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Tj's 01 WJ Build thread

70K views 388 replies 35 participants last post by  Bama_WJ 
#1 ·
Well figured I would start my own build thread, seeing as how I have gotten so many ideas of others thread, I figure maybe I can do the same for someone else so here it goes.

Cant find any pictures of when i bought it new, so ill just start with the oldest pics! Right after purchasing it I went to a local off road shop and ordered a 2in bb and some US Wheel D windows
 

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#351 ·
Got the front bumstops installed


Then set it down on the wheels with no springs installed. Sitting on the bumpstops. I dont like the fact that I had to bumpstop it so much in order for the shocks not to bottom out. I have PLENTY of room for more up travel before I start hitting metal. But, when I ordered the bilsteins a while back, I didnt think I would be on long arms and just orderd wj 4.5" lift shocks from KOLAK. When I move up to 6" and the 37's ill probably measure for the largest amount of travel I can actually fit. Instead of just a generalized shock. But anyway....






After that I installed the springs all around. Installed the front lower spring retainers I got from ballistic, and set it down on its own weight for the first time in 5 months! I cant wait to wheel this thing on the 29th!
 
#352 ·
Ive been super busy at work with a lot of side work. But finally got to give the jeep some love today. The poly performance straps came in, so I was able to get the front mounts all welded up


After that I stared on the rear upper adjuster mounts. These also have mounts for my rock lights. This is the beginning of the unibody plating process as well. They will get welded to the rear body crossmember.


Right side clamped in place


Aside from all that, I decided to expand into the fabricating business a little bit more, so I invested in more tools. I bought dimple dies.


My sand blasting cabinet will be here Tuesday. Then I will be ordering a Jd2 model 32 bender with 1.75" die (to get started) within the next week to two weeks. Once that arrives I'll be ordering the hydro upgrade from Swag off-road, as well as bend tech pro software. That should give me a great start. I'm excited to bend tube again, I haven't done it since school and really miss it. I just haven't had the funds to pursue this part of the hobby until l now.
 
#353 ·
Got the rear lower strap links welded up today. I also got the rear upper mounts welded in as well. I don't know how, but for some reason I was way off on my rear strap measurement. I needed 14" but for some reason I came up with 17". Either way, the correct rear straps are already ordered from poly. It's gonna be down to the wire, but I should be making the black Friday ride in wellsville next week.

Rear lower mounts tacked together


Rear upper mount welded in place.
 
#354 ·
So, I just busted *** trying to make it to the black friday ride, but sadly didnt make it on time. Good thing is though, I got a crap ton done, and was able to take the jeep out for a test drive and to try out the flex. All I can say is wow! love me some long arms!






Sad thing is, I just installed that 231HD that I built and its going to be coming right back out. Just picked up a 231 with terra low for a great price from a real good friend of mine. Only thing I worry about now is snapping axle shafts like toothpicks with a 4:1 ratio, and a locked 30 on 33's.




Still have a few very small things to do the dub, but as of now I could wheel it as is. Id like to get the hydro assist installed, as its a PITA to steer with the front axle locked and the wheels loaded. I still have to put the belly skid on, but I wanted to make sure everything was good before I put it up. Then rock lights and some other little stuff, but nothing of huge importance.
 
#357 ·
Good to see you're putting some of those parts to use finally! Looks good man.

I bet that new 231 will be fun.
Haha yeah definitely the longest install EVER! I agree, I cant wait to get this 4:1 kit in. I want tear the case halves apart though, and make sure it has a wide chain in it before I put it in. If it doesnt then the wide chain, and terra 2 low kit from my 231 installed now will go into the new one.

Nice! I don't know if I will be able to keep up with you out at SOR
Ah you will be fine. Its been a while since Ive been there so I would just be taking it easy for a little while. I have to get familiar with the place again.
 
#359 ·
Thanks!

As an update.

Ive beed driving and enjoying the wj for the past couple days. I just wanted to make sure the suspension, locker, t-case, and everything worked as it should before the next round of upgrades.

I think my little beater toyota got jealous, as it sprung a coolant leak some where in the back of the engine. Once I get that squared away, ill bring the jeep back in for some more goodies.

Next round of upgrades are going to include:

1: finishing the hydro assist. When the front axle is locked, its a PITA to steer.

2: terra low kit. Ill be tearing apart my 231 hd and robbing the wide chain kit, and terra 2wd low kit, and installing them in the terra low 231 i recently purchased.

3. Dual battery setup. Its always been in my mind to get the electrical system up to par. I think now is the time. Ive got a new switch on its way from otrattw on its way, along with a 12voltguy 100% duty cycle solenoid, ballistic battery box, and a battery cable kit on the way.

stay tuned....
 
