This is my build thread. It started back in july of 2006.

This thread is basically the pics copied over with the old post's.


(07/06/06)

DAY 1


So I picked up the skeleton tube fenders Patrick at Those Guy's Fab. made for me. Great Job on the desing and build too. Patrick's da man. :sing:

Anyways I got further along than I actually lplanned today. chris came over today to help out. I think he wanted to do this today more than me. But today turn out very good for starting at around 2:30 or 3pm. and ending at 6:30pm. Here's some pics of the progress.


I didn;t start taking pics until after the first fender was off and the skeleton mocked up. This is a pic of the skeleton with 1 piece of skin tacked on.







I wanted to keep the inner fender well still on. So we found the easiest way was to start cutting. We unbolted the fender from the radiator and all the support brackets, then came the fun. Much faster too. :




I Like this look, only wish it was street legal. :knght:





This is as far as we got today. Both fender's mocked up. Lower triangle piece of skin welded on both fender's and ground down. No top piece skin's yet. still looking for some. If anyone has some sheet metal laying around please let me know. All I need is 1 piece that is about 20"x40" 1/16th.




Hopefully tomm. night they'll be sitting in the garage drying. Then come Monday evening I'll put them on. :

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90 YJ, mall crawler special

"If you cant roll with the punches, don't step into the ring"

Day 2.1 The real day 2


OK I left work at about : and started at about pm. And just called it quits for the day.

Stuff I got done today:
Top piece of skin's attatched.
Inside fender well attatched to the tubing.
everything ground down and primered.


Here are some pics with comments.






Welded and started grinding the weld.







Attatching the fender well. That was a major PITA and not very easy.


Primered and drying





Tomm. will consist of bondo and final paint. Now I see why Patrick wanted to charge 450.00 for tube fenders with skins. These things are a work out. I'm sure it didn't help that I never wrote out and design. It pretty much has stayed in my head the entire time. [/b]

_________________
90 YJ, mall crawler special

"If you cant roll with the punches, don't step into the ring"

Day 3 continued....


Ok came to some conclusions today. I was going to paint them Gloss black for the final finish. Well with all the dust in the air there turning out pretty poopy. So I ended up coating them wil duraliner truck bed crap. Or whatever it's called. Looks much better. But I did find out I need to add some more sheet metal. I dont have to but for cosmetics I do.

Anyways more pics with comments:


Bondo's and sanded


Primered.




Gloss black finish :knght: I didn' like.






So I decided on this finish.

_________________
90 YJ, mall crawler special

"If you cant roll with the punches, don't step into the ring"

DAY 4


95% finished. All I need to do now is cut down the rock rails, paint them and install. Fender's are doen for now. I could add more sheet metal but its nothing majorly ugly or understood. More or less a personal pet peave of mine. But anyways Here are the latest pics.







This is just cool. 8)





The rock rails are going to be painted the same as the fenders. Also thinking about painting the rear fender flares the same. The JEEP sticker , I'm going to have reprinted but in black. And see if I can get the Sahara sticker in black or I'll just take it off. (IDK). Also the H2 recovery sticker will have to be reprinted in black. When I get the new cage it's going to be in black. I guess I'm kinda giving it a Vietnam desert color scheme. :knght:

_________________
90 YJ, mall crawler special

"If you cant roll with the punches, don't step into the ring"

DAY 5 Done for now.

Ok cut the rock rails. I ran out of wire so I didn't cap off the end. Probably do it after this weekend. But I decided to paint the fender flares the same. Here's the pics.

_________________
90 YJ, mall crawler special

"If you cant roll with the punches, don't step into the ring"

Here we go. Got the jeep all stripped down and ready for the cage. Should be done friday evening.

Before pic:



I snapped a spy pic today. Looking good so far.




Cage done!!! :

_________________
90 YJ, mall crawler special

"If you cant roll with the punches, don't step into the ring"

Installed LED's. Tailights, license plate. I was originally going to run round LED back-up lights, but I decided to use fog lights. Mainly because they will light up the area behind me while back. I was going to get some cheapo's but I found these high intense beam fog lights. Basically really fawking bright. Here's some pics.



with back-up lights on





I have some diamond plate corners coming in tomm. I'm going to paint them black (ofcourse) and run them to fix my bent to fawk corner's. Also to hide the boo-boo I did today. ( I cut the first hole in the wrong place, Didn't realize it until I had to cut the hole on the otherside)

_________________
90 YJ, mall crawler special

"If you cant roll with the punches, don't step into the ring"

ok time for update.

RCI Fuel cell. Shadow series AN fitting's

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90 YJ, mall crawler special

"If you cant roll with the punches, don't step into the ring"

Here's some pics of what I got done today.

