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Unread 03-28-2009, 09:53 AM   #1
brunosplace
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1997 TJ Wrangler 
 
Join Date: Mar 2007
Location: Michigan
Posts: 1,096
Bruno's Lapis Blue build (Tummy Tuck)

EDIT: Links to various projects as I post them

Skid Plate Nut-sert replacement (this post)
32RH vent relocation
Transfer Case shifter linkage
High clearance trans mount
Deep pan and temp sensor on 32RH
High Clearance skidplate (tummy tuck) Before & After
Upper Spring Bucket Relocation and rear bumpstop extensions
Outboarded rear shocks



I am in the process of doing a tummy-tuck / high clearance skid on the Jeep now. I have to give a big shout-out and thank you to my brother for all of his help on this, and for letting me take over his shop for a week, as this is being done on evenings after work. He has been doing all of the heavy lifting since I tore up my shoulder and am awaiting surgery to repair the damage, so we are trying to get this done before I am completely unable to work on it for awhile.

I hate the look of a body lift, so this is being done without one. The skid I will be using will end up about 1.25 inches total below the frame rail. There are several mods to be made to accomplish this project without a body lift. I will be using a modified low profile mounting system for the trans mount, and be making exhaust mods to make it fit.

So, here are a couple of before pics.







As part of planning this I discovered that 3 of the nut-serts (part # 06035739) were spinning in the frame, so I bought them ahead of time from the dealer, and replaced all six of them. Here are the new inserts in place. (still need to tack weld them.) For removing the old ones, we found that using an air hammer with a sharp chisel was the best, just chisel off the flange, then use a punch to knock the sleeve up into the frame rail. After that grind the old tack welds off smooth. Takes about 60 seconds apiece to remove them this way.









__________________
Quote:
Originally Posted by Boodyrider View Post
............
Big tires, done right, are FREAKING EXPENSIVE. Deal with it, or don't go there.
Quote:
Originally Posted by woodnjeep View Post
I live in the land where they salt cure roadkill.
97 Jeep TJ Sport, 4.0L, Auto, 3" BDS Lift (SOLD)
98 Jeep ZJ Laredo 4.0L, Auto, Stock Totaled, parted out and scrapped
96 Jeep XJ Sport, parted out and scrapped

Tummy Tuck without a body lift. Finished!!

Superior Axle & Gear TJ/XJ Dana 44 Discovery Shafts (DC45 kit) for sale

Last edited by brunosplace; 05-19-2009 at 03:12 PM.. Reason: more info
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Unread 03-28-2009, 10:08 AM   #2
brunosplace
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Join Date: Mar 2007
Location: Michigan
Posts: 1,096
I also decided this would be a great time to relocate the vent on the 32RH auto trans. Since the trans is already out we took the opportunity to replace the front and rear seals in it (the rear was already leaking) also did the engine rear main seal along with the oil pan gasket (and a new oil pump since I was already in there, it was cheap insurance). (the Jeep won't be marking it's territory anymore. LOL!!)

plug in original vent:





Point of NO Return: (drilling into the case) I decided on this location for the vent after looking at several write-ups. First I tried to put an elbow in the original vent to then drill through the bell housing for the hose, but there is not enough clearance behind the torque converter. The elbow would now allow the torque converter to fully seat. Another write up showed placing the new vent directly above the old vent in the ridge area right behind bell housing (the farthest forward cleaned area in the first pic.). I ruled it out due to it being above the front pump seal, and the possibility of ruining the pump by drilling into it.

When I drilled the hole, I had my brother using the shop-vac to suck up the chips along with stopping frequently. When the hole showed to be starting to break through we coated the bit in bearing grease so that it collected the chips. Once drilled, I moved onto tapping the hole, using the bearing grease on the tap to prevent the chips from falling in. We stopped frequently and cleaned off the tap of the chips and grease, giving a new coating before starting again.





