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Old 11-06-2009, 07:30 AM   #1 (permalink)
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Pale Horse TJ Build

Hey yall, like all the cool kids on Pirate here's my 1ton TJ build, Pale Horse.

I bought the Jeep used in 04 looking like this:



It went through many stages over the last few years. Alot of bolt on parts made it perform pretty decent but I knew things could be better. I started going through the builds here started getting some bad ideas.

After saving up for a while and reselling some parts heres the list of parts that I started with and what my TJ looked like just before the tear down started



Stock wheelbase, stock cage, stock all white 99 TJ, 4.0/AX-15/NP231

Hybrid 44/60 front axle; HP 44 pig with a 35 spline ARB locker & 4.88's, ball joint 60 C's, Solid Axle ball joint knuckles/keyed high steer arms/5x5.5 outer kit, 35 spline inner and outer shafts.

Rock Crusher (Solid Axle) semi float rear HP 60, alloy shafts, 4.88's and an ARB

Genright Parts: High line tube fenders, rear strech corners, strech rocker guards, fender relocation kit, rear coilover buckets, rear 4 link brackets, Poly Performance truss

Atlas 4 speed t-cases; 5.4.1, NorthWest Fab cable shifters, HAD pinion brake, and 1350 flanges.

Misc parts: 14" Fox triple rate coilovers, 12" Fox dual rate coilovers, JK control arms, whole bunch of Johnny Joints, tube adapters & jam nuts, Bilstein 4" air bumps, custom rear frame, upgraded PSC Steering, 17" OMF Beadlocks, 40" Comp compound Maxxis CC's...and alot more parts im forgetting.

Last edited by Skooter_Built1; 11-06-2009 at 10:26 AM.
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Old 11-06-2009, 07:51 AM   #2 (permalink)
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yes I like stickers and Michigan winters SUCK! Fukc Salt.




Rear axle is out, bolt on armor removed and other then the rear Hanson bumper everything has been sold.


Damn there is a lot of crap here; the evap junk, OBA junk, and ARB compressor are already off.

New fender vs. Old fender

Genright Hi-line flared tube fenders, Tub guards(yellow), strech rocker guards & rear strech corner guards.

From the back.
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Old 11-06-2009, 08:02 AM   #3 (permalink)
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Frame cleaned

Coilover hoop mocked in place


Here the Jeep is sitting on the coilovers

a borrowed 39" Irok being used for mockup.

Humm i forsee a few issues here, High steer is hitting the frame


60 with TJ brackets, quality control at RockCrusher for their welders was non existant. Super thick goober welds.

Stripped clean, I love using my Hypertherm Powermax30

Poly truss starting to be mocked up.
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Old 11-06-2009, 08:24 AM   #4 (permalink)
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Rear frame stripped of brackets


Dicking around with the plama cutter, prepairing to trim a little sheet metal


Theres some good clearence there, rear body mounts/body cross member was rotten, so chop that bitch out!



Frame hung a little low, time for it to GO!


I brought the new 2"x4" frame rails level with the bottom of the tub and had notched the factory frame for the new rails to fit inside them just slightly.


Poly truss trimed to fit the rear 60
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Old 11-06-2009, 08:53 AM   #5 (permalink)
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Took my 02 7.3 Diesel F-250 to Dearborn MI (feet away from the River Rouge Ford truck plant) to pick up a highly anticipated delivery Cute trailer huh, there was a 05 SuperDuty front 60 in the bed so no room Also you can kinda see my 78 Cherokee Cheif.


thats the hottest box ive ever layed my hands on

Stripped naked and very sexy



Around July I came across 1 hell of a smoking deal, 8 brand new 40" Maxxis comp. compound CC's and 2 spare's. I sold 1 set to a buddy of mine and kept the other set for myself.


I chopped off the stock steering box mount and relocated it


Steering clearence


Here I reused the factory rear frame crossmember
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Old 11-06-2009, 08:55 AM   #6 (permalink)
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At this point the project kinda stalled out. I was working alot and was getting ready to start up at college again to finish up my engineering degree, so the Jeep sat like this for a month or 2


Then this happened With college and work I had almost no time to finish my Jeep. Luckly I know this awesome builder thats across the great state of Michigan and he agreed to finish up my Jeep for me. So here is where my part of the build ends and my buddy Kevins build begins.
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Old 11-06-2009, 10:43 AM   #7 (permalink)
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After unloading my Jeep and all the parts that I had at my builders shop the real work started. My buddy first finished up the front suspension, welded up the the coilover hoops, made a hoop brace, finished up the steering, clearenced the frame, built a new front cross member/bumper, mounted the coilovers...





Then after the front was finished he moved onto the rear. He finished up the rear frame, welded on the 4 link frame brackets, welded on the rear coilover buckets & modified the frame to make things work, made new skid plate frame inserts, mounted the coilovers, built new links; 2" 3/8 wall lowers, 1.75" 3/8 wall uppers with Johnny Joints at both ends, welded on the axle truss...







Finally after months of resting on jack stands my Jeep became a roller again. There are no spings on the rear coilovers and the armor hasnt been worked in the rear yet. The wheelbase is around 102"




Last edited by Skooter_Built1; 11-06-2009 at 10:48 AM.
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Old 11-06-2009, 11:13 AM   #8 (permalink)
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After getting the suspension to being about 95% done, Kevin moved into the interior and built me a front cage. Works with my hardtop and will work with my soft tops, factory white and a Viking soft top. Truth be told that in the 5 years that Ive owned this Jeep ive never ran a soft top and have only had the hard top off once





After finishing up the cage with frame tie-ins, the armor was finished up and installed.









Now came to the truly custom & most difficult part of this build, the fuel tank. There was NOTHING on the market that I could use that would work for me, so a 1 off tank had to be built. The tank had to be under the Jeep, around 15gal, only 8" deep with a sump, and work around the new frame, suspension and axle. Here is what my buddy Kevin built me. I need out how to work the fuel delivery system as everything will be external and frame mounted.









Well so far thats my TJ build. Hopefully everything will be finished by the middle to end of this month. Sorry for the huge pics
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Old 11-06-2009, 11:28 AM   #9 (permalink)
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That tank looks nice.
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Old 11-06-2009, 01:08 PM   #10 (permalink)
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Nice...I never get tired of reading build threads.
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Old 11-06-2009, 07:34 PM   #11 (permalink)
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I am liking the way its looking in the pictures towards the end of your post. Be even better when its one color.
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Old 11-06-2009, 09:11 PM   #12 (permalink)
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i liking it alot....got any more pictures of the front end?? you got an idea of how much the front and rear is stretched??i looking to stretch the front too and keep power steering and just turn it like you did
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Old 11-07-2009, 07:46 AM   #13 (permalink)
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i liking it alot....got any more pictures of the front end?? you got an idea of how much the front and rear is stretched??i looking to stretch the front too and keep power steering and just turn it like you did
I think i have about 5" strech in the rear and about 4-5" strech up front with the JK arms. What I did was look at Swags build, Slinky Blue balls build and a few others to figure out how to chop off the factory steering box mount cut it down and rotate it.
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Old 11-07-2009, 03:05 PM   #14 (permalink)
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yeah i been reading those builds that who i got the ideas from too....
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Old 11-07-2009, 04:38 PM   #15 (permalink)
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Looking good skoots. Kevin does some nice work.
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Old 11-07-2009, 05:49 PM   #16 (permalink)
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Looking good skoots. Kevin does some nice work.
yep, best private builder in Michigan, bare none! Now our rigs have something in common, some of that Kentucky Bling
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Old 11-10-2009, 08:09 AM   #17 (permalink)
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My buddy got some more work done this weekend, finished you the front bumper and got the air bumps installed. I want to do up some tube work on the bumper just like how KirbyIV has on his TJ and add on some d-ring mounts.




Sexy welds



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Old 11-10-2009, 02:02 PM   #18 (permalink)
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anymore pics of the tank in the jeep .... thats pretty trick.
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Old 11-10-2009, 03:20 PM   #19 (permalink)
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anymore pics of the tank in the jeep .... thats pretty trick.
at this point no I dont My buddy Kevin would rather work then take pics He builds his tanks all by hand. From the fittings to the skid, he's truly a fab master on the highest level.
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Old 11-15-2009, 12:31 AM   #20 (permalink)
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at this point no I dont My buddy Kevin would rather work then take pics He builds his tanks all by hand. From the fittings to the skid, he's truly a fab master on the highest level.
and how much does he sell his tanks for?
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Old 11-15-2009, 07:43 AM   #21 (permalink)
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Damn, what part of the Jeep didn't have rust on it lol? Nice build
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Old 11-17-2009, 04:57 PM   #22 (permalink)
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Where did you find the yellow piece of body armor. I can't find who makes them.
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Old 11-17-2009, 05:03 PM   #23 (permalink)
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I love a white TJ with a white hardtop. Keep the theme if you can.
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Old 11-17-2009, 05:56 PM   #24 (permalink)
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Where did you find the yellow piece of body armor. I can't find who makes them.

Gen-Right makes them....
http://www.genright.com/ProductInfo....ductid=TPG2001
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Old 11-19-2009, 04:22 PM   #25 (permalink)
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I love a white TJ with a white hardtop. Keep the theme if you can.
thanks man

when it goes in for paint, which is hopefully soon everything thing is gonna go back to white. Had a buddy mix up the brightest white he could make. Im gonna go and pick up my TJ hopefully tomorrow so ill post up a bunch more pics then.
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