the first thing to go was the balding tires and somehow I ended up with a brand new spare with alum. wheels off craigslist for $100 so i threw the steel wheels with tires in the shed for safe keeping and mounted up 4 brand new 33x12.5x15 BGF A/T's from costco on the AR 15x10 alum. wheels. At the time I was still driving it on the street and wanted a more street friendly tire.

Just like any guy would do with new tires I went to try there effectivness out in some new fallin snow out at my parents ranch. The result of too much skinney pedal in reverse in a snow drift and bam!! went reverse

In the middle of tearing it apart I found a freshly rebuilt AX-15 with external slave on craigslist with best offer. Called him up turns out UPS dropped this tranny on a delivery and it somehow was "bound in gear" offered him $100 and brought it home with me. Removed the tail housing to find out that the shift rail was missing set bolt that held fork on shifter. installed bolt from my broken tranny and wala had a new tranny. I removed the rear tail housing from my broke ax-15 and installed it on new one( rebuilt one was clocked for a XJ) then proceeded to do an external slave on my previoiusly internal jeep.

Then proceeded to enjoy my jeep for awhile.............

 

Shortly after all the fun with the transmission my wife was begining to trust the jeep to take Me from point A to Point B. It started running rough . I decided to check the oil in the jeep since it had'nt ran very well recently. Yup confirmed my fears Milk in the oil.

broke as a joke!! so I started reseaching some possible upgrades and came accross this thread http://offroad-review.com/new/index.php?page=68 Then found a guy on craigslist( starting to see a trend here??) in the free section giving away two jeep motors one out of a '93 xj with 4.0 and a 4.2 out of AMC eagle so I buzzed over to his place and cleared his garage.while explaining to him what I was about to attempt he willingly offered up the complete wrecked jeep XJ (the one the 4.0 came out of) wohoo I hit the jackpot. :cheers:now I had all the stuff I needed for my 4.0 head swap. I followed the thread word for word, then went to a Junk yard an got an a HEI from a 198? chevy truck straight six. bought the parts to rebuild it with a drive gear from a 304 out of a CJ.
By this time I had done a enough research on the interweb about 4.0 head swap, HEI and MC2100 carb that my eyes should have been bleeding:crying:. It was about then that my Wife really said what the Hell have I done:laugh:

 

After I got the jeep back on her feet again I ran across an ad on craigslist for a warn winch for $150. I called and it turned out to be a 5687 winch so I picked it up it was pretty beat up but still worked well.

I quickly went to work on building me a winch mount for the front of the jeep. I made it all out of 1/4 steel. Drilled all the holes with a bi-metal holesaw steady hand and trusty drill. I tacked it all together with my craftsman 120v welder, then took it over to my buddies shop to finish burning it together with his 240v mig welder.

It stayed like this for awhile up until about a year ago when I finished it I did a build thread in the fab shop here is a link:http://www.jeepforum.com/forum/f37/yj-stubby-winch-bumper-1286302/ At the same time I ripped the horribly awful tube rear bumper off and made a rear bumper with a receiver out of 2x4x3/16 steel, with plans to add a swing away to it.

 

Im in. Its about time you make a build thread

 

Thanks Man your jeep has been a big inspiration to mine! I had been regretting not starting a build thread since my Father lives so far away now. I want him to be able to follow along with me. I feel that this build will be able to keep him in the loop to as what is happening instead of me trying to explain it to him over the phone. Dont worry there will be plenty of tech coming up, and wheeling pics of Moab. My buddy just bought a built YJ with a V8, tons and 37's so I finally have someone local to me to wheel with.

 

alright still bringing it up to date. after the winch and bumper I drove it like that for about a year and did some wheeling and just some general fun in it. Picked up a '96 ford exploder 8.8 with 3.73 open for $75 on craigslist. I tore it down slowly buying parts to rebuild it and was on the look out for a set of 4.56 gears for it. Then one day after a softball game Im driving home and Snap!! clunk clunk!!. 1/4 mile from home rear tail cone on transfer case exploded.

