The Round Eyed YJ - JeepForum.com
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post #1 of 22 Old 02-09-2020, 02:51 PM Thread Starter
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I should start by saying that I have been working on this build, on and off due to limitations of money, time or both, for the better part of 12 years.

I bought my 94 YJ in 2000, instantly falling in love, so the mods came quick. A 3.5” lift and 33s, brush guard and big tire carrier were among the first. After putting more than 240k on her in the salt belt, Chicagoland, she was not in the best shape. Mainly the holes in the tub, dripping diffs and TC, not to mention the fairly high-mileage 4.0L. Hating the thought of parting with her or getting a new Jeep, I decided to rebuild. As many know, this is a very slippery slope and can go in many expensive directions.

I planned on engine and body work mostly, which resulted in a rather large trickledown
effect of other various mods, many by necessity, some by my desire. After all my research came up with frame work a 93 SBC Chevy 350 TBI, my recently rebuilt AX15, a flipped twin-sticked Dana 300, Ford 8.8 with 4.10s, 4” DMW lift and, of course, a fiberglass grill with round highlights (I’ve always loved that classic look of round headlights on wranglers, this was my chance to make my YJ round). All of these modifications have required a myriad of adapters, customizations, and planning.

I made the tough decision to take it down to the frame. I still think this was a good decision but it definitely added a lot to the expense list and the build time.

After a long break, I’ve been able to make some good progress lately. I have the brake system completed, minus the calipers and rotors. Today I finished just the P/S hoses. It was a little tricky getting the right fittings but I went with -6an adapters from the gearbox and pump with braided hose.

While working today I noticed some rust and corrosion buildup where the intake manifold meets the cylinder heads. This engine has 0 miles, it was a newly rebuilt engine when I bought it. I have started it but only twice since the project began. The last time being probably 6 years ago. I think this may have caused the intake manifold gasket to fail due to the coolant sitting for so long. I definitely want to change the intake manifold gasket before going much further, obviously the oil too. Wondering if there is anything else I should be concerned with?

The photos below are the current state of the build.

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post #2 of 22 Old 02-09-2020, 02:58 PM Thread Starter
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Just a couple of the hundreds of project pics.
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post #3 of 22 Old 02-11-2020, 04:54 AM
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Nice!

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post #4 of 22 Old 02-11-2020, 10:33 AM
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I would definitely treat that engine with care after sitting that long. put a little oil in the cylinders and roll it over by hand a few revolutions before trying to start. Also pull the distributor and run the oil pump with a drill to pump oil through everything.

Most importantly, before going any further, get rid of that god awful grill and put a proper YJ grill back on there. Nah... it's your Jeep, you can ruin it if you want.
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post #5 of 22 Old 02-12-2020, 09:08 AM Thread Starter
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Thanks for the suggestions! Those are all things I am planning on doing prior to starting. I have a oil priming tool, and was going to turn it by hand this past weekend but for some reason didn’t think to put oil a little new oil in before hand turning, definitely will do that.

Oh I knew I would catch some heat about the round headlights, definitely something you either love or hate, I just happen to love it. I will never get rid of my original grill, just planning to hang it from the wall somewhere and do some cool back lighting as a little tribute.

Thanks for the staring tips!
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post #6 of 22 Old 02-12-2020, 01:53 PM
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Originally Posted by YJ94SBC View Post
Oh I knew I would catch some heat about the round headlights, definitely something you either love or hate, I just happen to love it. I will never get rid of my original grill, just planning to hang it from the wall somewhere and do some cool back lighting as a little tribute.
I actually think the round headlights look pretty good sitting on top of the square marker lights.

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post #7 of 22 Old 02-12-2020, 09:51 PM Thread Starter
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Thanks! I do too, it’s a Kentrol grill I think, I bought it probably 8 years ago while stocking up on parts.

