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Discussion Starter · #1 · (Edited)
flatlander757's 03 TJ build/update thread(now D60/D70 swap/stretch on 40s)

My build thread has gotten out of hand and being as ridiculous as it is, it's very hard to sort through it, or sit down and read it all at once. This table of contents is going to be a work in progress and I hope to get it up to date within a month or two. Thanks for checking it out:cool:

Page 1 - Table of Contents that you're reading now... then the build starts! Scroll down you big dummy!

Page 2 - 3" Full Traction lift fully installed, 33x10.50 TSL Radials, spaced out tire carrier for bigger spare

Page 3 - More pics of tire carrier bracket, MV1050 compressor installed, rock lights, Uwharrie wheeling trip

Page 4 - SYE, CV shaft, JKS rear UCAs, cut front bumper, RE rear trackbar and angled bracket

Page 5 - Redid rock lights, Pioneer DEHP4000UB radio, JKS Quicker Disconnects, Cobra 75WX-ST CB, Nth Degree engine skid, RE steering stabilizer, Poison Spyder steering box skid

Page 6 - Uwharrie wheeling trip, pics from the Outter Banks, Raptor liner install

Page 7 - More Raptor liner pics, AtoZ rocker guards installed, pics of carnage from Starr Motors Offroad Day 2008

Page 8 - BESRK tire carrier install, bought a welder, custom 3rd brake light, rock lights redone AGAIN

Page 9 - Pics of girlfriend(now wife) posing with Jeep, lots of chatting

Page 10 - Uwharrie wheeling trip, Christmas Jeep pics, picked up a HP30, started spacing the EVAP canister and installing CJ style tail lights

Page 11 - Finished CJ tail lights, license plate light, THE WORST IMPULSE BUY EVER: I bring home a D60 and D70HD :evilgrin:

Page 12 - Cut EVERYTHING out from under the Jeep... there is no turning back now! Started cleaning the old brackets off the axles and frame, etc.

Page 13 - Still cutting brackets off the axles, comp cut on the tub, cut the front fenders up, some parts starting to arrive

Page 14 - Tires arrive, fuel tank mounted in the tub, start fabbing rear bumper, mounted the first of my tires

Page 15 - Rear bumper fab continues, rear leaf spring mockup, mounted another tire("how to" mount on a beadlock wheel)

Page 16 - Final-welding in the rear suspension, bunch of chatting and answering questions about the build

Page 17 - Start checking clearances at the front axle for driveshaft and steering, cut the front crossmember out of the frame

Page 18 - Steering box relocated for more clearance, start playing with the 3-link calculator, built new front crossmember

Page 19 - Finalized crossmember, D30 vs D60 axle shafts, D300 installed and clocked to check DS clearances, front axle brackets starting to get mocked into place

Page 20 - Rear axle brake calipers replaced, brake lines run, fabbed frame-end brackets for front suspension

Page 21 - 1.25" BL, front suspension tacked into place and mocked up with dummy control arms

Page 22 - Welded in some of the control arm brackets on the axle, and mocked up with real suspension links

Page 23 - Cycled front suspension, Branik high steer D60 arm installed, coil mounts tacked in place, drag link mocked in place, trackbar mounts tacked in place, welded a BUNCH of stuff in for good

Page 24 - Pics of all the stuff welded up, final teardown, started painting EVERYTHING

Page 25 - Painted suspension components, mounted the last 2 tires, final touches on rear bumper, Spyder giving me crap(lol)

Page 26 - Reassembled, IT SEES DAYLIGHT for the first time in 9 months!

Page 27 - Problems with not turning tight enough

Page 28 - Tie rod built, replaced a wheel bearing, had some problems with siezing a heim in my new tie rod

Page 29 - Built front shock mounts, pics of front end and steering

Page 30 - Pic of my Jeep next to a stock Jeep(Zach's), JK turn signal install, side clearance lights, started building rear axle shock mounts

As I said, this is a work in progress... you'll get the rest of the 140+ page build up sorted when I have time to kill.

------------------

The Build starts HERE!!!