The bracket:


with back plate





In the Jeep


I decided to make the back high enough to protect the AN fittings from crap I might through in the back.




Tomm it will be painted up, bolted up and maybe even plumbed.

_________________
90 YJ, mall crawler special

"If you cant roll with the punches, don't step into the ring"

Yeh my luggage rack will cover it.

But finished up the fuel cell project today. Here's some pics.









Fuel line, return line, and roll over line ran through the tub, tapped into the stock fuel lines.

_________________
90 YJ, mall crawler special

"If you cant roll with the punches, don't step into the ring"

OK just picked it up from Pat and I tested it out before I left the parking lot. Drove it off the little wall he has all the vehicles lined up on. Works great!! No more dented oil pans or tranny's for me.

Here's some pics.





back looking forward.



side view.



forward looking back.



:

_________________
90 YJ, mall crawler special

"If you cant roll with the punches, don't step into the ring"

Sneeky Peak.






LOL... I've been talking about this for a long time now. She must of stole my idea. Anyways here's the finish. About 90% done. Kinda scared to see what it looks like in the daylight

The next few days I'll be creating a special hood decal for it.






The paint is Made by Dupli-color. Its the Metal specks series, Burnt copper is the color.

I put a clear coat on it. Had too its pretty dull without it. Here's some more pics.


Its not perfect in anyway. I'm no Chip Foose.










Ok sneaky peak. ran out of vinyl I have to get some more black for the center piece on the hood.





Ok back on topic and moving along. Here's the finish I think




Ok you guys are to slow or I'm in patient. Well I guess its both So here's what I came up with. I hade to keep the hawk kinda tribal'ish to go along with the hood stripes. So hows this look?

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90 YJ, mall crawler special

"If you cant roll with the punches, don't step into the ring"

Ok heres my junk with the new leafs in the rear. Flexin out on the nieghbors rocks. Rear leafs are a bit stiff and need to be broke in. But still has plenty of flex. :

_________________
90 YJ, mall crawler special

"If you cant roll with the punches, don't step into the ring"

ok well tonight we started by stretching the wheel base a bit. I'm thinking about turning it into a sand rail :2fingers:






They Joel got some new meats

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90 YJ, mall crawler special

"If you cant roll with the punches, don't step into the ring"

ok so I went shopping tonight and came home with a locker. So here's a teaser pic.




Just did a front axle upgrade. Basically a chromoly Dana 44.


By jonsjeep, shot with DMC-FZ7 at 2008-03-05


By jonsjeep, shot with DMC-FZ7 at 2008-03-05


By jonsjeep at 2008-03-05


You can re all about the budget built at this link
viewtopic.php?t=4596


But today I did a few adjustments. first I had to solve the severe clunking noise coming from underneath. After pulling the rear drive line I found out the pinion angle was wrong and caused my Cv joint to max out at angles.

So today I re-shimmed the rear axle to almost dead on, pointing at the T-case. I also had to move my front axle back 1" to correct steering linkage. I'm still a little worried about the drag link hitting the pitman arm.
But the only way to tell is to flex it out. But I cant get my damn Yoke off to swap out for the correct yoke. (You were right Tony the stock 44 yoke wouldn't work). All I have left to do is swap out the yoke and then bolt up the drive shaft.


Had the breaks flushed today and and alignment. Wanna here some funny shit. I eye balled lining up the front axle. I got it dead on the money. No grab walking for this jeep.

_________________
90 YJ, mall crawler special

"If you cant roll with the punches, don't step into the ring"

Cant be afraid to cut, that's my moto

I had to solve the problem with the pitman arm hitting the drag link when flexed. Plus the steering linkage and drag link almost crossed over. I tried fixing it by moving the front axle back about an 1" but they still hit. So it was time to cut.

This is going to be a slow build due to lack of time. Looks like I'm out for this weekend. My new deadline is May 22nd.

Ok this is kinda where I started. Somehow Gina and Curtis convinced me to sell my bumper to them. So that gave me the motivation to actually do this.


By jonsjeep, shot with DMC-FZ7 at 2008-04-28

So tonight I started cutting. :chain:


By jonsjeep, shot with DMC-FZ7 at 2008-04-28


By jonsjeep, shot with DMC-FZ7 at 2008-04-28

and this is about where the steering box will be mounted.


By jonsjeep, shot with DMC-FZ7 at 2008-04-28

Leaving me with plenty of clearance now.


By jonsjeep, shot with DMC-FZ7 at 2008-04-28

_________________
90 YJ, mall crawler special

"If you cant roll with the punches, don't step into the ring"

So after making 2 trips to storage and finally empty it out, I started on my steering and cross member.

First the cross member/air tank/boner bumper. 3/16'' thick. 42" long, ends capped off.


