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Unread 08-23-2010, 11:55 AM   #1
Rhoener
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1997 TJ Wrangler 
 
Join Date: Jul 2009
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Posts: 141
YJ Restauration or a "CJ-Y" Build

Hi Folks,

after reading a lot in this fantastic forum, I thought I should delight you with a build thread from Germany

I decided together with my son to restore a 91 YJ with 2.5l motor . Hope it's not too touchy, but it will become a "CJ-Y", means CJ front (grill, hood, fenders, tailgate).
Color will be orange, 2" OME, 1" BL and 31s.


How the Jeep looked, when we got it .... almost stock




November last year was start of project, we began to disassemble the YJ




I sold the stock tyres, so here with 31s of my TJ.




The frame has realy had better days




All screws, smaller parts etc will be stored in freezer bags with a label




Some surprises




Nearly "naked"




My "3 best friends": Rust Release (??), our local beer, WD40




The mounting of the safety belt, will not imagine what could have happened




One major milestone




To be continued....

Cheers

Rhoener

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black TJ 4.0, 31", 2" OME
91 CJ-Y 2.5 currently rebuilt: http://www.jeepforum.com/forum/f22/yj-restauration-cj-y-build-1092686 Restoration-Doc: http://www.youtube.com/watch?v=HoGhKuQVTT0
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Unread 08-23-2010, 12:05 PM   #2
wjb4000
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Wow, nasty looking rust!! Good luck with the build. Used to have a 1984 CJ7, really miss that Jeep.
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Unread 08-23-2010, 12:18 PM   #3
Rhoener
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Hi,

next part


Bad looking frame




Deinstall of motor and gearbox





And again surprise, surprise. In Germay in winter a lot of salt is used on the roads, that's the result






I think that's it why you guys call it "frame off" restauration




Starting to work on the frame with sand blast and grinding disk




Some "cosmetics" on the axles






Front axle












My supervisor



...to be continued.


Greets from Germany

Rhoener
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black TJ 4.0, 31", 2" OME
91 CJ-Y 2.5 currently rebuilt: http://www.jeepforum.com/forum/f22/yj-restauration-cj-y-build-1092686 Restoration-Doc: http://www.youtube.com/watch?v=HoGhKuQVTT0
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Unread 08-23-2010, 12:40 PM   #4
Rhoener
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Hi,

next part (it's like Rocky movies )

"Professional" deinstall of the u-joints (please do NOT copy)




Cleaning of the shafts







Some parts start to look good




While we were waiting for the ordered parts for the frame (traverse, shock absorber mounts), we started to work on the dash board.

The work of water for many years:




After grinding and priming:




Primed as well




After a "wellness course" with warm water, brush and degreasing we sprayed the interieur with black color





Before and after





Think it looks good


Meanwhile some other parts: grinding, degreasing with Marine Clean, Metal Ready and POR15






...to be continued


Greets from Germany

Rhoener
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black TJ 4.0, 31", 2" OME
91 CJ-Y 2.5 currently rebuilt: http://www.jeepforum.com/forum/f22/yj-restauration-cj-y-build-1092686 Restoration-Doc: http://www.youtube.com/watch?v=HoGhKuQVTT0
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Unread 08-23-2010, 12:59 PM   #5
Rhoener
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Hi,

next part


Some treatment of the skid plate




Meanwhile the new frame parts arrived






Did some ebay business:

The new face of the YJ




Under the 12-coated bullet proofed army finish a nearly rust free grill appeared




Some motivation, how it shall look like



...and primed




And the rear:





Some work on the tank cover



Grinding, cleaning...



...finally POR15




...not "Man in Black", but "Axles in Black"





...to be continued


Cheers

Rhoener
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black TJ 4.0, 31", 2" OME
91 CJ-Y 2.5 currently rebuilt: http://www.jeepforum.com/forum/f22/yj-restauration-cj-y-build-1092686 Restoration-Doc: http://www.youtube.com/watch?v=HoGhKuQVTT0
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Unread 08-23-2010, 01:03 PM   #6
ArrizX
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I am liking what I am seeing, keep up the good work and the picture updates!
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Unread 08-23-2010, 01:10 PM   #7
Rhoener
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Hi,

...I still have a new part


Cause the POR15 can was just open







Some new parts arrived...




