Why??

The most commonly asked question when I tell someone I'm buildin up a Grand rokee for DD/exploration/Moab in April. bottom line is the price was right I have mountains of spare parts from the last 6 cherokees I've had, 4.0's are bullet proof and have been a favorite for me. I can seat 4 in air conditioned comfort, haul all my camping gear and *almost* stretch out to sleep in the back if need be. however in stock form they have some flaws. Obviously the unibody and axles being the main, but Grand's also only came with a auto except for the occasional 5spd in 93'. that said I wanted a 5spd rig capable of doing grocery duty, pack some friends/gear/dog/ whatever go wheelin all day travel 1700km in a few months and not break and get me home. So to the shop it goes.

I grabbed this 93 ZJ off Jeepnut/the fabricator (mike of karnage fabworks) at the end of September, it had what he believes a 6" skyjacker lift and some bald ass 33's the 4.0HO and an AW4 auto D30LP and an iron xj D44 with disc brakes. I gotta say thanx to Mike and the Karnage crew aswell cause i've spent a few hours loitering around his yard/shop and continually ordering random steel from him, great prices too!!!
http://i80.photobucket.com/albums/j200/redder22/ZJ-1.jpg
http://i80.photobucket.com/albums/j200/redder22/zj2-1.jpg

I wheeled it/drove it for a week and blew up the np242:Whatever: and I hated the auto to begin with sooooo. In went a 98' AX15 with external slave
New clutch (dynapac cheap and they work)
http://i80.photobucket.com/albums/j200/redder22/086.jpg
http://i80.photobucket.com/albums/j200/redder22/093.jpg
http://i80.photobucket.com/albums/j200/redder22/DSCF1631.jpg
pulled the TCU to find less work, thank jeep:*
http://i80.photobucket.com/albums/j200/redder22/DSCF1648.jpg
I had to butcher 3 sets of pedals by bending, cutting, drilling,welding in order to have a clutch pedal, yet still have the suppot required to push the master cylinder, this was the shittiest past of the swap.
http://i80.photobucket.com/albums/j200/redder22/DSCF1652.jpg as for wiring, I merely tricked the computer to believe it's in P/N for now which is outlined in the haynes manual:* I also ran a switch *somewhere* into the cab to act as an anti theft, I merely flick it and it think's it's in gear and won't start, also spliced the reverse ligths into the old harness and are functioning
http://i80.photobucket.com/albums/j200/redder22/DSCF1654.jpg
http://i80.photobucket.com/albums/j200/redder22/DSCF1655.jpg

Then to make up for the loss of crawl provided by the torque converter I made some deals with foxtrot (local vancouver island based machinist/wheeler) and he made me a "FOXBOX" which rocks BTW *thanks again Chris* Np231D HD from a dodge dakota V8 and a 86' D300 new seals and yokes
http://i80.photobucket.com/albums/j200/redder22/DSCF1647.jpg
http://i80.photobucket.com/albums/j200/redder22/DSCF1645.jpg
Cummins beige

in with speedo hooked up and new driveshaft tacked
http://i80.photobucket.com/albums/j200/redder22/DSCF1657.jpg
before doing all this I pressure/steamed cleaned underneath *no more grease* and no rust to be found
http://i80.photobucket.com/albums/j200/redder22/095.jpg
http://i80.photobucket.com/albums/j200/redder22/DSCF1628.jpg
Then it was onto a crossmemer/Link mount as I wanted a custom 3-link long arm front suspension and a dual trianulated 4-link in the rear.


*I've since put aside final welding on the crossmember and am waiting on some chassis stiffeners which were cheaper to buy then to buy steel and waste days making*

apparently my camera lense didn't want to open
http://i80.photobucket.com/albums/j200/redder22/098.jpg
New tranny mount using an energy suspension GMT350 mount
http://i80.photobucket.com/albums/j200/redder22/100.jpg
Nice and flat
http://i80.photobucket.com/albums/j200/redder22/DSCF1635.jpg

