My YJ Project

[korda]

I previously had a XJ that I retired.  I've lived in NY, MA and MN and the winters took their toll.  When my wife started complaining about the rocks and tree branches coming up through the floor I figured it was time for something new.  I wanted something with less glass and body with a frame.

What I kept from the XJ:

• Front Axle: HP 44, narrowed to Waggy width, 4.56 gears, Detroit, Yukon shafts w/Ox Joints
• Rear Axle: Semi-Float 60, big bearing 9" housing ends, Moser 35 spline shafts, Detroit
• Transfer Case: Atlas II, 3.8 gearing, HD outputs
• Tires: 36" Super Swamper SX on 15" DIY steel beadlocks
• Other: 8274, other random stuff

I ended up buying a YJ body, frame and springs and planned:

• Re-using my axles, tires, Atlas and other stuff
• Drivetrain: SBC, 700r4
• Suspension: Simple spring over to clear the tires, decent shocks

What I started with:

[korda]

I started getting the axles prepped.  I added flat top knuckles so that I can do high steer when I get to it.  I actually ended up selling the axle I had and got a housing from a F250 so that I could use the stock leaf perch that?s cast into the housing.  The other housing I had was from a coil sprung truck and had all the brackets welded on it for a Jeep front end.  I decided it was easier to sell it complete vs. trying to cut all those brackets off it.





Got the perches and shock mounts ground off the back and the axle cleaned up:



Picked up some stock front Waggy springs to use in the back.  These will give about a 1.5? stretch to the back because of the offset center pin.  They are slightly longer than stock also.

[korda]

This ended up being pretty tall but there?s only a tub on it:


Since I was going to go with a SBC I cut the motor mounts out and got the shock mounts too:




The front had a shackle reversal done.  I think they made the front hangers this long to keep the angles on the front end good.  I can set the pinion angle and caster wherever I want so I wanted to cut them down.



Picked up some free TJ seats and made a little bracket to mount them to the YJ brackets.  I?ll probably end up mounting them to the cage when all is said and done.

[korda]

Fixed some issues with the body.  The rear must have had recessed lights in it that were cut out with either a jig saw or a rabid squirrel.  The top rail on the passanger side was pushed in a bit too.



Then a guy from my club in MN found a good deal on eBay for a TPI engine out of a 1985 Vette.  He?s done a few TPI swaps into various rigs so he can help out with wiring etc.



I got the front bolted in with parts from RuffStuff, it?s pretty nice stuff.  I?m going to run the stock YJ booster with a MC from a ?68 Vette and a n adjustable proportioning valve.  I ran this setup on my XJ and it worked really well.  I got a brake pedal from an auto YJ.

[korda]

For the fuel cell I wanted to run the RCI 2161 cell.   With the rear 60 pushed back there wasn?t room for the stock tank.  I decided to sink the cell behind the rear seat so that the bottom was flush with the frame rails.

I started with a cross plate and tabs, then made some straps for it.





I dimpled died the holes.  I?ve seen this on so many rigs I had to buy one and try it.  I built a little mini-press with a bottle jack to use it.

[korda]

I had a 700r4 built with the typical HD parts.  I also had a 23 spline AA output put in to match my Atlas.  This also saved my 1? in length on the drivetrain.



Got the engine mounts tacked in:

[korda]

Then came mounting the tranny and t-case.  I wanted to keep everything tucked up and do a flat belly on it.





Front shaft clearance:



Welded up the floor:

[korda]

I installed some fuel pickups in the fuel cell:



Bought a universal aluminum radiator.  I wasn?t sure how to mount it so for now I made a saddle that bolts in the stock spot.  I still haven?t made the top clamp yet but it?ll bolt to the top of the grill.  I figure this will keep the radiator attached to the grill.  The other option was to make saddles on the frame but the steering box looks to make that a pain.



I made a battery box because I?m a dumb stubborn guy.  I found the one I would have bought later that night while searching the net.





I got some rocker guards and corners from Gen-Right.  Also bolted on some TJ flares.

[korda]

In the above picture I settled on running a Waggy main leaf a stock YJ pack in the rear.  In the front it is the main leaf of the custom springs that were on the Jeep when I bought it combined with stock YJ springs.

Once I decided on the springs I wanted to get as close to having the full weight on it so I could see how it all sat.  I figured making the bumpers would be a good break and start to accomplish that.

I made a front to mount the 8274 I have:



Then worked on the rear this past weekend:

[korda]

That's about how it sits right now.  Sorry the post is all chopped up.  I was copying and pasting from my "home" forum.

I know I glossed over some stuff so if you have a question on what I did or what I used, let me know.  If anybody spots something I did that looks wrong please let me know, I'm learning as I go.

[ON-THE-ROCKS]

Nice build. looks very similar to my YJ, I started off with waggy springs in front and back but later swapped out fronts with air shocks. I just installed a tj seat on my yj and found that they sit much higher. I had to cut the stock seat brackets to get them to work.
keep up the good work and keep us posted. ~punk

[hammeredtoys]

Nice work it's looking real good!!!!!!!! ~cool2

[Big boy]

That looks great ~clap

[korda]

Thanks guys.

I got the top radiator mount made.



Also put in a rear crossmember with an additional support for the Atlas.  I'm planning on running my traction bar to it as well.

[korda]

Nice build. looks very similar to my YJ, I started off with waggy springs in front and back but later swapped out fronts with air shocks. I just installed a tj seat on my yj and found that they sit much higher. I had to cut the stock seat brackets to get them to work.
keep up the good work and keep us posted. ~punk

Good to know on the seats.  Ultimately I know I'll end mounting them to the cage or getting some aftermarket seats and mounting them to the cage.

[spiderjp]

very impressive build  I really like that u made everything on ur own thats what jeepin is all about

[korda]

Thanks.

Yup, the seats are way too high.  I might just mount them to the cage when I get that far.

Not much progress to show, got the fuel all plumbed and almost all the engine wiring done.  The engine runs which is nice since I never heard it run a year ago when I bought it.  ~innocent

Next up is all the under-dash wiring.  I'm planning on a flat dash:

[korda]

Been a while!  Nice to see the forum working with my ISP now.

I cut the seat brackets down a couple inches, they were way too tall.



Had a club member back in MN cut me a dash.

[korda]

This is where I ended up on ride height right now.  Used the National Springs that were on it when I bought it for the front.  The rear is a Waggy main leaf and then a stock YJ pack.



Checking the clearances/heights for shocks.





Built a traction bar for it.

[jeephead63]

This rig is going to be Friggin SICK! Good job man, keep the picks coming!