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UTChavok's build thread.

57K views 454 replies 55 participants last post by  UTChavok 
#1 ·
http://www.jeepforum.com/forum/showthread.php?t=631891

Heres a link to my build thread already in progress in the Jeep Registry, Im pretty sure thats where there supposed to be but no one actually looks there, therefore you get 0 input which blows.

Heres some pictures of how she started.
Stock: Lost the picture, everyones seen a stock jeep with 7 year old soccer players in the back seat :rofl:
BB and 30" ATs:


3.5 and 32s:

(before I spent my best $100 on a lockrite


Current at 3.5 RE and 1.75 spacers with 33 KM2s:



 
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#428 ·
Went to Gulches OHV park for our first club trip. Had a great time, broke a few parts. Threw a U joint in my rear driveshaft and wallowed the CV out. My driver door latch ripped out of the door so gotta figure that one out. Some pulley up front is ticking like a boss now, might be my power steering pump. Gotta take a stethoscope and see which ones making the racket. And when I drove back in front dig after taking the rear shaft out something was clunking like mad and it varied with the throttle. Well see what happens, might just rebuild my tcase since my rear driveshafts out.



Check out some of the videos we got. Didn't get many pictures. If you haven't subscribed to our YouTube page I would appreciate it!



 
#435 ·
Got the main foundation of my bumper done. I'm still debating how to wrap it around the side, and how much sheet metal I'm going to cut out. Contemplating cutting a lot of it out and plating back in. I have so many cracks in the rear of the unibody by the liftgate.

Started with a piece of 4x4 1/4 wall, wanted 3/16s but went by out steel place 3 different times after they told me they had it in stock so just got fed up and grabbed 1/4. Its a heavy biatch. Cut out the ends to bend them in.



Painted up on the Jeep


It has three 1/2 grade 8 bolts in the stock trailer hitch locations holding it on. Im going to drill two more holes through the side of the unibody to sandwich it vertically too. Yesterday I took apart the 8.8 to replace outer axle seals. I love having C clips and having to take the aussie locker out just to change seals. Got it all done in an hr and a half, feel like I'm getting a little better at taking everything apart on the Jeep quickly.

Anyone else going to RBD??? Leaving next Friday and am super pumped. Got to build my tcase skid, replace rear coil posts, fix a leaking water pump, find doors, and a few other things before the trip so Ill be busting butt on this guy.
 
#436 ·
Went to RBD this past weekend at Morris MTN. My 2nd time at this park both times for RBD. Last year I ran Good Bad and the Ugly right when we got there and ripped my steering box off. This year I wanted revenge, ran it 3 times and then on the 4th time I ripped the balljoints out of the passenger side of the 44... broke both shafts too. Found a big enough socket and banged in some new balljoints to get it off the trail. Wheeled 3 dig the rest of the weekend.

Only picture I snagged.

 
#438 ·
Havent posted in a while. Got full chromos in the front now. Ripped the latch out of my driver side door and passenger door window track is destroyed. Picking up a set of half doors this Saturday. We went to Harlan KY for the OffroadSC.com ride and had an awesome time. Didn't break anything for the first time in 2 years on a trip. Chain in the tc is loose and slopping and my johnny joints needs to be rebuilt. Been saying it for probably 2 years now but gonna build a front bumper real soon. Heres some Harlan pics. Skip so theres about 45 seconds left in the video if its not already edited down. Worth it.









 
#440 ·
nice build man. Going to be tearing into my 9er next summer. Had been thinking of an HP44 and Super 88. I plan on 37's though. Anything you would have done different on your axle set up?
 
#441 ·
To be honest with how I wheel I wish I went straight to a set of tons. I plan on running 37s and in order to have the peace of mind and not break stuff every trip I need more than half ton axles. If your easy on the skinny pedal and dont follow buggies on 40s than an HP44 and a matching full width 8.8 would last you. I have confidence in the 88 rear on 37s but the 44 worries me.

If I was to do half tons over though I would get a ford HP44 rather than the jeep low pinion I'm running. And for all things holy don't run a welded front end unless you do hydro assist. Turning in the rocks is impossible.
 
#442 ·
understandable. I feel the same. I know an 8.8 (esp. a super 88) would handle the 37's. Just not 100% confident in the 44 being pushed by the 5.9 I have a Ford 9.75'' rear sitting at home I may use (basically a smaller version of the sterling 10.25). I may just jump to a 60 front and be done with it.
 
