This is my first real build post so be gentle. I'm building an '89 YJ with a spring over, 60's, and stretching it to about 108" to 110" inches, and 42's. I didn't put it in hardcore cause it seems like anymore if your not going with a 4 link and rockwells its not hardcore.
The 1st pic is what I started with in '04. 67K original miles when I took a torch to it:smokin:

With the first build I went with Waggy 44's, a 4 1/2 Rubicon Express lift and 35's. I wound up with pic 2. It worked really well and I highly recommend RE springs for anyone wanting to stay spring under. I wheeled that for 3 years and decided it was time to go big or go home. I started amassing parts about a year and a half ago. bought a junkyard rear 60 out of an E-350 van with factory discs for $150. got the front off a buddy out of a Chevy. It already had 35 spline Yukon outers, Warn Hubs, A high steer kit, and a Rock Logic steering assist on it and He threw in the 8 lug beadlocks for $1500. I also bought a junkyard TBI 350, and found a TH350 for free. The original plan was to swap in drivetrain at the same time. After getting started, I realized that it might be a little too ambitious to pull off all at once moneywise. Also time wise, I'm already jonesin for some wheelin, and I've only been down about 4 mos.:shaking:

Looks like more build threads are slowly poppin up in non-hardcore.

Sounds like a good plan. Sounds like you will have a nice rig when done. Goodluck. Make sure you post alot of pics of your progress.

Is your stock motor the 4.2 or 4.0? if its the 4.2, can I have the leftovers of the motor?

Lookin forward to your progress.

I am working on a small build thread myself currently. its in my Signature.

Goodluck

I used 2x4 square tubing and some spring mounts from RuffStuff, and stretched the rear. For the front spring mounts, I just cut off and rewelded the factory mounts in their new locations. This is what I wound up with, still sitting on D44s & 35s. I will be using Waggy offset bastard spring packs for a little more length on the finished product.

Next, I pulled my D44s and sold them to buy Yukon 5.38s, a spool for the rear, a detroit for the front and rebuild kits. Aren't they pretty?:smokin:

When I tore down the rear 60 i found that it had 32 splnie axles. i had ordered the spool 35 spline on purpose hoping that the factory axle shafts would fit and I could upgrade later for cashflow reasons. It didn't work out that way and I got some Yukon 35 spline Chromoly's to go.:D

I set the gears up myself. This was my 1st time to do it starting from scratch. I gotta say thanks to Billavista as I used used his D60 Tech article almost exclusively for instructions. Here's a couple of pics. Difference in a 3.55 pinion and a 5.38. initial setup. Final tooth Pattern with everything in spec. I didn't think it was too bad for a newb:grinpimp:

Sorry, I got those in the wrong order, but you get the idea.

Once I finished the rear axle(1 last pic of 32spline vs 35spline shaft), I got to work building spring packs. I used the eye leaf from a front waggy, for the offset centerpin. then I took the military wrap leaf, and the leaf with the brackets on it from my RE springs, and redrilled them. I added a few more Waggy leafs and bolted them together. I wanted to use the military wrap to help with strength, and maybe to keep from bending up the waggy springs. I will start with this setup and keep all my extra stuff to make adjustments as necessary after I see how they do on the trail. I know they look like sh!t:eek: Don't worry, I will clean them up and paint them before final assembly.

In the mean time, I got my D300 off of E-bay for $250. The 4to1 gears, twin stick, and tranny adapter are on the way. I also got my new skins, and mounted them on my new to me beadlocks.

Looks like more build threads are slowly poppin up in non-hardcore.

Sounds like a good plan. Sounds like you will have a nice rig when done. Goodluck. Make sure you post alot of pics of your progress.

Is your stock motor the 4.2 or 4.0? if its the 4.2, can I have the leftovers of the motor?

Lookin forward to your progress.

I am working on a small build thread myself currently. its in my Signature.

Goodluck

Thanks, I need it. BTW I checked out your turbo buildthread, that's going to be freakin SWEET!
As for my motor, it is the 4.2 but I guess its gonna stay 1 more year. After starting all of this I figured out that I just wasn't going to be able to afford it all at once, so I'm keepin the motor/tranny swap on the backburner til next winter.
I had intended to stroke my TBI 350, but after some research, I learned a few things. 1. I can buy a 400hp 383 crate motor about as cheap as I can build it. 2. I don't think the factory TBI is going to move enough air/fuel to run it, so I was looking at even more money to fix that problem. 3. By the time I do all that, it's way cheaper to buy a good motor out of salvage and put it in. So, the current plan is to sell the TBI 350, and find either a 6.0ltr Chevy, or a ramjet 350 in good condition and just run it.

Oh by the way, if anyone is interested I have a motor, T-case, and other misc. parts listed in the classifieds that I need to sell so I can pay for this money pit.:ogre:

Nice to see non-hardcore not seem so.....newbish. Keep us updated. You might be able to pic up a pro-jection kit off ebay or the classifieds for cheap and you can run your 383. But again...more money :homer: Oh and your rear springs are 2.5" BDS??? They look ALOT like mine, i cut the rear military wrap as well due to it hitting the frame.

Nice to see non-hardcore not seem so.....newbish. Keep us updated. You might be able to pic up a pro-jection kit off ebay or the classifieds for cheap and you can run your 383. But again...more money :homer: Oh and your rear springs are 2.5" BDS??? They look ALOT like mine, i cut the rear military wrap as well due to it hitting the frame.

