[BozoWise]

I installed a second factory switch panel in place of my ashtray.

It was fairly simple and I had no issues but tools are key here. I removed both of the mounting legs from the switch panel with an sir saw and hacked the factory ashtrey roughly out of the dash surround. I then used a carbine burr bit on my dremel to shape all the plastic pieces. Tacked them inplace with jb weld and mounted them with plastic mender 2 part epoxy.

You will need to remove a slight bit of the width of the switch panel to get them to fit side by side. I clearanced the dash surround equally on the passenger side to make a rectangular opening. The carbine bit is one of the best tools for this because you can shave the plastic off without it melting on you. It allows very fine adjustments to be made. I use 3m "tar" style sealing compound to hold the parts together while fitting. I learned this trick many years back installing car stereos. We often had to build entire new dash panels.

Now I need more switches to fill the holes I also moved one of the factory switches to the far side to equal out the "look" I filled the cig lighter hole with some abs for the moment until I decide what to use it for.

[BozoWise]

I drove into 4wheelparts to resolve the MileMarker issues:

Funny thing is I sent another email to MileMarker last weekend expressing my feelings toward there product and service. Expressing my concerns more over the handling of the issue vs the actual junk winch. I got a phone call on my way to 4wheelparts and they claim they sent the call tag and it must have been lost. humm Anyways I was already past done with them by then; so I got an RGA for 4wheelparts to use for return of the winch.

But the guys at 4wheelparts took care of everything without hesitation and all the MileMarker issues were resolved with a simple bolt on solution

As you can see from previous pictures the KN filter was occupying the area I wanted to use for the relay box. Since I have the dash controls I decided I would rather have the Warn box installed underhood and out of the weather. I felt the somewhat sealed area of the KN cold air box was optimum for this and I would get some additional use out of the free KN, (you know above the 80hp increase that I got mainly do to the stickers)

I had to make a single 1 1/2" cut on one of the corners of the cold air box to bend it and added another bracket to hold it in place (I do not think the bracket was needed after the install) I then used a hose clamp to mark the location on the tube were I planned to cut it. Traced around the clamp with the airsaw, cleaned up the edges and reinstalled. By cutting off part of the tube it allowed me to move the filter back and change the angle all in once. I think it turned out super! I drilled and mounted the relay box to the cold air box with the two mounting stubs on the back of the relay box.

The coiled wire visible there is the lead for the relays I still need to install controlling the air compressor that was previously installed under the master cylinder.

I installed new 2guage wires from the outputs on the box to the winch and cut everything to length, removing all the now extra length of the main power wire. Now the man power wire that is hot all the time is loomed, underhood and hopefully away from any possible chaffing and shorts. The single wire through the grill is the ground and everything else runs under the grill and up the inner fender.

[20004x4TJ]

Everything just looks awesome on there man. I'm having fun checking out your updates for ideas. HA HA!!

[MuDD OlllllllO]

You are an animal.


Great job.

[BozoWise]

Just a tip since I work without an extra set of hands most of the time.

If you have to work on the transfer case linkage and need to reinstall the bracket by yourself. Take two pieces of wire and tie a not on each end. Thread them through the bracket mounting holes and the body tub. Then you can pull the bracket up to the tub from the inside and install the bracket with the other two mounting bolts, remove the wires and finish bolting it all up.

[BozoWise]

Worked on some welding last night

Not much to say but the pictures. Everything went smoothly. I only tacked one bracket on in the wrong place and it took me about two seconds to go that doesn't look right.

Went with the Terra brackets from DC4WD they are great people with awesome customer service. So much I called him back today and ordered a Tom Woods CV shaft, front and rear upper adjustable RE control arms and the 4.56 gears for the 8.8

There is some minor fitment with the Terra brackets but it was not too bad and I did it all with a flapper wheel. I filled the factory vent and have yet to decide where I am going to place the new one. I am going to wait until I have it test fitted under the TJ to decide if I can do it where the factory abs sensor was routed.

I got all my measurements from Stu's site and double checked with my 35. Thanks for the help and info Stu!

http://www.stu-offroad.com/axle/8.8axle/8.8axle-1.htm

[BozoWise]

more pics...

[BozoWise]

last set...

[cbowles]

OMG I'M GONNA FAINT. ITS SO PRETTYYYY!