#445 ·
Might be picking up a Juggy chassis soon to begin swapping parts. Not 100% sure yet but found it on nc4x4 for a good price. Had some more nasty body damage to the ZJ on the last trip.



Also got part 1 of my tramper down.. Just need a truck and trailer now haha

1968 Bethany Chief. Baller status with the pink coral paint. Shes in great shape. It has been in my family since 68 when my grandpa bought it and passed it down through his sons. My uncle just dropped it off yesterday. Ill snag some better closer pictures later. Gonna have the most vintage tramper out there.
 
#447 ·
NICE! Love that camper. I really don't want to get rid of the ZJ. I've always been a grand guy and love them but the trails we run don't exactly treat a full bodied rig very well. Maybe one day I will find another and build up a trail rig I don't beat the snot out of. I don't know how soon the buggy/juggy swap will start, hell I may backhalf the niner instead of swapping over to something else. Still up in limbo.
 
#450 ·
Back from the dead. I have been working on it the past couple weeks. Jeep has sat way to much, got beaten up and abused and neglected. She deserves a makeover.

Started stripping the interior.

Lots of trips of stuff left in the Jeep and leaking water all over made for a nice mess.

Interior was pretty easy, until I got to the passenger seat where the seat was stuck over the bolts. Got out the torches and did some surgery.



So on to paint. I chose to flat black it, using Rustoelum professional. I currently have two coats on it and am waiting to put the third on when I have a nice day. I need to find a matte clear coat as well. I also have not started on the doors, ran in to some rust with my half doors. Once the Jeep is finished I am going to start on the doors. If I decide to pony up for a cage the Jeep may never see doors again. I also need to find new seats, mine were trashed. Either going to get suspension or some WJ seats.





Got more to post, have to get back to teaching.
 
#451 ·
Theres where I am with the paint. Need to put another top coat on and clear it with some matte flat. I also started rebuilding the driveline, tcase needs a tear down and the rear end may need to be rebuilt too. It locked up on me going 35 so I know there is something up with it, atleast a chipped tooth that jammed the gears together.

Also some helpful advice... when you doubt a gasket is doing its job do not rely on it to hold the transmission pan up. FAIL


Figured this might add a little bit of tech for anyone tearing down their 231. First off, I was going to take pictures each step but it slipped my mind after the first couple bolts and I figured Ill just do it when I put it back together.

I found the FSM online and printed it out for tear down. I set up a shelf right next to the bench and labeled all parts and ordered them in the order I removed them.

http://www.lunghd.com/Downloads_and_Links/NP231.pdf

I am going to purchase a master rebuild kit and a new chain. I found these on Amazon for cheaper than most everywhere else. I have not ordered them yet but probably will by the end of the day.

http://www.amazon.com/gp/product/B0...rd_t=36701&pf_rd_p=1970559082&pf_rd_i=desktop

http://www.amazon.com/Alloy-USA-11650-Transfer-Chain/dp/B005BFY8I4/ref=pd_bxgy_auto_img_y

One issue I have is I bought the 231 with the SYE already and do not know what brand it is or if a seal for the SYE output is the same as the stock tailcone seal. Guess I will find out when the kit comes. Also the bolt on the SYE that looks like a fill plug (I never removed it except to try to reseal it) leaks so I have to find an o ring or something for that. There was slight scaring from the chain slapping the case but nothing to serious. I do have a question about all these small cracks that you can see in the pictures below. Is this anything to worry about or is this normal? Is my case about to spider crack everywhere and explode next time it takes a big shock load, or is this imperfection in the casting?


Don't have my good vice bolted down yet... had to improvise. Beat the bearings out with my 3/4" sockets. Those big ol sockets are coming in really handy.


And my redneck parts washer. Purple power actually does a decent job cleaning it up. Going to throw some black engine enamel on it and then start the rebuild when parts come in.
 
#455 ·
Just a standard rebuild. Figured with this case lasting me 6+ years and who knows how long on the previous owner, I can get away with a normal rebuild. Probably won't be running it for longer than 1-2 years anyway.

Good to see this thing getting some love. Any plans to change anything up?
I have tons of plans :rofl: what happens though will probably depend on what deals I find. Over the summer I would like to start building a set of tons for it. It REALLY needs a cage, and now would be the ideal time to put one in it with the interior completely gutted. My friend with a bender though has been extremely busy and these real life bills are starting to add up. I thought I would have more money after I graduated and got a job... I didn't read the fine print. :rtft:
 
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