I thought about pro-jection, I also saw somewhere where you can use the throttle body off of a 454 to get more flow, but in the end I still think I can do it cheaper and still get the desired result.
My springs were all Rubicon Express 4.5". They actually came factory with only the one end military wrapped. Are you pretty happy with your BDS springs? I'm going to try to get by with what I've got, but I'm afraid it's going to be too tall. If I can't get it low enough I may be in the market for new springs. I've got a couple of ideas to get it lower (shorten the shackles and spring mounts) but thats just an 1 1/2" to 2" I'm afraid it's still gonna be too tall.

I like them because you can't kill them. They worked ok until they sagged down, then they worked really good :D. For a SOA application on 38s i would consider the 2.5" set, my 3.5" sagged at least an inch, to the point where i run them bastardized in the rear of mine now. So a 2.5" would most likely do the same. I really wish somebody would make a basic BDS style military wrap spring with 0" of lift that flexed well.

Well, it's been almost a year since I posted. I wound up moving and getting a divorce :flipoff2: in the mean time, so the jeep got put on hold for a while. I'm back on the job now though, and have been getting a little work done. I got the front 60 built with a Detroit and 5.38's. Got my my Dana 300 built with the 4:1 gears:smokin:. The rear axle is in, and now I'm building brackets to outboard the front springs. Got a steering box out of an Astro van and tapped it for the Hydro assist. Should have front axle in this week.
More pics coming. I've gotta resize them:homer:

Nice to see another Jeep being built in Norman!

Nice rig. I just picked up a Dana 60/14 bolt setup for my 80' CJ7. Gonna start my own thread as soon as I get more parts. Can't wait:D

In no particular order really, here are some pics of what I've gotten done. I drilled and tapped my astro steering box for hydro assist. Built the brackets to outboard my springs, and got them tacked in and the springs mocked up to make sure they are where they need to be. Lucked out and hit it the first time:smokin: While I was under there, I put ol girl on a diet and removed some superfluous iron from the front end. Tomorrow, I'll weld it all up, and should have it sitting on 42's by sundown:D

I also got the 4:1 gears installed in my Dana 300. It was right around time these pics were taken, that I was ready to get on a plane for Detroit and kick the sh!t out of whatever jackass wrote the manual on this damn thing.:mad3: The manual simply states to "tap the intermediate shaft out with a wooden dowel" and makes no mention which direction to "tap" it. After splintering a dowel into friggin toothpicks, I took a BFH and beat it on it for about 45 minutes. It came hard all the way :flipoff2: I later learned that you tap it out from front to back, or else you fight the o-ring thats on it all the way thru. doh!!!!:homer:

Well, after learning a few things the hard way, mainly that Trent Mcgee made this look a lot easier than it is on superlift offroad tv:flipoff2:, I got it all back together in spec. :smokin:It's only as I am posting this that I realized I didn't take a pic of it all put back together and painted, with my snazzy new twin stick shifter installed. Trust me, it's pretty:grinpimp:

lookin god man.....nice build....you'll be happy wit hit when done, you got a good combo...

Thanks man, I appreciate it. Finally got the axles in today.

Pair of Dana 60's......$1650

Locker, spool, gears, and axleshafts.....$2500

42" TSL's on beadlocks......$1500

Finally getting all that shit installed after a year and a half....Priceless:smokin:

Looks good. Can't wait for 42's on mine!

Pair of Dana 60's......$1650

Locker, spool, gears, and axleshafts.....$2500

42" TSL's on beadlocks......$1500

Finally getting all that shit installed after a year and a half....Priceless:smokin:

Man, that's awesome! Wish you would've posted more pics from the build though. Looks awesome.

i like your stance man, looks really sharp, how far did you push the front?..just from looking at it i guessed....
bastard waggys = 2"
moving of the hangers = 4-6"
total= 6-8" front push??

looking good man :smokin: But who in the hell cut (let you cut?!) the rear panel like that??? Were they (you) drunk:laughing:

Hey Mike, That looks awesome!!!!

My old junk wheels and axles look pretty freaking good underneath your rig. cant wait to get it on the trail and tear some shit up.

Still planning on coming down and picking up my jeep on the 13th and swapping in your tranny and t-case?

When we get building on my junk I think that I am going to try and use same dimensions that you used so don't forget what you did. Write that shit down and don't leave it in your shop or we will never find it again. got any other pix? I would like to see some of the newer ones in the daylight.

i like your stance man, looks really sharp, how far did you push the front?..just from looking at it i guessed....
bastard waggys = 2"
moving of the hangers = 4-6"
total= 6-8" front push??

Yeah, I think it was just a hair over 7" forward, and the back about 8" back. I'm happy with the looks. Now just need to see how it wheels:smokin:

looking good man :smokin: But who in the hell cut (let you cut?!) the rear panel like that??? Were they (you) drunk:laughing:

lmao, yeah I kinda hacked em. I had drawn my cut line and started cutting before I realized I hit the inner fender. Piss poor planning on my part:flipoff2: I'm fixing to comp cut them and put some armor over them to cover it. It'll be good as new:D

Your rig turned out damn good lookin! You still have the 4.2? I want the crank

I'm still running the 4.2 for now. i just bought a 98 grand cherokee, I'm gonna swap in the 4.0 head and fuel injection and auto tranny, and run that for awhile until I can afford the v8 swap.

Did you ever finish it up? I live in Tuttle, I almost have mine done, its real similar to yours.

http://img134.imageshack.us/img134/5093/dsc00005xgc.jpg