ShadowNWPA 91ish YJ Build Thread - Page 13 - JeepForum.com
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post #181 of 239 Old 05-27-2015, 10:11 AM Thread Starter
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Thanks, I plan to keep it pretty clean as far as salt is concerned. It will be parked in the winter... at least until I move south.


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post #182 of 239 Old 08-09-2015, 12:35 PM Thread Starter
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Today... took some poser shots and measured for bump stops.









The front tires will stuff clear up to the tubes of the fender, the rears had a couple inches left. I picked up a set of warrior products extended bump stops when I started the build, I might have to cut them down to 5" before installation.

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post #183 of 239 Old 08-16-2015, 12:11 AM Thread Starter
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Today I finally made a back bumper for it. First I mitered and capped the ends of the rear crossmember which had been pretending to be the bumper. Then I notched and bent a piece of 3"x4"x3/16" square tube, this piece got thrown back in the pile and I started over as there wasn't enough left over on the other side. To mount it I used four 1/2"x1"x3 1/2" long, tacked them to the bumper for drilling and tapping (using a Bridgeport mill and an air tapper) then put the bolts in, broke the tacks, and welded the bars to the crossmember.

Eight 3/8-16 bolts hold the bumper on. I used cutting wheels for all the cuts, took about 7 of them. I used the same (as the front bumper) 1"x2 1/2" bar which was drilled and milled round on one end for the clevise points, these go clear through and are welded front and back. For the hitch receiver I used a 2 1/2" to 2" reciever adapter since I wasn't able to get to the supply house before they closed for the day to get the raw tube in that size. The actual receiver tube cost twice as much and the only difference was some 1/4"x 1x2" bar wrapped around the end. Once I got everything notched, bent, mitered, capped, and welded I threw it out on the driveway and sandblasted it.


















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post #184 of 239 Old 08-17-2015, 03:05 PM Thread Starter
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Today I put some black on the bumper. Will sand the runs later.


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post #185 of 239 Old 08-17-2015, 03:16 PM
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Looking good!
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post #186 of 239 Old 08-17-2015, 03:41 PM Thread Starter
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Quote:
Originally Posted by kidddhawk View Post
Looking good!
Thanks

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post #187 of 239 Old 08-21-2015, 11:04 AM
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I like that. Looks like a very stout bumper

87 YJ, 5.7/TH350/NP241/HP Dana44/9", Custom 4 link/ Radius Arms, ADS Nitrogen Shocks, 35" Cooper STT


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post #188 of 239 Old 08-21-2015, 11:13 AM Thread Starter
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Quote:
Originally Posted by daddyjeep87 View Post
I like that. Looks like a very stout bumper
Thanks, eventually I'll get to try it out. I can be a harsh critic of welding and fabrication efforts but I think this one turned out nice. I need to redrill and tap some mounts still, but I have a rattlecan paint job on it now and it's almost ready to go back on.

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post #189 of 239 Old 11-25-2015, 07:04 PM Thread Starter
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Tonight I got some evidence of why I had gas leaking out of the fuel injection wiring loom... cracked injector leaking it unto the socket. The one on the left was empty but wet when I unhooked the clip.. filled slowly when I turned the key. The injector socket smelled like it had burnt and melted. I put in four matching used replacements and it leaked from the o-rings. Gonna maybe get new injectors and o-rings soon... probably replace the pigtail end too, it looks a little melted.



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post #190 of 239 Old 01-31-2016, 06:22 PM Thread Starter
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12/29/15

Today I ordered a catalytic converter, 4 hole bosch injectors, and a replacement pigtail for the injector that had cracked and melted last time I drove the jeep. I got a tj downpipe for Christmas so I'll be able to replace all the exhaust that wasn't replaced when the jeep was torn down.

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post #191 of 239 Old 01-31-2016, 06:24 PM Thread Starter
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1/9/16

Today I spliced a new injector plug pigtail, installed bosch 4 hole injectors, and finally put in the 4.0 throttle body. I started on the TJ downpipe but ran out of time.







Pa legal tube fenders are excellent for under the hood work... they're almost worth it to have a workbench.

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post #192 of 239 Old 01-31-2016, 06:24 PM Thread Starter
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1/15/16

*Last night it was kinda decent outside so I drug the welder and creeper outside and tacked up the tj downpipe and catalytic converter. A couple tacks didn't hold very well, the ones that had a skid plate to work around, so I'm going to have to put it back in again to refit and tack. Got 3 of the 5 welds done though, little 110 campbell-hausfield fluxcore welder works well for exhaust. Might finish tonight.

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post #193 of 239 Old 01-31-2016, 06:25 PM Thread Starter
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1/31/16

Today I found time to finish the tj downpipe installation. I welded all the connections except the one where the new cat mates to the muffler, where a clamp went in hopes I'll be able to remove in two pieces if the need should arise. I also got the passenger motor mount removed with the busted riser bracket, then started making a replacement riser bracket. I need to pick up a few nuts and bolts then I can continue after some welding and paint.






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post #194 of 239 Old 02-02-2016, 06:58 PM Thread Starter
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Just got done making a motor mount to sill spacer bracket thing... needs painted but it's plenty stout enough.

Old one -



New one -




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post #195 of 239 Old 02-03-2016, 03:38 PM
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Subscribed. Ill catch up tonight!

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