[BozoWise]

Originally Posted by cbowles

OMG I'M GONNA FAINT. ITS SO PRETTYYYY!

Thanks I think

[BozoWise]

Well she is up on blocks now. I have all the brackets installed on the 8.8 less the shocks mounts. I actually want everything aligned and complete before I install them. I have some thoughts on that which I do not want to rush. I got the 8.8 mocked up and will take it to have the gears installed later this week. Still waiting on brown to deliver the upper RE arms front and rear.

With everything mocked up I'll have measurements to give to Tom Woods tom for a driveshaft.

I got the t-case stripped and installed the SYE that I removed from a friends YJ. The front is coming out tom night for spring replacement.

Now that I look at the pictures I hope I got the engagement ring installed correctly when I put in the sye. I see that the larger end on it is swapped on the two case halfs (the ring that the shift fork moves to engage 4wd) Can anyone confirm if it is installed correctly on the short shaft case or on the factory slip yoke case???

Ohh and do not forget to install the oil pump in the t-case before you rebolt and torq the halves. It will make you mad to have to do it twice, and now maybe three times if I got it wrong. I do know that the case was set in 4low during the install and I dropped it into 2wd after I was done and was able to turn the front shaft freely to reinstall the front d shaft.

[BozoWise]

Just an FYI but the larger shoulder of the engagement gear goes towards the front output. So in the pictures the factory long shaft case has it installed correctly. After all the confusion I decided to take the case apart again and confirm 50% chance it was wrong. Well it was in there right, ohh well now I won't worry.

SYE is complete. The new speedo gear should be in friday along with and Advanced Adapters shifter bracket so I can rid myself of that factory to body mount junk.

Got the adjustable uppers from RE installed front and rear. And relaced all the springs with some fabtech 4" I scored in a swap. I blasted and painted the springs since the had some surface rust on them.

I ended up adding a 1 3/4" spacer in the front and removed the factory isolator for a 1" gain and it just about sits level. The back is sitting .5" higher then it will be at rid height in the picture.

I'll go pick up some wheels and tires tom. and after that this thing has got to get out on the trails some. The tube projects start after summer.

[IMYY4U]

First off, I gotta say, I love the Jeep, I don't know how you get the money for all of this, but this is brilliant. Question for you though...I just ordered the Bestop Oversize Tire Carrier and plan on installing that ASAP once it arrives at my shop. How long would you say the install took you? And got anymore pics of it, just different angles of what it looks like - more specifically, bumper clearance, I'm gonna be holding a 33x12.50 tire on it.

Thanks and keep up the work, be sure to keep posting your pics to the final touches

[blacktjsport]

Everything looks great!! I am starting my 8.8 build as soon as I can get the axle from the dealer I'm talking with. I already have the Detroit, brackets and gears, just need the actual axle!!! Keep up the good work!

-matt

[BozoWise]

Originally Posted by IMYY4U

First off, I gotta say, I love the Jeep, I don't know how you get the money for all of this, but this is brilliant. Question for you though...I just ordered the Bestop Oversize Tire Carrier and plan on installing that ASAP once it arrives at my shop. How long would you say the install took you? And got anymore pics of it, just different angles of what it looks like - more specifically, bumper clearance, I'm gonna be holding a 33x12.50 tire on it.

Thanks and keep up the work, be sure to keep posting your pics to the final touches

As far as money, I have a great job. No wife, no kids and a company vehicle I can use for personal driving also. You do not have to make tons of money when you have no bills, or mouths to feed. Plus I do lots of horse trading parts (speaking of I have a Karr K9 pistol up for grabs right now)

Shoot me an email I'll send you any pictures you like. I hate to post even more pictures then I already do but I have about 5 times as many as I post here. I learned from past builds to take tons of pictures because I have a bad habit of selling off everything in short order. Everything I own is for sale for the right amount of money.

As a case in point I called a buddy to give me a ride one Friday night because I sold the motorcycle I was riding at a Sonic drivein with a date on the back.

Originally Posted by blacktjsport

Everything looks great!! I am starting my 8.8 build as soon as I can get the axle from the dealer I'm talking with. I already have the Detroit, brackets and gears, just need the actual axle!!! Keep up the good work!

-matt

Ohh the 8.8 is just too much work, send me the detroit and I will put it to good use. I'll even pay the freight.