New project: Cheap junk YJ

[mbryson]

I have a buddy that is super interested in starting to wheel and has expressed interest in building a cheap wheeler. We were able to secure a YJ in unfinished state for him and I hope to document the buildup in this thread.

Currently the YJ has a carbed 350, SM465 (?) 32 spline and a slip yoke 208 (that's not in the rig). It's also got some uber sweet 10 bolt Chev axles that will be going away.

It's got some 6 lug 35" MTRs with about 1/4-1/2 tread on them. We'll likely be selling/swapping those for some 8 lug somethings.

We've talked about utilizing the carb 350 and adding propane for wheeling. We've also thought about just swapping in an FI Chev small block and it's transmission as well.

We've secured a set of Chev SRW one ton axles. Trying to figure out how to lock it up (cheaply) and still have it be "streetable" enough for a 16 year old girl to drive (selectable lockers would be ideal, but we'll have to see if the funds are there). The axles have 4.10 gears, so we'll likely be swapping those out as well. They might be OK with some 37" tires and 1st gear in the 465, though.

Wheelbase is stock (at least for now) and the suspension is spring over with YJ springs.

He's into the current rig for about $2K, maybe a couple-few hundred less at the moment.

I've lined up a fixed yoke 208 and we'll detail what swapping that input shaft will entail and how that will work with the 32 spline 465. We'll also be utilizing stockish/available drivelines and having them lengthened/shortened to fit our needs.

Current list of wants:

big TJ flares
14 bolt locker
YJ springs in new ore good shape (I'll check Brad's stock at RadJeeper )
UHMW or similar for a skidplate

Need to move:

23 spline Dodge 208 tcase
10 (?) spline Chev 208 tcase (was mated to a 465 that could also be available)


I intend to get some pictures and detail the build a little better than I did with my build.

 

[Kiel]

Nice project, sounds like someone else is missing their project though B***

 

[Tacoma]

I've got some 8 lug rims laying around... 16? or 17's? What's yer pleasure? Reusing the 4.10's would be swell w/that 465, and cheaper. I've got a ton of bits and pieces, as you know. Ask, if you're missing something.

 

[Bart]

Nice project, sounds like someone else is missing their project though B***

Hahaha, you have a good memory.

 

[mbryson]

Just an update:

He's secured 42" Iroks and one ton Chev axles. We've gotten a hold of a 32 spline Dodge 208 and will try to combine the Dodge (fixed outputs) and the Chev case to get the thing moving on it's own over the next little while.

We're looking for a TBI setup for the 350 or possibly propane/dual fuel setup.

 

[skippy]

what ever happened to this dead thread

 

[cheepin]

Old thread for sure.
One thought I have is that is too long of a drivetrain to keep the stock wheelbase.I would drop the 208 and find a D300 to adapt to the trans.This will shorten the drivetain plenty and will work with the stock wheelbase.Although 42's and stock wheelbase(94") will bring the suck.

 

[mbryson]

what ever happened to this dead thread

ah....I do have some updates....I'll try to get them up over the weekend.

Old thread for sure.
One thought I have is that is too long of a drivetrain to keep the stock wheelbase.I would drop the 208 and find a D300 to adapt to the trans.This will shorten the drivetain plenty and will work with the stock wheelbase.Although 42's and stock wheelbase(94") will bring the suck.

We did drop the 208 and moved to a 241. Swapped the carb 350 to a TBI 350. Moved from the 465 to a 700. The 241 is a Dodge/Chev hybrid (basically just put the Chev 241 input into the Dodge case).

Unfortunately, we're trying to stick with the stock wheelbase. It's "interesting" but will likely work. We will likely leave the rear in the stock location and move the front if we do make some changes.

We've acquired an ARB for the front 60 (not exactly cheap, but CruiserOutfitters made us a deal we couldn't refuse--see Kurt for all your needs) and likely a Detroit or possibly a Grizzly locker in the rear. I just bought a Detroit for my Jeep so we can use my Poly perf. mini spool for temporary in a worst case scenario.

The bad of the axles is the 4.10 gears. The 42" Iroks are very similarly sized to my 40" MTRs. I'd call them 41" to be fair. I don't really know how the 4.10s will work out, but I'd bet we move to 4.88 or 5.13 gears. The 700 isn't quite the crutch as the 465 is but we'll check it out.


Current wants:

some new(ish) YJ springs
a soft top of some kind (we might just need some new windows for this top?)
misc. brake lines, hoses, etc.

 

[mbryson]

other details and pictures

We'll be adding a PSC steering box and ram and updated "family" cage with tie ins to the frame.

The color of the Jeep will be green. Not quite "sublime" green, but something a little more active (if that's possible). As you can tell, there will need to be some pretty serious body mods in the rear just to clear the tires. The front may be getting "highlined" with some tube fenders. We'll just have to see how the tires clear. The object is to have the thing street legal. He's talked about getting an additional set of "street" tires to run on the road. I'd imagine the IROKs will wear out pretty quickly, so I think that's a solid idea. I've made some things work with aftermarket TJ flares and mudflaps for tire coverage on my Jeep. Those things will be incorporated here.

The deviation is to have a "rub rail" all the way long the rocker and the flare edges. The "rub rail" will be 2x4 steel tube and flares will attach to that. (not really my speed, but it's his Jeep ) I've seen this done a few times. Once it looked pretty good and the other times it looked like ass. We'll see how it works out.

 

[Greg]

Awesome Marc! Is he concerned about the wheelbase with those huge tires? It will be neat to see this thing on the trail.

