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97 TJ Heep to Zombie Killing Jeep Build

438K views 825 replies 181 participants last post by  cpia84 
#1 ·
So I always wanted a Jeep Wrangler and recently had an opportunity to pickup a 1997 TJ for cheap. Being that it is an SE with 4cyl and auto trans dana 30 and 35 cheap is really all it was worth anyway:laugh: But now i had a platform to start with and with our first child just being born I will be selling my motorcycle which will help fund the build. Along with what I had sold of a collection of 1/5 scale RC cars, one of which paid for the Jeep. But still looking to do this build on a budget and so I won't be buying $900 bumpers. The Jeep is taking place of the motorcycle as a toy and I still have my F-150 daily driver so can afford to have it down(torn apart for days or weeks at a time).

What I purchased in October of 2010


What I sold to buy the Jeep


First thing I did was gut the carpet, it was trashed. Also took out trunk thing to remove rust and repaint.


Parked next to the daily driver.


Took off the fenders to repaint and removing the stock steps. Also cut off front bumper jugs


With the carpet torn out the floors revealed some rust but not as bad as I would have thought with the condition of the top which would be my next purchase.




Brought it by a friends house to put some H2 tow hooks on the rear bumper:rofl:


Home in the garage for the first time. Took off mirrors and wiper blade arms and sanded and repainted. Let the money spending start. Did alot of tune up things like plugs, cap and rotor, new battery, O2 sensor, TPS, valve cover gasket etc...............


Put new black top on with tinted windows and removed rusted spare tire and spare tire holder. Added NRA sticker.


So after putting a black top on I decide I wanted the interior to be black (slate) so I purchased a dash out of a wrecked 06 TJ to install.


Painted the headlight bezels black with Krylon Fusion. And took off the front bumper to expose the rust under it. Ground it down and repainted, then installed smitty bilt stinger.



 
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#149 ·
Well the pro to putting it overhead is that the speaker is right up there near your head when you're wheeling, the Jeep people I've wheeled with say it's easier to hear that way. I have mine mounted under the dash, I like that it's not really visible, but then again, CB's aren't really a hot-ticket item for people to take...

Haha yeah, I imagine it'd blow you around a little bit on the freeway and such. Plus it'd look a little more buttoned up if it was lower, I think.
 
#150 ·
great radio you got there, cant believe you got it free. Its nice to have the weather band, but im a techy, and I like listening to monotone weather talk.

Ill stop there before I bore the thread with endless CB talk.
 
#153 ·
great radio you got there, cant believe you got it free. Its nice to have the weather band, but im a techy, and I like listening to monotone weather talk.

Ill stop there before I bore the thread with endless CB talk.
Yeah really lucked out, and it works. except for the night watch but cant complain for free.

The spare looks fine, I wouldnt bother with moving it unless your really unhappy not being able to see out. The cobra cb looks great too, i like the older classic metal look on the cobras, better than all the new plastic cbs
I don't know, I'll have to run it around and see how it does mounted up that high then decide on how to move it if need be.

can you flip the tire mount over?
it is a bit different looking that high.
nice CB.
I have the mount that puts it over the left a/c vent.
due to the bolt holes in the mount it only goes one way. An alternative is to buy a set of spidertrax adapters like I have on the axles, just expensive. I like the mount like yours but this radio is pretty large and wouldn't fit. I think I have settled on doing the smittybilt SRC cage kit with the overhead gear thing to mount the radio to.
 
#158 ·
pictures of the doors.



My little helper working out were we should put the CB radio.


and just because I like this picture, makes the spare not look so bad


Will be busy this weekend selling off a ton of crap on ebay. It's things that just lay around and never get used so they will help fund some more jeep parts:thumbsup:
 
#159 ·
I've been slowly turning my garage into an area that is easy to work on the Jeep and store extra Jeep related parts (hardtop, doors etc..) So I cleared off the work bench and set to listing somethings on ebay and related forums to the items I'm selling. Worked out great have the bench cleared off to work on Jeep things now and made $600 that I put toward some front seats. I really wanted the Mastercraft's but couldn't handle $1000, so went smittybilt XRC for $425 and they will be here tomm. Got to love Amazon cheap prices and fast shipping. I have so much I want to do in preparation for the seats. I will be removing the interior pieces currently in the jeep to do the monstaliner in the tub. Also want to repaint the roll cage and padding, may just leave the padding out but not sure yet. Will try and get more done tonight and this weekend to post pictures of the progress. Need to clean out more parts of the house to generate jeep funds for axles and SYE next.
 