#362 ·
#363 ·
Im going to use a v8 wj pump. Because they use a power steering actuated hydraulic cooling fan, the pumps needed to be upgraded to keep up with the demand of the fan. They are basically factory hi flow pumps. All you need to do is block off the return port used for the hydro fan, or switch the reservoirs. That should be plenty, but if for some reason its not, i may try the wto mod.
 
#368 ·
Few new things to report.

My little toyota beater car died, blew a headgasket. Mind you the heads been leaking oil for awhile, so it deciding to stat leaking coolant wasnt a surprise. Its going to be going off to that drive-in in the sky sometime soon.

So, I bought a new DD. 97 xj, 2 door, 4.0L/ax15, 4x4. Its a little beast! High mileage of 250K, but it drives like its brand new! I got it from a customer of mine who just last month had me do $1000 in repairs to it. I have no off road mod plans for this thing though. The plan is to squeeze every bit of mpg I can out of the thing, and as of now its getting 20mpg. Almost as good as the toyota! Anyway, on to the pics....





Also, since I now have a DD again, that means the wj can come in for the next round of upgrades. Its currently on the lift waiting for me to find the time to start tearing it apart. Goals for this go round are to install the terra low, dual battery setup, finish all my lighting (complete with emergency strobes), and install the hydro assist. As always, stay tuned.
 
#375 ·
Keep us up to date on the dual battery setup. I am looking to do the same thing in the future. I like where you are going with your setup and might like a parts list from you in the future.
 
#378 ·
Well, same update as always. A bunch of new stuff, and no time to install it. We just got our salvage license at the shop, so getting that part of the business up and running as well as working out all of the bugs is just killing my time. As of right now my job title is ASE Master Certified Technician/Auto repair manager/shop manager/loader operator/scrap car crushing manager/salvage lot organizer/ salvage co-manager. Ya, WAY too much right now! But, thats life when operating a family business.

Oh, and not to mention my little repair/fab business that I do on the side. Thats been going pretty good too. Its kinda crazy though that its been nothing but grands in the shop lol.

wk 4.7L for valve cover gaskets


wk for a drivers front axle that was froze into the diff. I also did the lift on this one. He also has my wj's street tires/wheels installed in these pics. Normally he has the factory wheels with 265/70-17 treadwrights.


wj for a 247-242 swap.


After those I was able to get my wj back on the lift to pull the t-case back out and add the terra low kit to it.


Thats where it sits for now, both t-cases are sitting on the bench waiting to be torn down and combined. The case going back into my wj will be a 231hd with wide chain kit, terra 2wd lo, terra 4 to 1 low, and a sye kit. The remaining parts will be put into a 231 with an sye that will be going into my buddies YJ

In between everything ive been order parts as ive found deals on them.

Purchased a set of used 3/4 ton hp44 knuckles that have already been milled,drilled,and tapped for highsteer. They included high steer arms, chevy brake conversion brackets, moog ball joints (will be getting warrantied out) and a slightly used set of mile marker hubs. I just threw the one on the axle to see how everything looked. They will be getting a serious cleaning, as well as new bearings and seals before full install.




Also got a hell of a deal on a brand new master gear install kit for the 10.25


On my lunch breaks ive been messing around with the axles a little bit. Have the 10.25 up against the wall, the hp44 in front of that, then a junk wj d30 in front of that in order to get some measurements for bracket placement.


Picked up a rust free gas tank SKID. Not one of the thin little brush guards. Now that I have this the tank lift can happen.


I also ordered a ARB locker for the 44 thats used. Bought it from the same guy I purchased the knuckles from. There was some slight confusion about what spline count it was at first (he thought it was a 35 spline at first so I wasnt interested) or I would have picked it up with the knuckles. After he got home and actually checked, it was a 30 spline. So now that will be coming in the mail sometime soon.

There is another wheeling trip planned for the 1st of March that I would like to make. Ill probably get the transfer case installed, maybe hydro assist too before then. But I REALLY dont want to miss this one, so if it gets too close just the t-case will be going in untill after.

The dual battery setup is on hold untill I order a different battery box. Just want to change plans a little bit, so a new box will be ordered soon. If anyone is looking for a ballistic fab battery box feel free to pm me as I have one available.
 
#380 ·
Made some other purchases as well. Mostly for the little fab shop im trying to put together.

Swag Hydraulic Upgrade for the Model 32 bender.


Bunch of stuff for the shop from harbor freight. I swear that HF is the way to go for things that your not going to constantly abuse. A hole jeeps worth of supplies for under $300!
 
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