__________________
Quote:
Originally Posted by Boodyrider View Post
............
Big tires, done right, are FREAKING EXPENSIVE. Deal with it, or don't go there.
Quote:
Originally Posted by woodnjeep View Post
I live in the land where they salt cure roadkill.
97 Jeep TJ Sport, 4.0L, Auto, 3" BDS Lift (SOLD)
98 Jeep ZJ Laredo 4.0L, Auto, Stock Totaled, parted out and scrapped
96 Jeep XJ Sport, parted out and scrapped

Tummy Tuck without a body lift. Finished!!

Superior Axle & Gear TJ/XJ Dana 44 Discovery Shafts (DC45 kit) for sale

Last edited by brunosplace; 04-02-2009 at 02:19 PM.. Reason: added info
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Unread 03-28-2009, 10:10 AM   #3
vincec
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I want more
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Unread 03-28-2009, 10:12 AM   #4
brunosplace
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Location: Michigan
Posts: 1,096
More of the vent.





New fittings: (the hose will sweep forward, and be brought into engine compartment.)



__________________
Quote:
Originally Posted by Boodyrider View Post
............
Big tires, done right, are FREAKING EXPENSIVE. Deal with it, or don't go there.
Quote:
Originally Posted by woodnjeep View Post
I live in the land where they salt cure roadkill.
97 Jeep TJ Sport, 4.0L, Auto, 3" BDS Lift (SOLD)
98 Jeep ZJ Laredo 4.0L, Auto, Stock Totaled, parted out and scrapped
96 Jeep XJ Sport, parted out and scrapped

Tummy Tuck without a body lift. Finished!!

Superior Axle & Gear TJ/XJ Dana 44 Discovery Shafts (DC45 kit) for sale
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Unread 03-28-2009, 10:16 AM   #5
brunosplace
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Join Date: Mar 2007
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Onto the transfer-case:

Went with a TeraFlex Extreme Short Shaft SYE kit: (man does this shorten things up.) I also put in a Dakota Digital SGI-5c to recalibrate the speedometer, since I no longer have the option of changing speedo gears. (For the 97-98 TJ's you will need to cut off and replace the harness plug for the speed sensor on the Jeep with part # 5014007AA)






I previously had made a t-case shifter bracket similar to the A.A. one, it will be modified as part of this to get the necessary body clearance. (pics later)
__________________
Quote:
Originally Posted by Boodyrider View Post
............
Big tires, done right, are FREAKING EXPENSIVE. Deal with it, or don't go there.
Quote:
Originally Posted by woodnjeep View Post
I live in the land where they salt cure roadkill.
97 Jeep TJ Sport, 4.0L, Auto, 3" BDS Lift (SOLD)
98 Jeep ZJ Laredo 4.0L, Auto, Stock Totaled, parted out and scrapped
96 Jeep XJ Sport, parted out and scrapped

Tummy Tuck without a body lift. Finished!!

Superior Axle & Gear TJ/XJ Dana 44 Discovery Shafts (DC45 kit) for sale

Last edited by brunosplace; 05-19-2009 at 03:29 PM.. Reason: added part #
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Unread 03-28-2009, 10:34 AM   #6
brunosplace
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The trans is also getting a deep pan kit, with a temp sender mounted into it, and the pressure line to the trans cooler has a sensor in it so I can see the temp as the fluid leaves and the temp of the oil returned to the pan. I previously had the sending units up by the radiator, but I noticed that they were very affected by the passing airflow and were not reading accurately.

That is all I have for this morning, more pics to come as the are a few things that are done, but I didn't take pics yet. I am taking today off from it so that the kids remember who daddy is. LOL!
__________________
Quote:
Originally Posted by Boodyrider View Post
............
Big tires, done right, are FREAKING EXPENSIVE. Deal with it, or don't go there.
Quote:
Originally Posted by woodnjeep View Post
I live in the land where they salt cure roadkill.
97 Jeep TJ Sport, 4.0L, Auto, 3" BDS Lift (SOLD)
98 Jeep ZJ Laredo 4.0L, Auto, Stock Totaled, parted out and scrapped
96 Jeep XJ Sport, parted out and scrapped

Tummy Tuck without a body lift. Finished!!