So I pushed it home and winched it in the garage. Now sure I could have just bought a new tail cone and slapped it on there but where would the fun be in that. I browsed ebay and found a AA SYE for $160 with free shipping so I pounced on that and set myself in for a complete over haul on the suspension.
If you remember when I bought the jeep it had a RC 1.5 lift and road like a dump truck with a flat tire. I wanted a better riding jeep and a little more wheel base, so with some more searching online through pirate4x4. I learned that 80's jeep grand wagoneers leaf springs give you 2" of stretch and 2" of lift. As budget conscientious as I was I figured this was the time to pull the trigger on it. I made up some excuse to my wife that if I didnt do it now with the SYE I would have to buy two drive shafts and that it would cost me $400 bones, Ha ha she fell for it :kiss: I hit up my local junk yards and with $90 I bought two sets of front waggy leafs I quickly went to work on installing the SYE mean while stirpping spare parts off my parts XJ. I sold most of the drivetrain parts that I didnt plan on using. I sold the rear 8.25 to a local wheeler and happened to mention to him I had a 8.8 he told me he had a set of 4.56 gears and for $100 they were mine. Score:highfive:

I swapped springs an turned around and sold my RC lift for $100 I was feeling pretty proud of myself and loved the amazing ride those waggy springs gave, but alas I didnt have enough money to swap in the 8.8 at the time so it sat. I used the front CV shaft from my parts xj and had it cut and balanced to run with my SYE.I lengthened my stock front driveshaft and continued to wheel on the dana 35 knowing it was on borrowed time. I was also proud of my new found flex

 

Those waggy springs have an offset perch right? Did you use them in the rear or build a bastard type pack with them?

 

Yes they are offset about 2" longer than stock YJ springs.I used them both front and rear. The fronts I used an XJ main leaf and made a mini military wrap.

 

Finally.

And in. :thumbsup:

 

Thanks guys! I have always wanted to do a build thread. Hopefully today I can get some more updates in.

 

keep it up subbed. gotta get back out in the garage and work on my 1 ton yj project.

 

So in the summer of 2010 I was scrounging craigslist again and came across an ad for a set of ultra alum. wheels for a yj. The guy wanted to trade for a set of black steel wheels. Ha :laugh:remember the wheels my jeep came with so a phone call and we were off to swapping wheels and I ended up with these:

My wife and I also like to go to yard sales and buy good used stuff well I happened upon this run down beat up 1987 Kawasaki 250 for $20 I begged my wife to let me drag it home :kiss: a few dollars later and some turd polish I had this. ** add pic later**It was a complete hack job from wiring to motor mounts when I got it. Oh and it didnt run so after a used stator from a clapped out junk yard find it purred like a kitten. Around that time I found an ad on craigslist (if you havent figured it out yet Im a craigslist junky) I find a guy wanting to trade a set of (5) 35x15.5.x15 Super swamper TSL SX for a dirt bike. A phone call later and I was on the road with the dirt bike in the back and came back with 5 fairly dry rotted TSL's. All hold air just fine.

that was just a pic of them mounted up to my dana 35:eyebulge:I could just hear it wincing in pain. I pilled the tires up in the corner of the garage and set out to one day install then for good once I got my 8.8 regeared.:2thumbsup:

 

In January of 2011 I finally had scrounged up enough money to buy a decent welder. I bought a Lincoln 180 mig, its been a great welder and can lay a nice bead.:thumbsup: In Febuary I had finally scratched the itch to install the 8.8 long enough and had saved enough coin to do so. We Left on vacation for Presidents day weekend and I swung by the shop of the guy going to install my gears for me in the 8.8. I had completly tore down the axle and had it all ready for him to setup my gears. As we were unloading the 8.8 Ryan just mentioned he happened to have a detroit locker for the 8.8 and for a extra $300 bones he could install it while he was doing the setup. We shook hands on the deal and I headed off to Island Park and a wonderful weekend in the snow with my wife and kids.:wave:
Shortly after we got back I set out on removing the old dana turdy-five.

I removed my gas tank also in preperation for doing the "dimple mod"
A few days later and I got a call that my 8.8 was done :highfive:

I didnt waste anytime getting it slung under the jeep.

Setting Pinion angle

welding perches on

I even stenciled the Punisher on the diff cover.

After all the $$$ I had spent in the last two months and the extra cash I shelled out for the Detroit my front axle regear was gonna have to wait.
Unorthodox front axle swap coming next:teehee:............