...and installed




Some before/after ..










Frame, axles are ready, just waiting for the ordered OME






..and some ebay shots



Collecting "CJ-Y" parts is done


Started to overhaul the motor





...to be continued


Greets

Rhoener
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black TJ 4.0, 31", 2" OME
91 CJ-Y 2.5 currently rebuilt: http://www.jeepforum.com/forum/f22/yj-restauration-cj-y-build-1092686 Restoration-Doc: http://www.youtube.com/watch?v=HoGhKuQVTT0
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Unread 08-23-2010, 01:20 PM   #8
bradf814
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I like what im seeing.
I will be watching, you are doing a great job!
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Unread 08-23-2010, 01:22 PM   #9
Rhoener
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Hi,

...next one



Grinding and cleaning ....








Decided to paint the motor Chevy Blue, finally my Jeep is a boy






Cleaning the pistons







And again a new ebay shot (just as a pattern for the reassembly )
No, just kidding. Needed some parts and got a 2.5 with gear box for low price.





Christmas in Germany is in July , the OME arrived




Could not resist to start ...





Start to like these before and afters








... to be continued



Greets from germany

Rhoener
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black TJ 4.0, 31", 2" OME
91 CJ-Y 2.5 currently rebuilt: http://www.jeepforum.com/forum/f22/yj-restauration-cj-y-build-1092686 Restoration-Doc: http://www.youtube.com/watch?v=HoGhKuQVTT0
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Unread 08-23-2010, 01:32 PM   #10
MA88XJDude
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I am also turning my YJ into a CJ. However I am installing a CJ motor and Dash also.

I love the attention to detail, looks like it will be a brand new jeep when done.
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Unread 08-23-2010, 01:36 PM   #11
Rhoener
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Hi,

...and the last one for today, that's the status where I'm now:


Trackbars painted and with new bushings




And the first day on own wheels (...ok they are still from my TJ)




Starts to look like a Jeep again






..and still like these before/afters
















...after done with the chassis, I continued with the motor

Bad lookin bearing




Exchange of timing chain and sprocket ...

Marking the old one as template



..and new one installed





That's where I'm today with my CJ-Y, keep you updated

Rhoener
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black TJ 4.0, 31", 2" OME
91 CJ-Y 2.5 currently rebuilt: http://www.jeepforum.com/forum/f22/yj-restauration-cj-y-build-1092686 Restoration-Doc: http://www.youtube.com/watch?v=HoGhKuQVTT0
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Unread 08-23-2010, 02:21 PM   #12
Rhoener
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Hi,

thanks for your replies

@MA88XJDude: will watch your thread and look how things are going on.
CJ dash will be an option, but I finished in winter the YJ dash. So maybe in
the future. At present I have enough to do with the rest of the Jeep. Engine
swap to CJ will be very expensive in Germany due to tax on CUI and
exhaust emissions. If the "CJ-Y" will be done, maybe a CJ-7 with V8 will
follow. For 30 + year old cars, an oldtimer registration is possible with low
tax


Cheers

Rhoener
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black TJ 4.0, 31", 2" OME
91 CJ-Y 2.5 currently rebuilt: http://www.jeepforum.com/forum/f22/yj-restauration-cj-y-build-1092686 Restoration-Doc: http://www.youtube.com/watch?v=HoGhKuQVTT0
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Unread 08-23-2010, 03:12 PM   #13
AustinTexasXJ
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Das ist gut!

Keep up the good work. cant wait to see it done.
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Unread 08-23-2010, 09:59 PM   #14
Rhoener
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@AustinTexasXJ: coll an answer in german

Keep you updated. Next step will be finishing of motor, cleaning and painting of gearbox and installation of Brakes, Brakelines and Fuellines.

Than we can start to work on the body....

Have a great day

Rhoener
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black TJ 4.0, 31", 2" OME
91 CJ-Y 2.5 currently rebuilt: http://www.jeepforum.com/forum/f22/yj-restauration-cj-y-build-1092686 Restoration-Doc: http://www.youtube.com/watch?v=HoGhKuQVTT0
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Unread 08-23-2010, 10:19 PM   #15
KINGJB
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This is awesome
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