Superior Axle & Gear TJ/XJ Dana 44 Discovery Shafts (DC45 kit) for sale
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Unread 03-28-2009, 01:41 PM   #7
jrb470
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Great Write-Up So Far!!
Nice Job!!
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(OlllllO)
65th Anniversary Edition TJ
Jeep Green


Rough Country 3.25" Suspension Lift
JKS 1.25" Body Lift & 1" Budget Motor Mount Lift
33x12.50/15 BFG All-Terrain's on 15x8 ProComp Series 51 w/ 3.75" BS
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Unread 03-28-2009, 03:53 PM   #8
brunosplace
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Quote:
Originally Posted by jrb470 View Post
Great Write-Up So Far!!
Nice Job!!
Thanks.
__________________
Quote:
Originally Posted by Boodyrider View Post
............
Big tires, done right, are FREAKING EXPENSIVE. Deal with it, or don't go there.
Quote:
Originally Posted by woodnjeep View Post
I live in the land where they salt cure roadkill.
97 Jeep TJ Sport, 4.0L, Auto, 3" BDS Lift (SOLD)
98 Jeep ZJ Laredo 4.0L, Auto, Stock Totaled, parted out and scrapped
96 Jeep XJ Sport, parted out and scrapped

Tummy Tuck without a body lift. Finished!!

Superior Axle & Gear TJ/XJ Dana 44 Discovery Shafts (DC45 kit) for sale
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Unread 03-28-2009, 04:13 PM   #9
Mainejeepin
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Join Date: Feb 2009
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Posts: 88
Very nice!

And I'm happy to see someone else with a lapis blue wrangler on here!
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Unread 03-28-2009, 09:33 PM   #10
JeepRocks86
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Location: Louisville, KY/ Columbus, IN
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looking good.
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Stretched TJ , Coil overs, 42" IROKS, 60/14 bolt...
'95 YJ fuel injected 302, 8.8, cage, ARBs.
'04 QC LB Cummins 4x4
My TJ Build Thread.
www.kifourwheelers.com
For Sale:
TJ Rear Dana 44 shaftsfor sale
3 11"& 2 13" BBCS shocks



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Unread 03-29-2009, 03:26 PM   #11
brunosplace
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Quote:
Originally Posted by Mainejeepin View Post
Very nice!

And I'm happy to see someone else with a lapis blue wrangler on here!
Thanks, they are a rare critter aren't they? I have only seen one other in person.

Quote:
Originally Posted by JeepRocks86 View Post
looking good.



A little update: (no more pics yet though )

My brother and I got everything stuffed up there for test fitting, and found what I expected. The t-case shifter is hitting the body, but we now have measurements to work with to modify it. And the bad.... the catalytic converter is about a 3/4 inch too thick to fit properly, we got the skid up there, but the cat is pressed into the heat shield above it so I will probably get this one from Magnaflow as it is much thinner and will fit in there with room to spare. I knew going into this that there would be little surprises to deal with, but the minister of finance isn't necessarily happy about it
__________________
Quote:
Originally Posted by Boodyrider View Post
............
Big tires, done right, are FREAKING EXPENSIVE. Deal with it, or don't go there.
Quote:
Originally Posted by woodnjeep View Post
I live in the land where they salt cure roadkill.
97 Jeep TJ Sport, 4.0L, Auto, 3" BDS Lift (SOLD)
98 Jeep ZJ Laredo 4.0L, Auto, Stock Totaled, parted out and scrapped
96 Jeep XJ Sport, parted out and scrapped

Tummy Tuck without a body lift. Finished!!

