Jeep Build- Jeep YJ Unlimited / family wheeler

[idahoyj]

Got the passenger side frame rail cut and the plates fit and tacked into place. I was able to weld the inside of the plates to the top of the existing frame rails. Next i will cap the tops and bottoms with flat bar.

 

[idahoyj]

Drivers side frame is notched and side plates are heavy tacked in place.

Motor mounts (engine side) are built. Also mocked the Amazon block hugger headers into place. Definitely a tight fit to the motor mount.

Next project will be the front bumper/cross member/winch mount. The winch mount will be tricky, because my steering box sticks up above the frame rail....

 

[mbryson]

Any close up pics of the underside of the D60 housing where you went spring under?

 

[idahoyj]

Any close up pics of the underside of the D60 housing where you went spring under?

This is the best I have right now. I can easily take more tonight though.
This pic was early mock-up of the front axle install.

 

[idahoyj]

I've been working on the front frame rails and cross member/bumper for way too long. I really wish I had just left them alone and spent my time installing the engine/trans etc.....

Pics of frame rail progress, ignore my mediocre welding ability.

I found a deal on an NP205 Ford tcase with TH350 adapter on KSL and convinced @JINX to drag it up to Idaho for me. I really want to run the Behemoth Strong Box, and I even bought an NP241 donor case. Unfortunately, I don't see the extra $700 coming my way soon enough to go that route now. I may still go that way some day though.
Pics of engine/trans/tcase bolted together.

I also purchased a Griffin radiator from Summit. Hope I can figure out how to mount it!

 

[STAG]

Good radiator mount pics.
http://www.pirate4x4.com/forum/jeep-hardcore-tech/963451-project-animal-relapse-3.html#post12706338

 

[idahoyj]

I haven't worked on anything lately, but I did get some new bling!

 

[Barnes 4wd]

I haven't worked on anything lately, but I did get some new bling!

Lots of great stuff in this thread, I love these shifters!

 

[idahoyj]

NP205s dont fit under a YJ with flat belly very easily......

 

[rustyoljeep]

Looks pretty amazing to me! Is it crazy that this is what I want to build for a daily?

 

[idahoyj]

Motor mounts are tacked in place. Gussets aren't done yet, but they are templated and ready to be cut. I built a sketchy stand out of conduit to hold the motor at the right heigh/position while I cut the tubes for the mounts. Tonight I plan to work on the transmission cross member and maybe the NP205 support.

 

[Jinx]

Looking good. Cool build!

 

[Bart]

Coming along nicely.

 

[idahoyj]

I can't believe I didn't get one of these sooner! What a great product! This Swag Offroad Portaband Table makes cutting gussets and tabs so much cleaner, easier, and faster than using a cut-off wheel or torch.

I built and tacked in gussets for the top and back of the motor mounts, and cut the trans/transfer cross member mounting brackets. I have the transmission mount all figured out, but I'm still deciding the best way to support the Np205.

 

[frieed]

That SWAG stand is about the handiest thing I have as well.
Try the Morse 811 blades in that bandsaw, I'm really impressed with them.

 

[idahoyj]

That SWAG stand is about the handiest thing I have as well.
Try the Morse 811 blades in that bandsaw, I'm really impressed with them.

I'm using the Morse blade too. It's the one I got free on the promo that you posted last year. The blade really seems to cut nice and when I wear this one out, I will order another of the same.

 

[idahoyj]

I got the transmission cross member built and tacked together, in place.
I will take it out and add gussets during final welding.

I'm still not sure what I will be doing to support the NP205. I have a cross member to match what I did for the transmission, and I think I will build a plate that bolts to the left 3 bolts of the output housing and the right 3 bolts of the large bearing retainter, then attach it with a poly bushing.

 

[idahoyj]

Hopefully my fab skills will be a little better than my "paint" skills!

 

[idahoyj]

Plate for NP205 rear support and cross member are done.
Started by removing the 7 bolts that I wanted to incorporate into the plate. I bought 1" longer grade 8 bolts to replace them. Next, we threaded the bolts up to the head and cut off the head to create studs. We installed the studs into the back of the case and installed a nut to tighten the output cover and bearing retainer. Then made a cereal-box-template of the bolt locations and cut the cardboard until it fit pretty close. Used my Swag benchtop band saw and cut out the bracket and did a bunch of grinding until it sat flat onto the nuts, previously installed on the studs. Welded on the poly mount and built a stand-off to attach the cross member.

 

[mesha]

looks great. It is coming along nicely!