#160 ·
Seats came in today and I'm really happy with the look and feel. Just have to figure out how I want to mount them. Have heard nothing good about the smittybilt mounts so looking at Corbeau. Now to start stripping out the jeep interior in preparation for Monstaliner. Also ordered an Aussie locker for the Dana 30 and a Riddler diff cover since I'll already have it apart.
 
#161 ·
will the stock mounts not work with the smittybilt seats? I was thinking about ordering some myself next year after my lift is done, but if the orginal mounts won't work I probably wont bother. I like the stock mounts, and was thinking about just sand blasting and painting them before the reinstall.
 
#171 ·
Well not a huge success of a weekend working on the jeep, but managed to get a few small things done. Radio installed, sounds great and more important I can plug the iphone into it.



So I got my new door pins and put the full doors on and have some issues. They have these gaps so ordered the delrin plastic inserts. Hoping that is going to straighten them up because at the moment I have to pickup on one door and push down on the other.:thumbdown:


Also finalized my CB antenna mount and hope it works out ok because it looks great. Still working out how to mount the Radio overhead, thinking smittybilt gear overhead console.



Also figured out I could flip the spare tire mount and drill out the threaded holes so the mount isn't so high. Looks much better and allows me to see what's behind me in the rearview some what.


Also added some red accents as I plan on the jeep being completely painted with the bed liner and having a few red pieces here and there. Maybe some new wheels:shhh:


Also ordered Smittybilt seat adapters, crossing my fingers they have worked out the issues with them. Have rear smittybilt 3" fenders coming, and plan on ordering the front flats with 3" flare.

To-Do List
Install JKS Adj. rear trackbar (yeah still not done)
Install Currie Anti-rock
Install Aussie locker and Riddler diff cover
Install XRC seats
Finish CB Radio install
paint,paint,paint
 
#172 ·
It's looking good man :thumbsup:

I installed my locker today and it was pretty straight forward. I only had a few snags hopefully some of this will help you:

  • The diff cover may not want to come off, tap it with a heavy hammer (I used a sledge) and it'll come free like nothing.
  • To remove the carrier put a 5/8" box wrench on one of the ring gear bolts and turn the drive shaft with a big adjustable wrench at the U joint. That will pry the wrench against the housing and it should come free.
  • Getting the roll pin (I think that's what it's called) out was a major PITA for me, make sure you have the correct size punch; 3/16th
  • If it isn't clear in your instructions (it wasn't in mine) when you install the Aussie put in driver and passenger side shaft connections (the end pieces) with their thrust washers first then the other 4 pieces slide in two by two (spacers inside already and the pins in the deeper, open holes. You will slide them to the other side to install the spring after everything is in).
  • Getting the carrier back in is somewhat tricky, make sure everything is lined up correctly then if it still won't seat use a 1 x 1 "shaft" of wood and a hammer (like a large punch) to coax it.
  • I used 85W140 oil per recommendation of 4x4explor.com and it's completely silent I can't hear a thing when driving in circles.

Good luck with it though! The install really isn't bad at all it was my first time inside my diff and it only took about 4 hours.
 
#175 ·
Looks good, it looks better with the tire lower.

Someone broke into mine the other night before moving into school :(. They took a rain jacket and then realized I didn't leave money/books/radio face plate, or other electronics in there. Nothing was broken, the glove box was ripped off, as it was locked, but I unlocked it and it went right back on, which is good.
 
#177 ·
That sux...people piss me off sometimes. I leave my baby unlocked most of the time in the hope that if someone tries to get in maybe they won't cut my windows out. The kids in the neighborhood use to mess with her and one night cut my driverside window out to get in. I solved that issue acouple weeks later when I heard them messing with her at 3AM. Its funny how fast kids can run when you pop a shotgun off in the air :laugh:
 
#183 ·
just another idea for you. works great for me.
Thank You for the idea, these are the sort of small jobs that keep pushing me toward picking up a welder. Think I may have to use this one, as I like the idea of having the radio up high but I'm waiting to see which bolt on roll bar kit to go with. This will be a great remedy for the time being and will work much better than leaving the radio on the floor:thumbsup:
 
#182 ·
The parts keep piling up in the garage, one of these days the heep is going to be sweet.


Working on getting the interior prepped for Monstaliner. Kicking around the idea of buying a cheap welder so I can fix my floor before rolling on the bed liner. Looking forward to when the cooler weather comes so I feel more motivated to work in the garage.