Superior Axle & Gear TJ/XJ Dana 44 Discovery Shafts (DC45 kit) for sale
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Unread 04-01-2009, 03:52 PM   #12
brunosplace
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1997 TJ Wrangler 
 
Join Date: Mar 2007
Location: Michigan
Posts: 1,096
Pic of the cat pressed between skid and heat shield, some how I didn't get any after pics yet:



Shifter bracket hitting:



A little more room after some cutting and welding:





New rear pinion seal installed:

__________________
Quote:
Originally Posted by Boodyrider View Post
............
Big tires, done right, are FREAKING EXPENSIVE. Deal with it, or don't go there.
Quote:
Originally Posted by woodnjeep View Post
I live in the land where they salt cure roadkill.
97 Jeep TJ Sport, 4.0L, Auto, 3" BDS Lift (SOLD)
98 Jeep ZJ Laredo 4.0L, Auto, Stock Totaled, parted out and scrapped
96 Jeep XJ Sport, parted out and scrapped

Tummy Tuck without a body lift. Finished!!

Superior Axle & Gear TJ/XJ Dana 44 Discovery Shafts (DC45 kit) for sale
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Unread 04-01-2009, 04:02 PM   #13
brunosplace
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Join Date: Mar 2007
Location: Michigan
Posts: 1,096
For the High Clearance Trans mount I am using what is called the Tab Kit for AEV/Nth degree Mobility's Tummy Tucker system. We modified it slightly to clear the strengthening rib on the Skyjacker High Clearance Skid that I am using for this build.

The lower pipe for the exhaust hanger was cut from below the mount and rolled inward and up into the formed V on the bracket:





The skid was drilled and countersunk to accept the AEV/Nth mount:





__________________
Quote:
Originally Posted by Boodyrider View Post
............
Big tires, done right, are FREAKING EXPENSIVE. Deal with it, or don't go there.
Quote:
Originally Posted by woodnjeep View Post
I live in the land where they salt cure roadkill.
97 Jeep TJ Sport, 4.0L, Auto, 3" BDS Lift (SOLD)
98 Jeep ZJ Laredo 4.0L, Auto, Stock Totaled, parted out and scrapped
96 Jeep XJ Sport, parted out and scrapped

Tummy Tuck without a body lift. Finished!!

Superior Axle & Gear TJ/XJ Dana 44 Discovery Shafts (DC45 kit) for sale
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Unread 04-01-2009, 04:04 PM   #14
brunosplace
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Posts: 1,096
Test fitting for clearances t-case to skid & mount system:







__________________
Quote:
Originally Posted by Boodyrider View Post
............
Big tires, done right, are FREAKING EXPENSIVE. Deal with it, or don't go there.
Quote:
Originally Posted by woodnjeep View Post
I live in the land where they salt cure roadkill.
97 Jeep TJ Sport, 4.0L, Auto, 3" BDS Lift (SOLD)
98 Jeep ZJ Laredo 4.0L, Auto, Stock Totaled, parted out and scrapped
96 Jeep XJ Sport, parted out and scrapped

Tummy Tuck without a body lift. Finished!!

Superior Axle & Gear TJ/XJ Dana 44 Discovery Shafts (DC45 kit) for sale
brunosplace is offline   Reply With Quote
Unread 04-01-2009, 04:10 PM   #15
brunosplace
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1997 TJ Wrangler 
 
Join Date: Mar 2007
Location: Michigan
Posts: 1,096
Added the Currie lower shock mounts:





Rubicon Express rear upper adjustable control arms:



Moved one of the trans temp sensor's to the line and pointed it in towards the trans to prevent it from being broke off:

__________________
Quote:
Originally Posted by Boodyrider View Post
............
Big tires, done right, are FREAKING EXPENSIVE. Deal with it, or don't go there.
Quote:
Originally Posted by woodnjeep View Post
I live in the land where they salt cure roadkill.
97 Jeep TJ Sport, 4.0L, Auto, 3" BDS Lift (SOLD)
98 Jeep ZJ Laredo 4.0L, Auto, Stock Totaled, parted out and scrapped
96 Jeep XJ Sport, parted out and scrapped

Tummy Tuck without a body lift. Finished!!

Superior Axle & Gear TJ/XJ Dana 44 Discovery Shafts (DC45 kit) for sale
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