallyZJ 06-13-2011 07:01 PM

Rock sliders built and installed. They have served me well over the past few years.

Sorry, no one took good photos of the process. I had to do the fab and welding so I couldn't take photos.

They are pretty much a copy of the AJ Rock Rails using attachment runners to the frame rail and long strips of flat metal pinching the body seam.

TallyZJ 06-13-2011 07:03 PM

Next was Aussie lockers front and rear. Same day. Took me most of the day to clean everything and install both lockers. Again, not many pics of the process.

TallyZJ 06-13-2011 07:09 PM

This year I did an OTK tie rod flip using a ZJ tie rod, right hand drive drag link and new tie rod ends and pitman arm from a TJ. I have a compete writeup on this project on this forum.

TallyZJ 06-13-2011 07:11 PM

I also installed my Rubicon Express 4 1/2" springs front and rear, adjustable rear track bar, Iron Rock Off Road front HD double sheer track bar and bracket, Rubicon Express lower front adjustable control arms, IronMan4x4 front upper control arms, IronMan4x4 rear upper control arms, JKS shock stem adapters and bar pin eliminators and Rubicon Express twin tube shocks.

This is what it looks like today and I have done no more mods to it so far. there are more coming soon.

TallyZJ 06-13-2011 07:12 PM

Finished my rear lower control arms tonight. Will install them tomorrow and get a measurement for the rear uppers.

Here is the steel tubing and 3/8" flat bar stock I got for $20.00 today.

And the cast iron drain grate I got for $18.00. This is now my Tig table top.

And here are the bushings and sleeves from Iron Rock Off Road.

TallyZJ 03-09-2012 09:35 PM

Used my angle grinder to make the notches for the bushing sleeves. I then did a mockup, measured twice, and by some miracle both arms were exactly the same length.

After mockup and another check for length I tacked the tubes to the sleeves and allowed them to cool.

TallyZJ 03-09-2012 09:38 PM

Now to Tig in the rest of the welds.

TallyZJ 03-09-2012 09:39 PM

Using strips of the 3/8" thick flat bar stock I added "sliders" to the bottom edges of the lowers to add strength and protection from rocks.

TallyZJ 03-09-2012 09:40 PM

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Now for some Rustoleum Hammered finish!

TallyZJ 03-10-2012 03:06 PM

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Finished the rear upper control arms today. A lot quicker than the lowers went.

TallyZJ 03-10-2012 03:35 PM

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And here is a shot of the arms installed (looking towards the rear of the Jeep)

TallyZJ 03-16-2012 09:40 PM

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Started the relocation of my sway bar mounting brackets.

After cutting off the factory brackets I decided to move the new brackets to the inboard side of the coil buckets.

I used card stock paper to make a template for the new bracket shape.

I used my press and press brake to put the bends in it and I welded the mounting pin to the bracket. I added strips of .250" flat bar to make the bracket almost 3/8" thick.

Once the brackets are completed they will be cleaned up and painted.

TallyZJ 04-07-2012 08:40 PM

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Today I began my front bumper build.

Going roughly by my plans for a modular bumper I started the center section.

This is the illustration of what I hope will be the finished product or very similar. I have changed a few things so far such as using angle instead of box section steel to cut some weight and allow access to the inside of the bumper once mounted.

TallyZJ 04-07-2012 08:43 PM

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So starting the center section I used some 6" channel in 1/4" thickness. I cut it 37" long and added a piece of 4" angle to make it wider.

The time now is 01:34 PM.

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