then it was onto the Links and axles. For lowers I'm using 2x2 .250 square and 1.5" Sch80 for uppers, which will be connecting up my S-turds (http://i80.photobucket.com/albums/j200/redder22/051320092116.jpg) old alxes which consist of a pre 80 passenger drop waggy D44 packed with yukon and superior/longfield goods and a narrowed custom 40spline 9" rear both with 4.56's and spools *eeek* not great for the street but there payed for (s10 got a 60'14 combo pics to come soon)
http://i80.photobucket.com/albums/j200/redder22/ZJlinks008.jpg

http://i80.photobucket.com/albums/j200/redder22/00005005.jpg
http://i80.photobucket.com/albums/j200/redder22/00005006.jpg



hand cut with an oxy/acy torch:)
http://i80.photobucket.com/albums/j200/redder22/ZJlinks010.jpg
http://i80.photobucket.com/albums/j200/redder22/ZJlinks012.jpg
upper link mount. adjustable seperation from 8"-4" on the axles and 6-3" om the "frame"
[IMG]http://i80.photobucket.com/albums/j200/redder22/ZJlinks005.jpg
all be heating and bending the over hangin piece around the tube for a larger weld and it will also be welded to a full tube truss
http://i80.photobucket.com/albums/j200/redder22/ZJlinks013.jpg
and 1 more on the bech mocking up my panhard which is 1.5"x.250 DOM with a 3/4" heim and high misalignment spacers
http://i80.photobucket.com/albums/j200/redder22/ZJlinks003.jpg

Thats it for now as my camera is out of batteries and the rear stuff is somewhat installed and it's raining out yuck

This thing's pretty cool. Looks like your taking your time and building it right.

so progress has been slow with work being so busy but we've got a nice long break 21st-4rth... so last few days have been kinda hecktec. pulled the shitty stockers.. note** those are not perminent jack stands it's on rollable sawhorses now, much safer looking lol

http://i80.photobucket.com/albums/j200/redder22/HPIM0375.jpg

got the mock up front in squared off, castor set to stock. and uppers and lowers nearly completed, lots of trimming and gusseting to do but stating to look like something. I've made a whole new double sheer mount for the panhard but I wanted it in the pic for reference

http://i80.photobucket.com/albums/j200/redder22/001-1.jpg
http://i80.photobucket.com/albums/j200/redder22/002-1.jpg

the upper link needs to be moved a bit but you get the idea, no flex pics cause of shitty superstore batteries.


http://i80.photobucket.com/albums/j200/redder22/004-1.jpg


then wheeled the battered shit box in to donate some beefier parts, and finally perminently have it's 60/14B swapped in, also gettin a set of 39.5's for it saturday (merry christmas to me) it's surprising just how big the grand is in comparison, it dwarfs this thing in every direction

http://i80.photobucket.com/albums/j200/redder22/HPIM0376.jpg

out with the old, in with the "new/old" needs a clean up bad
http://i80.photobucket.com/albums/j200/redder22/HPIM0377.jpg
. going to pull all nighters after christmas to get it done once and for all, staring at it since September has drivin me nutz

So I had a bit of a hick-up so to speak last few days with a trip to the hospital.. So little PSA. Wear safety glasses even if you are wearing a face sheild.. had a zip disc explode and some shit went into my right eye. No damage was done thankfully so onto the goods.
http://i80.photobucket.com/albums/j200/redder22/0102.jpg

so onto the 9" took the hole saw to a piece of 4x6x.250 rectangular tubing and this is what I came up with
http://i80.photobucket.com/albums/j200/redder22/012.jpg
http://i80.photobucket.com/albums/j200/redder22/014.jpg
Then I made some LCA, out of 3x3 3/16 box tube. I'm going to open these up to match the front, and free up some more room for the joint
http://i80.photobucket.com/albums/j200/redder22/006-1.jpg
http://i80.photobucket.com/albums/j200/redder22/009.jpg
got the 9" stripped of all it's old mounts still need to move the caliper brackets, anyone have a D44 Bracket I need onw more. then rolled it under jacked it up and set my pinion and coil mount angles
http://i80.photobucket.com/albums/j200/redder22/008-1.jpg
http://i80.photobucket.com/albums/j200/redder22/016.jpg
this just makes me smile everytime I see it lol
http://i80.photobucket.com/albums/j200/redder22/017.jpg

since I really hated my front LCA mounts I got out the hole saws and went ape shit again and am very happy with how they turned out, I didn't have any tube to spare. the right one isn't hole sawed to fit the axle because of the cast housing, it will be welded to a flat plate connecting it to the coil bucket and a piece that's been drilled and tapped into the housing, so I don't have to worry about welding to cast
http://i80.photobucket.com/albums/j200/redder22/0062.jpg
http://i80.photobucket.com/albums/j200/redder22/0052.jpg

this mount still needs to be moved a bit, but the coil bucket needs a trim to do so
http://i80.photobucket.com/albums/j200/redder22/018.jpg


then in an effort to be a real cheap cunt, I decided I'd use the old flex joints for the rear uppers, they were still in really good shape, only problem was I needed a 60" pipe wrench to break the jam nut loose:Whatever: kudo's to whomever did those up DAMN! lol
http://i80.photobucket.com/albums/j200/redder22/0012.jpg

Then it was back to the 9" and started on my rear truss/UCA mounts traceed out my mock up diff

http://i80.photobucket.com/albums/j200/redder22/005.jpg
dug out the largest piece of tubing I had left and traced it on
http://i80.photobucket.com/albums/j200/redder22/007-1.jpg
then cut it out, still needs alot of finish work, and I may actually go a different route, depends on what it turns out like today
http://i80.photobucket.com/albums/j200/redder22/011.jpg

last thing I did last night while being somewhat blind in 1 eye was ream the pitman arm for my 1-ton TRE's.
it's not done up tight in the pic but it worked perfectly
http://i80.photobucket.com/albums/j200/redder22/0082.jpg

hopefully today I can have atleast 1 end sitting on it's own weight provided it's accident free ahaha

also snapped a pic of width... tires should stick out a few inches which is exactly what I was after, it looed to narrow prior
http://i80.photobucket.com/albums/j200/redder22/020.jpg

Also ot the 14B in Sans shock mounts/welded tubes and then snapped a pic of it's new fat width, I'm goinf fullwidth for now and give it a try I can always throw my narrowed 60 in if need be, but shafts and shit are $$$$$
http://i80.photobucket.com/albums/j200/redder22/015-1.jpg
http://i80.photobucket.com/albums/j200/redder22/016-1.jpg

40 spline ford 9" = :smokin::smokin:


good greif, most guys have a hard enough time building a single rig.... let alone two at once.

looks good, keep it up.

I didn't accomplish what I set out to do today, other things called life got in the way but I did manage to get the front end buttoned up besides a bit of gusseting and final welding.

pics don't really describe what a pain in the ass these were to make, but I had them stuck in my brain and wanted them made from one piece so they started out as a 6.5" piece of 3.5x3.5 3/16 and after a few hrs they were holding weight
the piece kicked up was actually cut and bent to the correct angle, not too pieces though 2 would have been easier, and just as strong:Whatever:
http://i80.photobucket.com/albums/j200/redder22/021.jpg
http://i80.photobucket.com/albums/j200/redder22/022.jpg
http://i80.photobucket.com/albums/j200/redder22/029.jpg
I could have easliy got a flat belly in the front, but had to compromise a little because of the rear. I didn't want to hack a big hole in the rear floor for upper links so everything had to drop a bit
http://i80.photobucket.com/albums/j200/redder22/028.jpg

just got back from pickin up my 40's for the S10 so on my way to the shop to get the front end in hopefully once and for all:devil:

thought for sure I'd have her done Yesterday, but hopefully late tonight, it'll atleast be rolling, I'll worry about plumbing brakelines and shocks another time. haven't had too many pics cause I dropped my last camera one too many times and it won't open the lens anymore, so I bought a new one, and for the money I spent I'm not impressed, anyways here's what is done.

Front everything except the final truss piece.
Front crossmember, it'll bolt to the rear one when finished
http://i80.photobucket.com/albums/j200/redder22/004-2.jpg
Passenger side LCA mount, behind the joint is 2 3/8" grade 8 bolts drilled and tapped into the cast housing, then plating wraps all the way around, with 2 more on the other side, and lots of nickle Rod in all the right places. It's never coming off. I had to hone the heads of the bolts a bit for the joint to have room but there in and tacked so they should be fine

http://i80.photobucket.com/albums/j200/redder22/006-2.jpg
just how much it hangs below the rails, rear is a little more, but is level with the front
http://i80.photobucket.com/albums/j200/redder22/022-1.jpg

http://i80.photobucket.com/albums/j200/redder22/020-1.jpg
http://i80.photobucket.com/albums/j200/redder22/021-1.jpg

and in there, after 2 straight days of fucking around with the draglink and panhard, clearances were so tight with how far I moved the axle ahead, and the diff being in the way, so I had to compromise yet again and ditch my highsteer, there was no way it was going to work, at least not with the "raised" arms I had.
http://i80.photobucket.com/albums/j200/redder22/023-2.jpg
and sittin on it's on weight... those are 39.5 in the pic too haha for the S10
http://i80.photobucket.com/albums/j200/redder22/027.jpg

http://i80.photobucket.com/albums/j200/redder22/HPIM04202.jpg
also made some trades and got a set of beadlocks and a kickass diff cover for the 14b
http://i80.photobucket.com/albums/j200/redder22/008-2.jpg
plan is to stay in the shop till probably 4am again today and get it fawkin done.

so 2 o'clock Saturday I was at this stage, now I'm waiting for paint to dry, so I can throw it all in. was in the zone so didn't take alot of pics. I hated my firts attempt at a truss so round 2 had better results. still needs a bit of bracing, and I might plate it in but I'm happy. If your wondering why the housing looks offcentered, thats easy to expleain. IT IS. when the diff was narrowed we only did one side thus getting it's 61" WMS and a centered pinion. Iam really not impressed with this camera. My phone takes better pics, anyone had trouble liek this from Olympus??? its an waterproof one, maybe it's just shitty???
http://i80.photobucket.com/albums/j200/redder22/029-1.jpg
http://i80.photobucket.com/albums/j200/redder22/030.jpg


So if you were wondering if I made my deadline..... well fawk was there a doubt??? lol Jan4rth 3:23AM and up for work @6:30 needless to say I just woke up haha. I'll get some better pics in the daylight and on proper tires, but all she needs is brakes, Shocks, Armour, and gasoline... Moab's gonna be dope!!!!
http://i80.photobucket.com/albums/j200/redder22/P1040001.jpg
http://i80.photobucket.com/albums/j200/redder22/P1040003.jpg

looking good. cant wait to see the outside shots with tires on:smokin:

Nice build. You work fast :eek:

Shocks and armor are luxuries, not necessities.... wheel it!

Nice build. You work fast :eek:

Shocks and armor are luxuries, not necessities.... wheel it!

not on Vancouver Island, your lines are determined by how far apart the next 2 trees are :laughing:

Nice build! I plan to do some work on my ZJ when i get back stateside too!

Got the brake lines run down the upper links and a few other things tidied up then rolled it out to measure for shocks, bumpstops, and limit straps. the front lower links were hitting the body right where I knew they would in the 2nd pic so a little trimming and she does much better now, be nicer once I find some wheels with better backspacing



2nd day I owned it http://i80.photobucket.com/albums/j200/redder22/090520091938.jpg

this morning

http://i80.photobucket.com/albums/j200/redder22/P1100008.jpg

and after some Grinder treatment. 42" at the lowest part off the tire and theres still room for more, doesn't really feel tippy yet either. I'm very pleased with how it turned out, the speed bumps and curbs at safeway or going to be a breeze

http://i80.photobucket.com/albums/j200/redder22/P1100017.jpg

http://i80.photobucket.com/albums/j200/redder22/P1100020.jpg

this has been lacking an update, so here ya go.... had to have it ready for the first of this month as we went down to Moab Utah, I was a bit late but still managed to pull it off

Finished up the all new exhaust, gas exits right out the back even snaked around the "interesting" rear suspension
http://i80.photobucket.com/albums/j200/redder22/P3070085.jpg
built some shock mounts
http://i80.photobucket.com/albums/j200/redder22/P3260097.jpg
stole the 14's off my S10 for now and threw em on
http://i80.photobucket.com/albums/j200/redder22/P3260098.jpg
Cashed in some hard earned overtime hr's on some 35" toyo's. rear driveshaft and a winch
http://i80.photobucket.com/albums/j200/redder22/P3260093.jpg
http://i80.photobucket.com/albums/j200/redder22/P3260106.jpg
picked up a new Tabor 9k it sure is nice not having a bird's nest for rope and a spider colony in your solonoid pack, I kinda like buyin new lol
http://i80.photobucket.com/albums/j200/redder22/P3260094.jpg

Whipped up some bumpers and sliders
http://i80.photobucket.com/albums/j200/redder22/P3290116.jpg
Cut out the bottom 2" of the stock Rocker guard and welded these in, I"ll replace them with some what boat sides later but I was pressed for time
http://i80.photobucket.com/albums/j200/redder22/P4040125.jpg

Once again pressed for time I decided to just get a provin system that took about 15mins to set up and got NWF D300 cable shifters, Kudo's Kyle there radtastic
http://i80.photobucket.com/albums/j200/redder22/P4040124.jpg

been tweaking the links and and trying my best to get it into alignment with a tape measure and so far, it's spot on and tracks nice and straight.

The rear end was super soft with the way my rear shocks were set up and I ran out of steel to make mounts p throught the floor for another set of 14's so I made do LOL, and to bear a bit more weight there's some bags tucked in there too
http://i80.photobucket.com/albums/j200/redder22/P4040122.jpg

it'll still do this with all that crap on
http://i80.photobucket.com/albums/j200/redder22/P4030121.jpg
http://i80.photobucket.com/albums/j200/redder22/P4030120.jpg

then I drove some 2300km in a untested rig ,et up with some friends in there what used to be sami buggies and ran a decent trail IMO... all and all it worked damn good dispite a few things but I'm happy.

http://img.photobucket.com/albums/v455/trev_guy/moab2010/DSC03012.jpg

http://img.photobucket.com/albums/v455/trev_guy/moab2010/DSC03020.jpg

http://img.photobucket.com/albums/v455/trev_guy/moab2010/DSC03033.jpg

http://img.photobucket.com/albums/v455/trev_guy/moab2010/DSC02914.jpg

http://img.photobucket.com/albums/v455/trev_guy/moab2010/DSC02886.jpg

http://img.photobucket.com/albums/v455/trev_guy/moab2010/DSC02974.jpg

http://img.photobucket.com/albums/v455/trev_guy/moab2010/DSC02987.jpg
http://img.photobucket.com/albums/v455/trev_guy/moab2010/DSC02992.jpg

http://i247.photobucket.com/albums/gg141/jeepsrule/moab2010297.jpg
http://i247.photobucket.com/albums/gg141/jeepsrule/moab2010300.jpg
http://i247.photobucket.com/albums/gg141/jeepsrule/moab2010394.jpg
YouTube - sketchyred.MPG (http://www.youtube.com/watch?v=9HtN5RlQEhs&feature=related)
YouTube - sketchyred2.MPG (http://www.youtube.com/watch?v=Q6CsSI0knxA&feature=related)

so did you find the weak link in that 40 spline rear end?:eek:

Nice rig! one question though, do you think the 4.0 will be enough motor? I wouldn't trade my 5.2 for anything, other than maybe a 5.9......

Nice rig! one question though, do you think the 4.0 will be enough motor? I wouldn't trade my 5.2 for anything, other than maybe a 5.9......

funny you say that..... i wouldnt trade my 4.0 for anything. cept' maybe a 4cyl cummins turbo. :smokin:

the 4.0 is fine for what I do, and did surprisingly well to and from Moab on the freeway... this is my "new" DD I live 5 mins from town and can take a company truck to get shit, so I really should be driving a civic or something but there way gay.. I do plan to add the 5.9 hood vents lol

so did you find the weak link in that 40 spline rear end?:eek:

yeah I suppose....1/2" grade 8 bolts that moser useses for studs, but in fairness, it was a combonation of things that led to there failure, most importantly I should have realized my rims weren't sitting flush 2nd I should have listened to my better judgement, as studs are made of spring steel and can stretch vs a bolt. stretching time and time again with numerous wheel changes/flat repair, just fatigued them