 

That rear end cover looks great? mine is has oil and terrible paint and the bolts look like they are leaking. What did you do to get yours so nice? Is is new or did you paint it?

 

Since the 8.8 went in I knew I was going to have diff/tank issues I couldn't afford a bling stretch tank so I used a thread on pirate4x4 on how to make my stock tank work. So I got to work.cut out the basic shape into the skid I cut out about 3 to 4 inches then rotated the piece I cut out 180*.

welding in the sides:

welding up the outside:be sure not to have any sharp or abrupt edges so as not to cut or score the tank

Primer:

heating up the tank:

This didnt really work too well I made a call to my stepdad and we combined the heat of my propane torch with a wide angle tip and his propane torch to give it a good even heat then after about 45min of careful heating it was definately plyable enough to slide into the skid. This is the most important part it needs to be heated very carefully so as not to burn a hole thru it. this is some really thick stuff so be pateint .:thumbsup:
finished product:I had to modify my pickup tube a little to make it work. I removed the screen off the tube and cut the smallest amount I could off, then slightly bent the tube up so it didnt jamb on the bottom of the tank. I have a carb so you guys running fuel injection may have different problems.

 

Since the 8.8 went in I knew I was going to have diff/tank issues I couldn't afford a bling stretch tank so I used a thread on pirate4x4 on how to make my stock tank work. So I got to work.

So wheres the pics? I'm doing this mod right now. I dropped my tank yesterday and will hopefully start cutting the skid today.

 

Nice mod on the tank. I saw that in gtxracer's build.

 

Thanks! Yeah I was following his thread over on pirate when I saw it then I finally noticed he had a build over here too when you mentioned the nascar pitman arm.

 

very nice. Just finished my skid today. Still have to dimple the tank

 

very nice. Just finished my skid today. Still have to dimple the tank

Very nice job. I will be updating with my rear upper shock mount relocation brackets.

 

When I installed the 8.8 I knew I was going to have to address my shock situation. Since my jeep sits pretty low I wanted my shock mounts up out of the way. I needed new shocks anyway so I made my own axle shock tabs out of some scrap 1/4" steel I had laying around. I made a thread on my M.O.R.E. inspired upper mount relocation brackets but with a twist since I was running waggy springs my shock angle would have been horrible so I made these. http://www.jeepforum.com/forum/f12/skyjs-version-m-o-r-e-shock-extensions-1345960/

Here they are installed:

and a fun little test drive to try them out:

 

Subbed. I just started going SOA with an 8.8 swap as well. Lets just say I'm taking notes now.

How necessary is the tank mod? I've got my tank out now and think I might need to add this to my list. Is your fuel gauge still accurate?

 

Subbed. I just started going SOA with an 8.8 swap as well. Lets just say I'm taking notes now.

How necessary is the tank mod? I've got my tank out now and think I might need to add this to my list. Is your fuel gauge still accurate?

Thanks I just checked out your build. I'm not sure on how necessary the tank mod is in your case. If your not stretching your wheelbase you shouldn't need to .Check out 92vegas build he just did it and he is spring over. http://www.jeepforum.com/forum/f12/just-another-yj-build-my-version-1341575/

 

Since I was broke as a joke after my 8.8 swap. I set out to install a dana 30 with 4.56 gears I picked up from my inlaws neighbor for a song. the only problem is............... Its a LP dana 30 from a ZJ with 4.56 gears. this is where all you purest can go:nono::nono: or :hahaha::hahaha::laugh::rofl::aban::aban::gunfight::gunfight::fear::fear:
Now that we got that off our chests.
Back to the install like I said I picked this beauty and its rear counterpart up for real cheap. with plans to sell them to some unsuspecting guy HA! that never panned out sooo...... The plan was just to temp. install it until I could afford the 4.56's for the HP 30. Ok now the good news this LP dana 30 came drilled for the tie rod flip, is a non cad and has one peice XJ shafts. so I got to work on cutting off the tin foil they call link brackets, and a few minutes later I had this.

then this:

It actually went really easy and was ready to start making spring perches.
well as luck would have it I just happened to have some 2.5x2.5x 1/4 wall square tubing in my scrap pile so I made these:my new garage sale drill press came in real handy for these

then I got to making me some shock mounts out of some more scrap I had:

Now as some would know to put spring perches on the dana 30 you need to have part of the perch offset over the casting of the diff so I made a perch out of 1/4 steel similar to how JB4x4 does their offset perches. Sorry no pics of that.
I slung it under the jeep set caster at around 6* the Pinion angle didn't turn out to bad either . Tacked perches in place and pulled it for final welding.