One thing I haven’t figured out is the throttle cable and bracket for the throttle body. It came with nothing and I can’t seem to find one. Anyone have any suggestions?
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post #8 of 22 Old 02-14-2020, 09:51 PM
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I've been working on and off on mine for close to 9 years i think. I lost my garage space or I'd have almost all of the sheet metal and body work done on it already. Yours is looking great. I also went with a cj hood,grill and fenders.

its a rusty one

https://www.jeepforum.com/forum/f22/90-yj-frame-swap-build-up-1434246/
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post #9 of 22 Old 02-15-2020, 01:48 PM Thread Starter
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Originally Posted by lovett86 View Post
I've been working on and off on mine for close to 9 years i think. I lost my garage space or I'd have almost all of the sheet metal and body work done on it already. Yours is looking great. I also went with a cj hood,grill and fenders.
Glad to know that I’m not the only one on the decade+ build plan!

Also that I’m not the only YJ owner that went round I thought about going with the CJ front clip, then I found this grill and thought I would give it a shot. Just a little worried, since it is my first experience with fiberglass body parts.
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post #10 of 22 Old 02-15-2020, 02:20 PM
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I've never worked with fiberglass before and I plan on cutting down my jeep body to make a truck cab and I need to shorten my hard top to match it. Some where around 3-4 years ago my wife was given a 79 Camaro. That now sits in my single car garage.

its a rusty one

https://www.jeepforum.com/forum/f22/90-yj-frame-swap-build-up-1434246/
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post #11 of 22 Old 02-23-2020, 02:41 PM Thread Starter
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With this heat wave we are having in the Midwest, I decided to replace the intake manifold gaskets this weekend. My assumptions were right, the coolant that say in the back of the manifold corroded the gasket and it likely wouldn’t have held up for long if at all. Really glad that’s out of the way, it was not exactly fun scrapping gasket for a couple hours.

Planning on getting rid of the posi-lok cable system I put in, I got rid of the CAD because it wasn’t working, and thought it he cable was the way to go. After reading more online, I’m just going to lock my front axel. Sure there are a couple drawbacks, but with how often this will be road driven, I’d rather just lock the front axel.
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post #12 of 22 Old 03-01-2020, 04:03 PM
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You could always just throw in a 1 peice shaft and add a seal to the diff.

its a rusty one

https://www.jeepforum.com/forum/f22/90-yj-frame-swap-build-up-1434246/
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post #13 of 22 Old 03-01-2020, 06:32 PM Thread Starter
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You could always just throw in a 1 peice shaft and add a seal to the diff.
That’s probably my next upgrade, Once driveable again. Likely if/when I brake my front shaft. Which I guess is bound to happen. I heard a TJ shaft fits... but I’d need to do more research. Plus I locked up the front axel today along with a bunch of other little things.

Think I finally found a throttle bracket that will work! Found it on EBay, but I had to swap the bolt-stud from the right side of the manifold to left. Ground off all the bits of rust and painted the bracket with undercoating. Now I just need to see if I can use the stock Chevy accelerator cable that I just ordered...

I threw on the fenders and dropped int the radiator to check my engine - electric fan clearance. It’s only 1- 1.5” but I think it will work, or I will look for a fan that is narrower.

I was planning to mount the ignition coil to the firewall with a bracket I made, but thought I’d hit it with some paint first. So that will likely be next, then I would like to put on my new calipers, and bleed the whole system, from MC to caliper. I’ve heard the best way is to drip bleed each line, but i was going to look into a handler vacuum pump type bleeder, since I’m doing it solo. Anyone have any tips or tricks?
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post #14 of 22 Old 03-09-2020, 06:38 PM Thread Starter
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Got sidetracked but made some fair progress over the last weekend. Mounted the throttle bracket and found that I will need a much shorter throttle cable. Only downside is the throttle bracket will either need to be cut down a little or I’ll need a smaller air cleaner.

I thought I was going to have to pull the tub off again. So I could drill holes for the rocker bar supports, they bolt through the bottom of the tub. Well a 12” - 1/4” drill bit did the trick. Now I need to take them in for sandblasting and powder coating.

Ordered up some bleeding tools, hopefully start bleeding brakes and the MC this weekend.
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post #15 of 22 Old 03-09-2020, 07:11 PM
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Ordered up some bleeding tools, hopefully start bleeding brakes and the MC this weekend.

You mean you ordered a piece of hose and an old, empty water bottle??



Just kidding. I assume you mean some type of automated bleeding system? Iíve always thought about picking up a pressure bleeder, but have never pulled the trigger. Let us know what you are getting and how it works.

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