More updates to come.
 
#186 ·
had the angle iron laying around. bought a can of black spray paint and the U bolts from lowes. total cost was like 15 bucks... beats the 300.00 overhead one..
 
#188 ·
Do it north! Buy a welder! I am so happy with the overhead console i made. It doesnt lock but you could easily make one that locks. if you do decide to make one I have a write up on how I made mine.

heres the write up: http://www.jeepforum.com/forum/f37/overhead-console-write-up-yj-1226898/

end product





if your thinking of buying a welder all I can say is do it. I make everything on my own, its 1000x more gratifying then buying anything.
 
#193 ·
hahaha, I think patience is the thing that has helped me find deals more than anything else. 4 of the 5 tires are used, but that guy had tons of money and just wanted them out of his garage. I wanted a hardtop long before finding one for reasonable, and was just lucky enough to call him before others and lock in a deal. I've had some Craigslist deals I went to check out that were bust also. I went and looked at a cargo rack, no good. And atleast another dozen items that didn't make the grade. I feel really lucky to have found the full doors and hard top, but had spent months checking craigslist several times a day (on iphone) before finding what I wanted. Oh and I'm not afraid to ask what they really want for the item and then offering alittle less. They list them because they want them gone.:thumbsup: Sometimes it's a shot in the dark and I would pay more but you don't know unless you ask, like the doors. It has been half the fun of building the jeep, a challenge of sorts to keep the cost down.
 
#194 ·
i use a forney 130 wire feed. for now i just use flux core wire. I love the portability and ease of not having a gas bottle. I weld up to 3/16ths with that since its only 110. If i need to weld thicker I use my lincoln arc welder.

ive been welding for years, its a great hobby and probably the thing that keeps me so interested in jeep.



if buying a little flux core welder will help you get on your feet doing your own projects like patching up your floor and making a center console, do it! the metal on the tub is thin, you can weld it with even the cheapest flux core welder.

the only problem with the really cheap flux core welder is that it will be hard to get good looking results. flux core wire produces ugly welds in general, and a cheaper welder like harbor freight or chicago electric will not help the way the welds look.

so YES buy any welder you can afford just if you buy a cheaper one be prepared to grind those boogers off! theres no shame in that!

and buying metal: if i just need some tubing or something i go to the hardware store but if your looking for sheet metal or bulk anlge iron / tubing then find a local metal supplier

if you want to see more of the projects i do with the little welder check out my build ive made tons of stuff all with this baby
 
#198 ·
i use a forney 130 wire feed. for now i just use flux core wire. I love the portability and ease of not having a gas bottle. I weld up to 3/16ths with that since its only 110. If i need to weld thicker I use my lincoln arc welder.

ive been welding for years, its a great hobby and probably the thing that keeps me so interested in jeep.

if buying a little flux core welder will help you get on your feet doing your own projects like patching up your floor and making a center console, do it! the metal on the tub is thin, you can weld it with even the cheapest flux core welder.

the only problem with the really cheap flux core welder is that it will be hard to get good looking results. flux core wire produces ugly welds in general, and a cheaper welder like harbor freight or chicago electric will not help the way the welds look.

so YES buy any welder you can afford just if you buy a cheaper one be prepared to grind those boogers off! theres no shame in that!

and buying metal: if i just need some tubing or something i go to the hardware store but if your looking for sheet metal or bulk anlge iron / tubing then find a local metal supplier

if you want to see more of the projects i do with the little welder check out my build ive made tons of stuff all with this baby
Great info and encouragement, I will be buying a welder but want to do some more research first. I just keep adding projects to do with a welder, the latest is hinges on the wall to hang my doors from when not in use.

I really like your build. I'm shopping craigslist daily for deals too. i got a Warn gas tank skid for 225, delivered. guy installed it and pulled it back off. apparently he changed directions during his build and I saved a hundred buck$.
Nice find, I need to locate a tank skid yet.

I hear you man, I'm defiantly gonna start checking Craigslist as much as I can. I don't know if you know about it, but Amazon has some good stuff. Its cheaper than most places and you get free two day shipping for a month.

Also, what do you do for a living? Cause I'm in high school and thinking about the air force but you obviously make a lot of money, so I might try that hahaha:rofl:
Oh yeah big fan of amazon and of red laser on the iphone. You put in the UPC and it tells you the cheapest place to buy an item. I made a good living selling construction equipment until the market died. Now I work at an auto auction and absolutely love what I do now.

Thank You.
 
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