AH!! back on all fours again.

Dont worry guys I still have my HP dana 30 quietly sitting in the garage waiting for its glory of when it can once again reside under the front of my jeep. besides when I can afford the 4.56 and rebuild I can still use the carrier from the LP so its not all that bad or I can keep building up a waggy dana 44 to throw under there ah!! decisions, decisions.

Next installment Tie rod flip whoes

 

I'd throw a LP D30 with 4.56's under my jeep if the price was right. Looking good. I think I know how the steering is going to turn out.

 

Thanks yea I got a lot of flak for putting it in but I don't care its held up to 35's and a trip to moab so I ain't to worried about it. I paid $100 for it and the rear end. It came with pratically new unit bearing to so I got my moneys worth.

 

my tank started leaking after a few years. the heating with a torch made the plastic a bit more brittle. i ignored it and it stopped. make sure there is something insulating the tank from the corners.

 

I saw you say that in another post too. I sure hope that doesn't happen to mine. It's been in there for about a year now. I did use a thin rubber mat between it was already in there between the tank and skid plus I flap wheeled the piss out of the skid to make it smooth. In the thread on pirate I haven't heard anyone mention this, not sayin it won't happen. Thanks fratis! I have always liked your advice.

 

when that thread on pirate came out i had already done mine but didnt have many years on it yet. people tend to do write-ups without actually testing things out. they get it together in the driveway and run to the computer to show what they did. seemed to get more brittle with age which makes sense.

like the short and low pro perches.

 

people tend to do write-ups without actually testing things out. they get it together in the driveway and run to the computer to show what they did.

I hear ya there. I have always appreciated your advice through the years even if it means I have to swallow my pride. By the way its been a long while since I have a seen a pic of your jeep?

 

I love you build man! Subscribed......

 

Thanks!!you kicked my @** in yjotm. You have done a good job on your jeep also. :thumbsup:look forward to the work you will be doing soon....
well except for the cloaks

 

Since the dana 30 came with knuckles already drilled for a tierod flip I mocked it up that way.
I had this problem:

I only had about "1 of uptravel before my draglink contacted my tierod.
so I created this thread http://www.jeepforum.com/forum/f12/tie-rod-flip-stretch-pitman-arm-interference-1358161/I decided to go with a ford ranger Pitman arm out of a '80's 2 wheel drive with power steering.
Ranger arm on left YJ on right:

I had to file out the keyways

on it in the arm to clock it for the yj steering and add a goferit insert into to arm, because the taper was bigger than the yj tre. I fully welded it in instead of just tack welding it.

then I ordered up another goferit for the tierod to attach to the drag link. It worked great and I ended up with plenty of clearance. My turing radius kind of suffered a little from it but not much.

flexed it out on a mound of dirt out at the ranch:

after installing the 8.8 I never really liked how spongy my brakes felt so I ended up installing a ford Van E350 master cylinder:it made my brakes muy bueno.

I still may order me one of those parts mike bracket that moves my steering box forward an inch but the ranger arm is working good for now I can live with the loss of radius it really isnt that much.

Moab wheeling trip pics and video next.........

 

Awesome right up!! love the wording. Felt like you were telling a good story. Sweet job on the work you did

 

Thanks!! I love to tell a good story. If anyone would like a more detailed description of anything I've done just let me know. I'm getting closer to being up to date on my build.

 

Loaded up headed out for Moab.

Made it safe and sound.

The begining of Hells revenge trail:

The Colorado River:

Coming out of Mickeys Hot tub:

My step-dad three-wheelin it all day.

Devils Highway Hot tub

It was about this time that we ran into the coolest group of guys running really built rigs. they let use tag along with them.

I always thought "Tip over Challenge" would be a bit more of a "CHALLENGE"

 

Man I wish I could have a place like that to wheel on near me!

 

It was a 13 hr drive for me:2thumbsup: