Wrecked Rubi - Project

**Savvy** · 03-15-2009, 11:10 AM

A couple of weeks ago I got another Jeep from DaveysJeeps. This one is a 2004 TJ Rubicon with a lot of drive train damage and a little body carnage. Total cost for this Jeep was $4700. It has 60,000 miles. I planned to make this Jeep a daily driver but capable to drive to the Rubicon or other trails (except for JV as I already have a Jeep for that.)

Here is the list of things needed to be done:

Axle swap - The front D44 is bent so it will be parted out and the rear will be sold. Edit: Changed mind will find replacement HP D30 housing.

Transfer case - Replace the 241 with another.

Suspension - Probably will build a mid/long arm 4 link front and 4 link rear with Currie Johnny Joints (fixed on one end for the lowers and fully adjustable uppers.) I will use the stock shock and spring location as is. Upgrade steering and track bars. I did the last Jeep with Genright 3/4 link Kits so this time I want to do it myself without the kit. I will buy a bunch of stuff from Ballistic Fabrication and Currie. They make and carry all kinds of brackets, tabs suspension and laser cut kits.

Body Damage and Parts - The front fender needs replacment and the A-Piller panel need a little work. I'll have a friend do the A pillar repair since it will be a DD and my body work skills suck. Need to replace driver window door glass. I'll be selling the remaining 3 flares that are currently on the Jeep. I'll be putting on rockers, bumpers and possibly some rear corners.

Interior - Need to get some new air bags and carpet kit. Probably will upgrade the radio.

So here how it sits:

Fender and A pillar damage

Passenger side is perfect!

Driver Side not so good but repairable

Destroyed transfer case

Check out the drive shaft

Front Axle is bent here

wes19d · 03-15-2009, 12:24 PM

Looks like a good place to start. Just wondering if you know what happened to it?

**Bennettj13** · 03-15-2009, 12:39 PM

Here we go again. I can't wait.

**Savvy** · 03-15-2009, 02:36 PM

Quote:

Originally Posted by wes19d

Looks like a good place to start. Just wondering if you know what happened to it?

Don't know what originally happened but from the looks of the impact it was hit hard on the driver's wheel. When that happens all sorts of crap breaks. The T-case was ripped off the back of the transmission. and the axle housing was bent badly. I can't even have it retubed as the pumpkin housing was cracked.

That's why I just decided to swap some bigger axles in and I also want to run 35s.

**Savvy** · 03-15-2009, 02:37 PM

Quote:

Originally Posted by Bennettj13

Here we go again. I can't wait.

I know! It is a addiction. I know it is not my fault!

**mudb8** · 03-15-2009, 03:14 PM

I wanna see if you can really stop at mid arms and 35's! lol.

**TJamz** · 03-15-2009, 03:37 PM

Looks like a good project. Will follow. I love these writeups!

TJSport01 · 03-15-2009, 03:41 PM

looks great im going to add it to my list of wrangler build ups

robncar · 03-15-2009, 03:43 PM

If you need a late model, stock, t-case skid, it's available free. Taking up space in the garage since the RE LA install.

**sduncan** · 03-15-2009, 04:13 PM

I know what happened to it. Picture the following:
Medium sized launch pad,
Idiot behind the wheel who just watched a couple of re-runs of Dukes of Hazzard,
He says" Hey ya'll, watch this!!"
Jeep about 8 ft in the air
Jeep lands on driver front wheel
Jeeps hits stationary object after landing.

You buy jeep with bent stuff all over it.

Have fun with it and post pics when you're done.

**Savvy** · 03-15-2009, 05:50 PM

Got the replacement 241 and new rear drive shaft in. Put a front 1330 yoke to replace the stock flange and made a rear drive shaft up from a old front shaft. To hve a front shaft shortened and balanced at Drivelines is $100. I had them put all new u-joints so it was $168 total and I had it in a day.

Flipped it around so I can replace the front axle and steering

**Savvy** · 03-15-2009, 05:53 PM

Quote:

Originally Posted by mudb8

I wanna see if you can really stop at mid arms and 35's! lol.

I already have the 03 with Long arms so I want to do something different. I do have another set of beadlock and 37 KXs in my warehouse but Blaine will disown me if I try to put them under the Jeep!

**Savvy** · 03-15-2009, 05:57 PM

Quote:

Originally Posted by robncar

If you need a late model, stock, t-case skid, it's available free. Taking up space in the garage since the RE LA install.

Thanks for the offer but I'm going to wheel this baby! So something a little more substantial like your RE skid is what I have in mind.

**mrblaine** · 03-15-2009, 07:19 PM

Quote:

Originally Posted by provelogear

Thanks for the offer but I'm going to wheel this baby! So something a little more substantial like your RE skid is what I have in mind.

No, if you're gonna run 35's on this pig, it has to be flat skidded to the frame.

**Savvy** · 03-17-2009, 10:30 PM

OK, after much thought on this build I have decided to build a Jeep that most anyone could do. I already have a Jeep with Spidertrak True HI9 / Currie Iron Jock D60 so I don't want to duplicate it. We want a very capable Jeep both on or off-road. It will be able to drive to any trail and be capable once it gets there and be able to return home.

We will try to minimize the truly custom work. The suspension is where the bulk of the custom work will happen. As I really like building the arms. Basically tubes, tube inserts cut and weld but I have discovered that I like to TIG weld even though it takes longer. We also want to do something a little different and a totally home built flat to frame TC skid and raise the body mounts.

We will utilize the existing axles but will supplement them with cromoly axle shafts and truss where possible. I'm looking at the Superior Super Kits. The front will have a Warn 5 x 5.5 hub conversion. Couple of reasons I went with the hub conversion is I like being able to unlock when I flat tow, strength and I have a nice set of Champion beadlocks sitting in my warehouse.

The body protection will be Savvy aluminum armor. Also, I like the Polyperformance DIY full cage. Undecided on tube fenders or keep the classic TJ look.

So in collaboration with MrBlaine I offically start this build in the new direction. Please feel free to ask any questions as we go. It will be a approximately a month before I can get started with the good stuff because the A-pillar needs to be repaired first. We'll be collecting parts and I want to have it done for a June Rubicon trip. I plan to drive there and back from Southern Californina so that is a 900 mile round trip drive.

A BOM (bill of material) listing will be included as well as cost for everything so you'll be able to decide if this is something you want to undertake.