So I figured I oughta start one of these threads before I get too far into building up my Jeep. The short-term goal(less than 5 months) is to have it sitting on 33in tires. Then the long-term goal(by this time next year) is to get it regeared for 35s, put some armor on it, flat-fender, and 35in tires of course. I probably won't be updating this every single day but whatever I do I'll take pictures:)

So anyways, here is my 03 Sport(4.0, dana 44, and NV3500) the day I got it a couple months ago:







And then 2 days later:








I made my own mirror for when the doors are off, seen here:

 

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Discussion Starter · #2 · (Edited)
Then within the first week or so it was sans-front-milkjugs:



Then just a couple days ago I got around to painting the fender-flares and headlight bezels w/ satin black krylon fusion... it looks great IMO!















And then not directly Jeep-related, I got out of the dealership I worked at and went to a very large used car dealer. They provide tools there, so I got to take home the ton of stuff I'd bought while at Hall Dodge:D



It's also a nice $$ increase so more goodies for the Jeep!
 

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Discussion Starter · #5 ·
Haha, it's funny you responded, I've read through your entire build-up... it pretty much gave me the inspiration to get off my *** and do something haha:laugh:
 

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Discussion Starter · #7 ·
No pictures, but soon to come is a FT 3" lift w/ 33x10.50 Swamper TSL radials:D

And so you know the flares and headlight bezels have held up great :)
 

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Discussion Starter · #9 ·
I just roughed them up with some 320 or something grit sandpaper, wiped them down with parts cleaner and a rag. Then sprayed them.
 

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Discussion Starter · #11 ·
So I have everything up front installed save for the sway bar stuff...





The only problem I ran into was the driver side front shock was being stubborn on the top mount. I couldn't get a good hold on the top of the shaft and it kept getting mangled so I cut up the cover and used vise grips and a 1/2in impact:D



Also there is no need for a tie-rod end puller for the track bar or the swaybar endlinks... here were my solutions:









...
 

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Discussion Starter · #12 ·
...and for the track bar tie-rod end, I did the same thing that I do for tie-rod ends in the dealership, loosen the nut enough to get loose but still hold when the tie-rod end is free, and hit whatever it mounts into with a hammer. It will take a few good blows but it works well. It may help to be wiggling/forcing the track bar w/ one hand back and forth or have someone rock the steering wheel back and forth while hammering.



And the pics in the last post aren't up to date, I've got the track bar and shocks all installed too and wheels back on. I've got one spring on in the rear, I'll have to finish tomorrow.
 

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Discussion Starter · #14 ·
So I've got all the physical parts installed, it looks freaking great:D I'm about to set the toe and straighten the steering wheel then test drive it. I'll take pics before it gets dark and probably post them between 10:00 and 11:00:)
 

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Discussion Starter · #15 ·
Well here it is... I have it aligned and all seems well, I'm not sure if I've got vibes or not, if there are any they're real subtle, but since I'm so paranoid about having them it's hard to tell if I'm imagining them or not.





:thumbsup:
 

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Discussion Starter · #17 ·
It looks 10x better now...

I just got the tires mounted but it was already dark out so here are some teaser pics until tomorrow:D











I was on my way to Slick Trick Performance and Off-Road to get tires and at about 60mph on the highway I got some hellacious death wobble all of a sudden, I was seriously afraid I was going to crash:eek: I had to slow down to 30mph on I-264 during rush-hour traffic between Independence and Witchduck road... not good. So I took a look when I got there and found that the tie-rod end of the front track bar had the adjustment-locking nut work loose so I tightened the ever-living hell out of it and all is well now... I'm carrying a 1-1/16" wrench w/ me now just in case, but if it happens again I'm gonna use thread lock.

The tires are awesome, they couldn't get them to dynamically balance, so did a static balance and it worked out great, no out of balance tires as far as I can tell:thumbsup: They aren't anywhere near as loud as some people on this forum make them out to be... :laugh: Ninnies. And driving w/ a 5 speed, 3.73s and 33in tires isn't bad at all either. I am so glad I didn't settle for anything less... I love my Jeep :drool:
 

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Discussion Starter · #18 ·
And here it is in the day time...

:drool:



Stupid spare tire, that's next on my list.


This is what belongs on a Jeep:


Mmmm...


Again...


The front springs/swaybar disconnects(which aren't great)
 

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Discussion Starter · #19 · (Edited)
...

Front shock and the brake line drop bracket:


Rear trackbar relocation bracket:


Front adjustable trackbar at the axle-end:


Frame-end of the adjustable trackbar:


I liked the kit, the instructions suck as they leave out a lot of torque specs and what bolts to use where so you pretty much make it up as you go, but the parts and all seem very nice.
 
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