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The Solution to Radius Arm Bind - Meet Lock-N-LoadFS: Jeep Fog Light LED Bulbs! Several Brightness Options! Rough Country Jeep Suspension Deals at Rockridge 4WD!

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Unread 05-02-2013, 09:07 PM   #16
tslroper
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1990 YJ Wrangler 
 
Join Date: Aug 2010
Location: New Mexico
Posts: 379
Here's a pic of a mock-up of the battery box on the battery tray. I almost decided to switch to blue rather than the hemi orange (the rest of the jeep is black and blue, as is the distributor) but a close friend who recently passed was the one who convinced me of the orange in the first place. It's staying.



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1990 YJ Islander, 4.2L MC2100 DUI HEI, 2.5" RE lift, 31x10.50 DuraTracs, HandenFab rear bumper / swing-out, Tough Terrain
off-road camp trailer.
Build thread: http://www.jeepforum.com/forum/f22/tys-yj-build-1502554/
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Unread 05-03-2013, 08:03 AM   #17
Cuder
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2000 TJ Wrangler 
 
Join Date: Feb 2009
Location: Arlington, Texas
Posts: 2,598
I would use a die grinder with a scotchbrit disc to take that area down to bare metal. If there is any rust then use POR15.
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Unread 05-03-2013, 09:37 PM   #18
tslroper
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1990 YJ Wrangler 
 
Join Date: Aug 2010
Location: New Mexico
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Alright, I'll give it a shot, thanks. I'm hoping to pull the excess wiring from the computer and clean up the engine bay by the middle of next week then spend next weekend dropping the motor back in. Once that's done I'll re-wire everything so I can be sure I have the lengths correct.
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1990 YJ Islander, 4.2L MC2100 DUI HEI, 2.5" RE lift, 31x10.50 DuraTracs, HandenFab rear bumper / swing-out, Tough Terrain
off-road camp trailer.
Build thread: http://www.jeepforum.com/forum/f22/tys-yj-build-1502554/
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Unread 05-07-2013, 10:35 PM   #19
tslroper
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1990 YJ Wrangler 
 
Join Date: Aug 2010
Location: New Mexico
Posts: 379
A little more progress was made today. I began wiring the relay boxes and preparing a lot of the wiring for the Jeep. A lot of what I'm planning may be over-kill but its certainly going to be better than the stock wiring.

Each relay box holds 5 relays. These are for:

Box 1:
Distributor (HEI, will be run on a relay)
intake manifold heater
electric fan
fog lights
driving lights (eventually)

Box 2:
headlight high beam
headlight low beam
killswitch
long range lights
reverse lights (eventually)

The thick blue wire is a 9 conductor wire i found on ebay for fairly cheap. It will make running wires into the cab for switches MUCH easier. The green wires are the grounds and will run to a common bus bar for grounds. Each relay box will be protected by a 60A maxi fuse in a separate fuse holder mounted next to the box.



__________________
1990 YJ Islander, 4.2L MC2100 DUI HEI, 2.5" RE lift, 31x10.50 DuraTracs, HandenFab rear bumper / swing-out, Tough Terrain
off-road camp trailer.
Build thread: http://www.jeepforum.com/forum/f22/tys-yj-build-1502554/
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Unread 05-10-2013, 09:14 AM   #20
tslroper
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1990 YJ Wrangler 
 
Join Date: Aug 2010
Location: New Mexico
Posts: 379
Another small update.

Got the motor back from the machine shop yesterday, was cheaper than i anticipated and they did an excellent job.





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1990 YJ Islander, 4.2L MC2100 DUI HEI, 2.5" RE lift, 31x10.50 DuraTracs, HandenFab rear bumper / swing-out, Tough Terrain
off-road camp trailer.
Build thread: http://www.jeepforum.com/forum/f22/tys-yj-build-1502554/
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Unread 05-10-2013, 09:47 AM   #21
Cuder
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I love the look of a freshly painted re-built motor on a stand. Do you live in Mesilla by the Stahlman farm? I hate that they closed down the gift shops.
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Unread 05-10-2013, 09:55 AM   #22
tslroper
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1990 YJ Wrangler 
 
Join Date: Aug 2010
Location: New Mexico
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Nah, farther north between Dona Ana and Radium Springs.
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1990 YJ Islander, 4.2L MC2100 DUI HEI, 2.5" RE lift, 31x10.50 DuraTracs, HandenFab rear bumper / swing-out, Tough Terrain
off-road camp trailer.
Build thread: http://www.jeepforum.com/forum/f22/tys-yj-build-1502554/
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Unread 05-10-2013, 10:02 AM   #23
Cuder
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I have a friend that lives in Dona Ana, he is Truck633 on here, he has a CJ. I could've had a job there years ago, but my wife would'nt move away from her family.
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Unread 05-10-2013, 10:10 AM   #24
tslroper
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1990 YJ Wrangler 
 
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Location: New Mexico
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Yeah, I ran into him at the Chile Challenge the year before last. Its a nice area, though the drought is kind of killing us right now.
__________________
1990 YJ Islander, 4.2L MC2100 DUI HEI, 2.5" RE lift, 31x10.50 DuraTracs, HandenFab rear bumper / swing-out, Tough Terrain
off-road camp trailer.
Build thread: http://www.jeepforum.com/forum/f22/tys-yj-build-1502554/
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Unread 05-11-2013, 08:06 PM   #25
tslroper
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1990 YJ Wrangler 
 
Join Date: Aug 2010
Location: New Mexico
Posts: 379
Another small update, though no pictures this time. I replaced all the drive shaft u-joints today while the drive shafts were out. One on each shaft was bad (broken and mashed needle bearings) though there was no play in the shafts before i pulled them. I also got a little more done on the wiring harness. This next week I get to pull the dash, remove all the excess wiring in the engine bay, and repaint the engine bay. I have some help coming over thursday or friday of next week to drop the motor in.

I started poking around the wiring in the engine bay and it looks like 75-80% of it will be gone with the computer. Anyone know what the two relays mounted to the side of the battery tray are? I dont think either are currently functioning, but before I trash them I'd like to make sure.
__________________
1990 YJ Islander, 4.2L MC2100 DUI HEI, 2.5" RE lift, 31x10.50 DuraTracs, HandenFab rear bumper / swing-out, Tough Terrain
off-road camp trailer.
Build thread: http://www.jeepforum.com/forum/f22/tys-yj-build-1502554/
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Unread 05-15-2013, 07:04 PM   #26
tslroper
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1990 YJ Wrangler 
 
Join Date: Aug 2010
Location: New Mexico
Posts: 379
Ok, I got quite a bit done today. I started with pulling the dash to correct the wiring behind it, remove the computer and make it easier to re-wire the accessories and switches. In doing so I found a bit of surface rust under the windshield frame. Time for a new gasket or whatever that thing is. Placed the order with Morris 4x4.


This is after I cleaned it up a bit with a wire wheel brush.


All taped off. I shot it with some rust neutralizer then painted over it in black just to prevent it from getting worse. I can honestly say this is the FIRST bit of rust I've ever run into on this Jeep.


Start of the re-wiring / wiring repair.


This is the only 'before' pic I got of the engine bay wiring, but i removed about 4 miles of electrical tape. I can also honestly say that what I found scared the #$%@ out of me. The previous owner was a fool to say the least.

And the after pics:


__________________
1990 YJ Islander, 4.2L MC2100 DUI HEI, 2.5" RE lift, 31x10.50 DuraTracs, HandenFab rear bumper / swing-out, Tough Terrain
off-road camp trailer.
Build thread: http://www.jeepforum.com/forum/f22/tys-yj-build-1502554/
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Unread 05-15-2013, 07:48 PM   #27
Cuder
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2000 TJ Wrangler 
 
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WOW, Good luck with all that!!!!
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Unread 05-16-2013, 10:57 PM   #28
tslroper
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1990 YJ Wrangler 
 
Join Date: Aug 2010
Location: New Mexico
Posts: 379
Today's obligatory update, this time all in pictures! (It's all self-explanatory)











__________________
1990 YJ Islander, 4.2L MC2100 DUI HEI, 2.5" RE lift, 31x10.50 DuraTracs, HandenFab rear bumper / swing-out, Tough Terrain
off-road camp trailer.
Build thread: http://www.jeepforum.com/forum/f22/tys-yj-build-1502554/
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Unread 05-21-2013, 04:32 PM   #29
tslroper
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1990 YJ Wrangler 
 
Join Date: Aug 2010
Location: New Mexico
Posts: 379
Another small update here:

Started mounting the accessory drives and repainted the fender wells and the underside of the hood as we had discussed earlier in the thread. In this picture the underside of the hood is still wet, it turned out very nice and isnt blotchy at all now that it is dry.



I also mounted the battery tray and the battery box i purchased from Ballistic Fab.



Several months ago someone attempted to steal my CB by cutting the wires off flush with the box. Fortunately they were stopped before they could get away with it. To keep this from happening again I've decided to set it up so the CB is easily detachable and can be secured in the glove box. I purchased a 2 pin quick connect online and soldered the leads onto the board in the CB (the old wires were too short to splice to).



And some information for anyone searching:
If your looking to upgrade the alternator on the 4.2L / 258 I dug around in the back at my local autozone and managed to find an alternator for a 1987 Chevy V10 1/2 ton P/U 4WD with the 5.0L V8. It is an exact fit for the stock serpentine belt bracket and puts out 100A. It's also cheaper than the stock replacement part from autozone.

http://www.autozone.com/autozone/par...60_23521_4678_

__________________
1990 YJ Islander, 4.2L MC2100 DUI HEI, 2.5" RE lift, 31x10.50 DuraTracs, HandenFab rear bumper / swing-out, Tough Terrain
off-road camp trailer.
Build thread: http://www.jeepforum.com/forum/f22/tys-yj-build-1502554/
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Unread 05-22-2013, 11:09 AM   #30
Cuder
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2000 TJ Wrangler 
 
Join Date: Feb 2009
Location: Arlington, Texas
Posts: 2,598
I used the same connector on my CB. I mount it on the tray on the dash.
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