By jonsjeep, shot with DMC-FZ7 at 2008-04-30


By jonsjeep, shot with DMC-FZ7 at 2008-04-30

Now back to the steering. This is the first mounting point.


By jonsjeep, shot with DMC-FZ7 at 2008-04-30

Two points done.


By jonsjeep, shot with DMC-FZ7 at 2008-04-30

mounted


By jonsjeep, shot with DMC-FZ7 at 2008-04-30




I got as far as three points pretty much done. I need to drill the fourth, then brace the bottom tab's. The top two are going to be through the frame and the bottom two are 1/4" link tab's braced to the frame. Should be sturdy as hell.

_________________
90 YJ, mall crawler special

"If you cant roll with the punches, don't step into the ring"

ok here's some pics with updates. all I need to do now is build the boner, reinforce the grill supports, (there are none ) and then plum in the air lines.


Here's where the gear box mounts.


By jonsjeep, shot with DMC-FZ7 at 2008-05-04

The lower tabs are supported by 45* plates. The picture doesn't really show it.


By jonsjeep, shot with DMC-FZ7 at 2008-05-04

Then I cut out the rest of the cross member. Originally I was going to use this and save it, but after further many hours of math calculations in my head. I decided it wasn't going to hurt to cut it out completely.


By jonsjeep, shot with DMC-FZ7 at 2008-05-04

Mock-up of the new cross member/bumper/airtank


By jonsjeep, shot with DMC-FZ7 at 2008-05-04

welded in place


By jonsjeep, shot with DMC-FZ7 at 2008-05-04


By jonsjeep, shot with DMC-FZ7 at 2008-05-04


By jonsjeep, shot with DMC-FZ7 at 2008-05-04

Painted


By jonsjeep, shot with DMC-FZ7 at 2008-05-04


By jonsjeep, shot with DMC-FZ7 at 2008-05-04


By jonsjeep, shot with DMC-FZ7 at 2008-05-04

A little more ground clearance


By jonsjeep, shot with DMC-FZ7 at 2008-05-04

But here's what i was going for. More clearance on the steering link to drag link. Before they were overlapping and would hit when the left tire was stuffed in the fender.


By jonsjeep, shot with DMC-FZ7 at 2008-05-04

Oh I forgot I still need to gusset the cross member to the frame. I think I might special order some cool ones.

_________________
90 YJ, mall crawler special

"If you cant roll with the punches, don't step into the ring"

new cross member is welded in and I thought it need some support. So I added some gussets made by Blue Torch fab.


By jonsjeep, shot with DMC-FZ7 at 2008-05-16


By jonsjeep, shot with DMC-FZ7 at 2008-05-16

_________________
90 YJ, mall crawler special

"If you cant roll with the punches, don't step into the ring"

Ok I guess I could give an update. Today we got the lowers links and 1 upper tacked on, cut the skid plate up a bit, and I cleaned up a lot of mud. That thing must of had 1 yard mud in the skid.


By jonsjeep

The skid is going to need to be reinforced now. The part of the oil pan is honestly like a diving board. So I expect to do more trimming or at least making it look better. I might have to make some angle cuts.


By jonsjeep

Here's where we ended.


By jonsjeep


Shane I saw your rig. Man that thing is Tall. :2fingers: But the suspension looks good. Should work out awsome.

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90 YJ, mall crawler special

"If you cant roll with the punches, don't step into the ring"

Tried to run over to your place Rick but Lexi was calling me wanting me to come home. But here's a pic for your guys. It still has some up travel left and down travel. Flexes like a mofo.


By jonsjeep, shot with DMC-FZ7 at 2008-09-11

Pat and I takin care of business on Blitz 8)


By jonsjeep, shot with DMC-FZ7 at 2008-09-11

_________________
90 YJ, mall crawler special

"If you cant roll with the punches, don't step into the ring"

OK ball joints done, exhaust fixed, but still need to secure some stuff. But here's a poser pic with Kalani behind the wheel.

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90 YJ, mall crawler special

"If you cant roll with the punches, don't step into the ring"

Alrighty....

Well today's project was to move the fuel cell to the back and install Lexi's seat. Got all of it done, took all damn day..


Had to reroute the fuel lines.




Seat and cooler mocked up.






Everything installed, Except I need to put a bar across the back for her shoulder straps. The bar will also be my high lift mount too...

_________________
90 YJ, mall crawler special

"If you cant roll with the punches, don't step into the ring"

UpdaTE: 3 seater done..

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90 YJ, mall crawler special

"If you cant roll with the punches, don't step into the ring"

Nice job on the rear seat. Good fit and finish and you left room for the cooler. Thats important!

PI

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Pirates On The Hood!
Gone Jeepin............