Blacksheep buildup progress

[BlackSheep]

Lots of work done in the last couple of months. Here's the short list:

Valve Job
New intake system
New exhaust system
New aluminum radiator
New shroud
new rock sliders
Aux tranny cooler
Re-seal of tranny pan
New multi-piece RE crossmember
Lots of painting and re-building of RE control arms and joints
Corner protection on rear bumper
Fresh powdercoat on bumpers

Photos here
share.shutterfly.com/action/welcome?sid=8AcNmLNszZtn7w

Work still needed to be completed:
grind rear axle spring perches (rubbed the shocks - caused one to leak) DONE
order new Doetsch tech shocks gonna hold off on this
install rear tires and get it off the jack stands DONE
trim down 4 body mounts for the PSC rock sliders - tried to get away without doing this - NO GO! DONE
install front bumper and winch DONE
Still have some cleanup to finish up in the engine bay
refill all fluids DONE
some other minor stuff. Will definately be driving next weekend, maybe tomorrow!

 

[I Lean]

Wow, lots o work! Impressive list.

 

[Nutz]

Very impressive indeed

 

[BlackSheep]

Thanks! I can't believe I forgot to include the new rock sliders as part of the work I've done! The funny thing is, what takes the longest is the cleanup before re-assembly. Breaking down those RE joints, partly due to the massive amount of tranny fluid that had leaked all over the old crossmember, was a *****! I must have gone through two rolls of shop towels!

 

[Tacoma]

Cleanup and disassembly always takes way long, and it's ugly. But shiny, rebuilt stuff takes all the pain away....

 

[BlackSheep]

Cleanup and disassembly always takes way long, and it's ugly. But shiny, rebuilt stuff takes all the pain away....

True. Every time I go to mount up a new shiny piece, I see the old rusted stuff underneath....Have to break out the sandpaper, wire wheel and masking tape to try to clean that stuff up as well. About the only thing I won't have fresh paint on is my axles....

Started to put my fresh powdercoated bumper on this morning, then got wrapped up with painting the anti-sway bar, front frame, jks disconnects and steering box skid plate. At this time, I still have not got the front bumper completely mounted. It is in place, and most of the bolts are in place, but I need to install the tow hooks and steering box skid, then I can tighten it all down. I dabated over re-painting the winch plate, but decided against it. Settled for a clean-up with wd-40 and a rag instead. Hope to have that completed tonight.

Also worked on grinding the rear axle spring perches for shock clearance. I don't know if I got them down enough, I guess I'll turn the old shocks around and put them on to see if I am still making contact before I get the new ones.

Unfortunately, not going to be running today. Next weekend is my target.

 

[yellowbronco]

Man, you are busy!!

 

[BlackSheep]

More stuff done. She's standing on her own four feet now. all chassis work is completed, now just need to grease and re-install the rear driveshaft, install the CB radio, refill the radiator / coolant system, change diff gear oil F&R, fill tranny, reconnect the battery and start her up!


Once she's running, I'll do a good wash and wax (several coats probably!).

Still have to re-install the trail goods - cargo rack behind the seats, spare parts, re-equip the recovery bag, re-pack the toolboxes, etc.

Then it's on to the trailer - needs to be re-wired and a new trailer jack. Thought about re-decking it, but don't think that is necessary for this trip.

the new tow rig will get a set of tires, a camper top / cap and a diamond plate toolbox.

 

[Greg]

I've said it before & I'll say it again... I love that TJ!

 

[Herzog]

I've said it before & I'll say it again... I love that TJ!

Me too. Such a good looking rig. JD - you've done good.

 

[BlackSheep]

Thanks guys! I'll post up some 'beauty' shots after she gets all cleaned up. Got to document the new parts, as I know those freshly painted and powdercoated and new parts will get scratched up during EJS.

 

[BlackSheep]

Update!

BlackSheep is back up and drivable!!!! Last night, I got the driveshaft installed , started filling the tranny and started on some of the trail gear (CB Install). This morning, I got up early and got right to work.

Had to clean up the mirror relocation brackets, so between oil & filter change and flushing out the coolant system, I was cleaning and painting that stuff. I filled and drained the radiator three times, running it until the thermostat opened each time.

The first drain was just nasty. The second drain was better, but still pretty bad. The third drain was definately better, but I think I will be doing another flush after EJS, just to try to clear out the rest of the nastiness. It takes a lot of 1 gallon jugs to flush the coolant system. No way was I dumping that stuff out in the yard! I ran out of jugs, otherwise, I would have done another flush. In a few weeks, I should have another stock of gallon jugs to store the used coolant until I can get it to a disposal site.

That Banks Monster Exhaust sounds awesome! Gives her a nice little rumble. The AEM intake and Banks Torque Tube do give her a bit of a boost, but with 35" tires and 4.10 gearing, she's definately not going to win any drag races. Seems to pull a little harder, so out on the trail will tell the tale.

With the new thermostat, water pump and radiator, she's running back in the normal range again. I didn't take her on the freeway just yet, as I needed to check for leaks and whatever I may have missed. After the quick test drive, I spent some quality time washing her up.

After finishing up the wash, I had to run to Radio Shack to pick up a new antenna cable for my CB, so I took the rig. When I got back I pulled her in the garage and crawled around underneath. Found one small leak from one of the Aux tranny cooler lines - behind the winch! Thankfully, I had positioned the clamp so I could reach through the winch and tighten the clamp. Haven't driven or run her since then, but I will be driving her tomorrow and to work on Monday, so I'll check it out.

Tonight's project is to give the paint a nice cleanup and wax job. Tomorrow I"ll pull her out and get some beauty shots. I'M STOKED!!!! I'll be leaving for EJS two weeks from yesterday.

 

[mbryson]

BlackSheep is back up and drivable!!!! .........

SWEET!!!

 

[Herzog]

I'M STOKED!!!! I'll be leaving for EJS two weeks from yesterday.

Can't wait to see you there!

 

[BroncoMama]

Can't wait to see you there!

X2. It will be great to see you and such a snazzy rig!

 

[BlackSheep]

X2. It will be great to see you and such a snazzy rig!

Hey,
I have made arrangements to stay friday night. We should definately hook up. My nephew will be with me, so can't be doing any big parties!

Got some 'beauty' shots this afternoon.

 

[SAMI]

lookin good... dayuuum...

 

[I Lean]

Needs more Armor-all tire shine goo.

 

[BlackSheep]

lookin good... dayuuum...

Needs more Armor-all tire shine goo.

Not gonna happen, but I did spend an inordinate amount of time applying the Mother's California Gold car wax system. It was worth it. I probably have only waxed that paint 3 times since I bought it in 2002. I need to buy a buffer and really go to town on that hood.

Finished up the CB install this afternoon, then I went out and bought the items necessary to get the trailer up to snuff. That will be my next project.

 

[Herzog]

Looking good JD! Looks even tougher than before.