 

[mbryson]

Awesome Marc! Is he concerned about the wheelbase with those huge tires? It will be neat to see this thing on the trail.

I don't think he is, but I am. We'll see how it goes. I'm pretty sure I've not seen a stock wheelbase Jeep like this on bigger than 37". It could be interesting. He's pretty concerned about moving the tank up into the floor of the Jeep. It's a bit of a project to do that and keep the rear seat, but ..... I'd do it again if it was my Jeep just to get the wheelbase.

Oh, it does run now as well. To make it move under it's own power, we just need a rear driveline and some fluids in it (probably a sawzall cut as well). Rear driveline will be an XJ front modded to the 1350 joint for the 14 bolt. Headed to see Eric at Six States for that one. Front driveline will be the stock Chev front (?) that was in the Jeep with the 465/208. I have no idea if that was modified length or not. It's scary how that front worked out with a 700/Dodge 241. I just changed the front output flange to the Chev yoke and the slip looks just right.

I need to assemble the steering linkage, arms and ram this week (?) and get the driveline modded. I'm curious to see how tall this pile is. It's definitely low buck and MUCH cheaper than even my Jeep was. (I bet he's into this about $4K at the most and the bulk of that is selling his .50 cal and reloader)

 

[Lifelong Jeeper]

It looks fun. I love built YJ's.

 

[Greg]

I don't think he is, but I am. We'll see how it goes. I'm pretty sure I've not seen a stock wheelbase Jeep like this on bigger than 37". It could be interesting. He's pretty concerned about moving the tank up into the floor of the Jeep. It's a bit of a project to do that and keep the rear seat, but ..... I'd do it again if it was my Jeep just to get the wheelbase.

Oh, it does run now as well. To make it move under it's own power, we just need a rear driveline and some fluids in it (probably a sawzall cut as well). Rear driveline will be an XJ front modded to the 1350 joint for the 14 bolt. Headed to see Eric at Six States for that one. Front driveline will be the stock Chev front (?) that was in the Jeep with the 465/208. I have no idea if that was modified length or not. It's scary how that front worked out with a 700/Dodge 241. I just changed the front output flange to the Chev yoke and the slip looks just right.

I need to assemble the steering linkage, arms and ram this week (?) and get the driveline modded. I'm curious to see how tall this pile is. It's definitely low buck and MUCH cheaper than even my Jeep was. (I bet he's into this about $4K at the most and the bulk of that is selling his .50 cal and reloader)

Awesome, I love low-buck projects! I would liked to see the transfer-case build come together, sounds like it was good planning and parts finding that paid off!

That $$$ amount is crazy-low, very impressive for 1 tons, 42" tires, etc. I'll be keeping a close eye on this build.

 

[mbryson]

Awesome, I love low-buck projects! I would liked to see the transfer-case build come together, sounds like it was good planning and parts finding that paid off!...

That was actually easier than I expected. Dodge 241. Chev 241. Take them apart and swap the input shaft from the Chev into the Dodge. I had the camera out there to document the swap, but it was to boring to document.

Oh, with the ARB, he's likely closer to $5K now. Forgot about that little issue

 

[DaveB]

The Dodge 241 swap with the chevy 241 input is way easy, I'm doing it on my commando project. Also with the dodge case if you re-drill one hole on the chevy trans adapter you can clock the 241D flat without using a clocking ring. We also swapped the six gear planetary from the 241C leftovers into my son's 231J which should make it stronger.
BTW I have a spare 241C that has the input for the th400 if anyone is interrested.

 

[Bart]

Project is looking great. Glad to see the updates.

 

[mbryson]

The Dodge 241 swap with the chevy 241 input is way easy, I'm doing it on my commando project. Also with the dodge case if you re-drill one hole on the chevy trans adapter you can clock the 241D flat without using a clocking ring. We also swapped the six gear planetary from the 241C leftovers into my son's 231J which should make it stronger.
BTW I have a spare 241C that has the input for the th400 if anyone is interrested.

I thought about reclocking that case, but how it bolted up, I don't know that I'll do any better than that.

Interesting re: the 241 case upgrade to the 231. I've got the Dodge input with planetary and the rest of a Chev 241 kicking around my garage if the parts are worth anything to anyone. I'd LOVE to get rid of the cast offs from the case project.

 

[mbryson]

Well, worked on it a bit today. He completed the swap for the 42" Iroks to something a bit more reasonable in 38" flavor. I'm still not sure about the 4.10 gearing, but feel better about it than with the 42". With the gearing and the rear seat parameters of the owner, the 38" tires are MUCH more reasonable for sheet metal trimming and frame height and whatnot. We'll see how things work.

We put some of the steering together again, and got fairly distracted by yokes and drivelines. I've got a 1350 (?) flange type yoke driveline from an unknown source but I'm a little concerned about bind on that one vs. using a 1310 XJ driveline. The bad is that the driveline will need to be 16.25" long. The 1310 CV and slip yoke will allow almost 1.5-2" of tube length while the 1350 CV and slip yoke will allow maybe .5-.75" of tube length. We'll have to see what Eric at Six States can come up with for me.


Question for the readers: Who's built something (CJ5?) with this short of driveline? How'd it work out and whatnot?

 

[UNSTUCK]

Have you looked at the angles with the jeep at full droop and on the bumps? As long as there is no bind you should be fine.

 

[mbryson]

Have you looked at the angles with the jeep at full droop and on the bumps? As long as there is no bind you should be fine.

Tough to do with the leaf springs unless I have a way to chain the Jeep down (maybe I'm missing a cool way to do that?)