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Lifelong Jeeper's '96 ZJ

Well after nearly 12 years in my TJ I was ready for a new project and more space for my family, so I sold it last Thursday and today I picked up my new '96 ZJ Limited and I am starting a build thread. Will post pics when my wife gets back from Phoenix with both of our camera's. :confused:

Currently:
Black exterior, tan leather interior, 155,555 miles (as I pulled in my driveway tonight), 5.2L, NP 231, 4" short arm, 33" BF Muds, D30/D44a with 3.73's and a rear spool. Warn 9000 XDI winch, tubed out front bumper, rock sliders, missing rear bumper skin, hack job body trimming and extensive body damage

Plans for the build:
Long arms, Boat sides, custom front/rear bumpers, hybrid exo/internal cage, bumper to bumper subframe reinforcement, Custom built belly pan and fuel cell skid, Ford 9" rear w/ Detroit, HP D44 front w/ ARB, 4.56 gears, 35" MTR's, repair drivers side doors/frames so they open and close better, pound out dents, removal of plastic body cladding in favor of bed liner, tube fenders, rock lights, cheap overall paint job when it's done.

Wishful completion timeline: Summer 2011. Cross your fingers
 
Click to expand...
Lifelong Jeeper

Lifelong Jeeper

Well-Known Member
Location
Murray
Whoa. You're right. I need to make updates.

Yes, I am still working on this build, but it has gone much slower than I anticipated. Here is my current.

I figure I will build this in two main phases.
1. Suspension, axles, tires, lockers, subframe reinforcement, exhaust.
2. Roll cage, bumpers, tube fenders, sliders,

I am collecting the final parts needed for phase 1: Rod ends, tubing for control arms, subframe reinforcement steel, suspension bracketry, front locker, new cat converter.

I changed my mind on the axles and tires than originally planned. I have acquired front and rear 60's, 4.56's, 37" MTR's on H2 wheels, Aero 3030 muffler, some bracket's and rod ends, rear disc brake conversion from 80's 3/4 ton suburban front 10 bolt axle.

I may be forgetting some details, but will be sure to keep everyone posted when the actual fun begins.
 
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Lifelong Jeeper

Lifelong Jeeper

Well-Known Member
Location
Murray
The fun has finally began!

Currently, the rear axle is out, suspension cut off, and frame reinforcement underway. I was going to try to keep the front axle under it until I set the back end down in it's "new shoes", but that isn't going to work cause the front lower control arm brackets are in the way of the frame reinforcement.

Factory crossmember is out and a 242 is going inplace of a worn out 231 that needs of a rebuild.

Engine respiration is improved with a full K&N Cold Air Intake, high-flow 3" Cat, 3030 Aero Muffler and 3" pipe with a turn-down in front of rear axle. Will install full exhaust out the tail end once suspension is complete.

Once the frame is done, the process for the Disc brake converted rear D60 w/ 4.56's, Detroit and custom triangulated 4 link will begin. I'm going to try to keep the suspension to 6" lift, but fitting 37's might prove to be difficult. More to come and will work till that point.
 
gertsch

gertsch

Well-Known Member
Location
West Bountiful
Lifelong Jeeper said:
The fun has finally began!

Currently, the rear axle is out, suspension cut off, and frame reinforcement underway. I was going to try to keep the front axle under it until I set the back end down in it's "new shoes", but that isn't going to work cause the front lower control arm brackets are in the way of the frame reinforcement.

Factory crossmember is out and a 242 is going inplace of a worn out 231 that needs of a rebuild.

Engine respiration is improved with a full K&N Cold Air Intake, high-flow 3" Cat, 3030 Aero Muffler and 3" pipe with a turn-down in front of rear axle. Will install full exhaust out the tail end once suspension is complete.

Once the frame is done, the process for the Disc brake converted rear D60 w/ 4.56's, Detroit and custom triangulated 4 link will begin. I'm going to try to keep the suspension to 6" lift, but fitting 37's might prove to be difficult. More to come and will work till that point.
Click to expand...

fitting 37's shouldnt be to hard with 6" of lift. i'm running notch custom flares that made it so I could fit 37's on my 6" lift. But I'm lowering mine to 4" and just 35's
 
Lifelong Jeeper

Lifelong Jeeper

Well-Known Member
Location
Murray
Quick update, by the end of Saturday, the goal is to have frame reinforcement done, rear axle installed (at least roughly) and crossmember/belly pan fab'd up and installed.


Sent from my iPhone using Tapatalk
 
Lifelong Jeeper

Lifelong Jeeper

Well-Known Member
Location
Murray
Update: rear axle installed minus sway bar and shocks, frame reinforcement done. Crossmember done. Front axle installed minus track bar and shocks. I'm going to have to go without a front sway bar until I figure that part out. Swapping in a master cylinder from a '99 Dodge 2500 for the larger brakes. New steering box installed. Need to bleed brakes, install drivelines, install shocks, front track bar, boat sides, winch, and taller springs. I have it 4" springs now but the 37's don't have much up travel. I'm going to put my front 4" spring in the rear and some 6" front TJ springs in the front and see how it sits. It will be driving tomorrow it the next day, at last.


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Lifelong Jeeper

Lifelong Jeeper

Well-Known Member
Location
Murray
I will get the build pics downloaded and will post action pics of our Moab trip. I think behind the rocks is on the agenda for tomorrow.


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Lifelong Jeeper

Lifelong Jeeper

Well-Known Member
Location
Murray
Well the trip was fun with only a couple issues with my jeep. 1- my hood was ripped open at 60 mph because of a wall of wind thrown out from a passing semi, 2- my upper control arm mount was coming in contact with the double Cardon joint on my front driveline.
How do I upload pics? Is it possible from Tapatalk?


Sent from my iPhone using Tapatalk
 
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