Idaho Jeep Build - Page 2

**Idaho-Jeep** · 09-01-2008, 07:41 PM

Today I finished smoothing out the welds on the corners and fenders - love that flap wheel!. The steel still has a film on it (except where I was grinding/sanding) anyone know what I should use to clean the steal prior to using filler and seam sealer? I also got out the cutting wheel and cut the larger wheel wells to match the corners. I have officially past the point of no return now.

I had to pull out the stock wheel well liner - I had hoped to make the stock ones work but after the cutting I realized I couldn't. I will paint the well with hammerite instead and use some rubber wheel well material for the area behind the tires.

Now the only problem seems to be the emissions evaporative canister and where to move it. I don't know where else I could locate it so it may have to stay. Any of you found places to relocate this?

So that finishes off my weekend, I will start the process of preparing all the parts for painting and pulling off the old lift next.

**Idaho-Jeep** · 09-06-2008, 01:27 AM

So I spent most of the week prepping the fenders and corners for paint - that is very time consuming work! I should be able to take them to the painters early next week.

This afternoon and evening I worked on taking out the drive shafts, exhaust, existing arms, axle etc.... So now I have the d44 out and can start prepping it for the truss (and the 4.88s and OX). I believe I am only cutting off the upper arm mounts - need to verify that. There is no track bar needed with this kit so that goes away. Might need to re route the brake line after the truss is installed.

Cutting out a perfectly good yet not re-usable (for me) exhaust system...

So I guess I will not be moving the TJ for a while now.

My D44 - pretty aint she? She will look better after the truss install, a new coat of paint and some long arms attached. hope I remember how everything goes back together

Got my beadlocks today - they are very nice! Will wait to show those

I wonder if there is anything else I should do while I have all of this room.... Gas tank skid? I don't want to spend any more money right now, but it would sure be an easy job right now.

**rubidriver** · 09-06-2008, 01:55 AM

pm sent....

04RedTJ · 09-06-2008, 07:52 AM

Looks like your doing a real good with this build. Really like those flat fenders, just need to talk to my wife so I can get some for myself.

Gabe · 09-06-2008, 08:12 AM

are those 4.5 flares or 3.5?

pumping4jane · 09-06-2008, 09:34 AM

Good thread. Cool Euro-retro home.

**Idaho-Jeep** · 09-06-2008, 10:01 AM

Quote:

Originally Posted by Dogman

Hey, nice job! You might think about welding a piece on the corners to fill that gap. I'm sure the paint will help hide it, but it would pretty simple to weld a piece in.

Yea, your right... It keeps bugging me so I think I will do it.

**Idaho-Jeep** · 09-06-2008, 10:04 AM

Quote:

Originally Posted by Gabe

are those 4.5 flares or 3.5?

They are 4.5"

I think they are the perfect size for me. They don't seem big to me at all.

**Idaho-Jeep** · 09-06-2008, 10:11 AM

Thanks for all the comments! Keep them coming - feel free to offer advice and opinions, even if you don't like something. This is a learning process for me so any information, advice, comments etc. is welcome.

Also, thanks for the comments (and PMs) on my house. I am an architect and designed/built my own home about 5 years ago. I documented that build too

. Anyway someone asked for some more photos of my house - I will delete these later to keep this thread on topic.

Thanks!

DeftLogic · 09-06-2008, 10:16 AM

Wow. Great looking jeep and amazing house. How do you like living in Mccall. I go skiing there each winter.

**Idaho-Jeep** · 09-06-2008, 10:21 AM

Quote:

Originally Posted by DeftLogic

Wow. Great looking jeep and amazing house. How do you like living in Mccall. I go skiing there each winter.

Thanks and thanks!

I love fall & summers in McCall. I don't ski as much as I used to so I get really tired of the white stuff. I play a lot of hockey and we have a great rink. Great hunting, fishing, jeeping etc... just hate Feb-May!!!
Maybe we should do a house exchange - We would love to go somewhere warm for a week during the winter/spring!

**Idaho-Jeep** · 09-07-2008, 09:28 PM

So last night I disconnected everything from the front axle and pulled it out from under the Jeep this morning. I am starting to get nervous! Seeing my jeep this way is SCARY!

My wife took a look this morning and said "you are never going to be able to put that back together" She has a lot of faith in me.

**Idaho-Jeep** · 09-07-2008, 09:54 PM

After pulling out the D30 I moved on the SYE. I have been anxious to install the SYE and actually bought the kit about 3 months ago but did not install since my CV shaft length would have to change during this build. Having the rear axle out made things easier as there was a lot of room to work which is why I decided to do it now.

The job itself was pretty easy and could be done by anyone with a few tools and a good write up. My only problem was with the RTV Gasket sealer as I put to much on and when I torqued down the cover I could see some inside of the TC. I pulled the cover back off, cleaned up all the RTV and tried again this time using less.

I used a write-up at 4x4 explorer: http://www.4x4xplor.com/SYE-CV.html this is a great write up, but if you use it, be sure to check your shift rail length as this write up does not discuss the fact that if it is over 1" past the cover, it will need to be trimmed down. I will measure and order my CV shaft after my rear axle is put back in.

The scene before I started:

The AA SYE kit, new 39 tooth speedometer gear, some ATF and Snap ring pliers:

All opened up:

All done!:

Gabe · 09-07-2008, 10:54 PM

what's the part # on the AA kit? I see a note in 4WPs system that says something about modifying the fork rail shifter or something like that??

carpekd · 09-07-2008, 11:01 PM

very nice build, and nice house too