Project Sarge buildup thread

[HULK]

I figure its about time to start a buildup thread since I will have increasingly more questions as I get further into this. My son is 3 and obsessed with the movie Cars, so since its got a willys front clip on it- it is being named Sarge. Here's the rundown:
TJ frame
4.3 vortec, th350 with manual VB and engine braking, Atlas 3.8
HP 44 narrowed to waggy width- chromo shafts, longfield joints, ARB
Rear 60, narrowed, 35 spline chromo shafts Detroit
Poly link brackets, Tera joints and inserts
Other general military based mayhem, like this shifter box...


Started with an 01 TJ frame, chopped it/narrowed it and boxed the frame.








I also got the AA motor mounts welded in place, and made a crossmember for the tranny.

It has holes for the bolts on the adapter, and a mount for the tranny bushing as well.


From there I got the axles linked up for the most part and set an approx ride height minus the tires on it. Should be about 22" off the ground to the bottom of the links, and skid plate will be above those. I also built myself a stubby little front bumper

[HULK]

From there, we started and built a base for the floor and rockers, and proceeded to build the sid rails- all one piece from the A pillar back. Got the B pillars in as well, and one spreader done.











Then it finally starting to look like something. Got the A pillar spreader in right awa, then bent up the two rear hoops, will still get a kicker down from teh back of the upper hoop. Got the kick azz door bars doe- a bit of a pain, but well worth the effort! Also got the front grill hoops done.

[soilantgreen]

I approve of the MB grill!

[Jeepermat]

Looks good, keep it coming

[UCTJ]

You gonna paint it OD? Looks good did you say what size tire/wheel combo your running?

[HULK]

Sorry, running 38 SXs on hummer double locks. And yes, it will be OD green.






We also added a spreader between the A pillar and front grill hoop. I got my seats in too, but they are supposed to be lowbacks so they have to be returned. Grr.....

Which leads to a question... originally I was planning to build some fenders on the front, and make the front bumper/hoop removable in order to get access to the bottom bolts on the winch. I would run the fenders into the spreader and use the tube clamps to make them separable. However, the thought occurred to me that I could put some holes in teh front of the bumper to gain access to those bolts, and then I could hardmount the bumper and hoop as all one piece. However, then the front bumper isnt removable and neither is hte steering box skid. Thoughts and ideas?

Second question- if you look at the pics, the drivers side header points straight down onto the driveshaft. Not gonna work. What other headers can I use- these are from AA. ANyone know of a set that runs back instead of down?

[silvergreentj]

Looking good. Looks like some planning went into the cage, which I find impressive.

[oldjeep]

Originally Posted by HULK

Second question- if you look at the pics, the drivers side header points straight down onto the driveshaft. Not gonna work. What other headers can I use- these are from AA. ANyone know of a set that runs back instead of down?

http://www.sandersonheaders.com/prod...products_id=70

[crusty1007]

can you get any better pics of the clearance issue with the headers?

we might have a fix.

[russellmn]

Originally Posted by silvergreentj

Looking good. Looks like some planning went into the cage, which I find impressive.

Bend Tech Pro!!!! Had the rig planned out and mostly designed before we grabbed the first piece of tube.

[cdub0451]

Originally Posted by russellmn

Bend Tech Pro!!!! Had the rig planned out and mostly designed before we grabbed the first piece of tube.

I can tell. Looks like Homer is sitting in your mockup model in the last picture.

[HULK]

Hehe, actually its a GI joe. I still gotta redo the rear tube of the mock up to match the new style!
OK so here are pics of how the headers point now, and I need them to dump back not down. Pretend that the green PVC is the driveshaft. It looks like the ones chuck posted will work since they dump back, but would love to hear whatever other ideas you may have...

[APU]

I had the same problem when i was running the exhaust on my willys. i tried to ues the stock exhaust manifolds but the passenger side on dumped right into the drive shaft. exactly like the problem your haveing. being too cheap and in a hurry i made up a set of simple manifolds useing small block chevy ones as donors for the flanges and bends. they work great. i came around the front of the engine, picked up the driver side then out. heres a picture.good luck
http://s153.photobucket.com/albums/s...t=102_4895.jpg

[oldjeep]

Of course there is always option "B" . I could make you up a set of my patented square tube headers like I had on my Willys

[angrychairmen]

those have to be the first square headers i have ever seen lol
hey if theyy work they work

nice build you got goen

[WildWilly4x4]

looks good...like the willys skins

[HULK]

Small update from this weekend. I got a couple hours in just cutting and notching some tube. Things are coming along slowly. Just got the front windshield in on loan from scratch and I think the ride height will be just about right once I mount the seats up on their mount tabs. Got some spreaders in the roof done, and got the rear C pillar spreaders in, built a bunch of cage connections and mocked the tailegate in place. Dead sexay if you ask me...






Oh ya, I made some custom atlas shifter knobs too...

Yeehaw.

[51 Jeep Willys]

love the shifter knobs, looks just like the one i got off of ebay for my 6spd, keep the pics coming on the build

[HULK]

I got mine off ebay too, just welded on a nut on the bottom.

Here's a question: What the heck do you do for tow poitns in the front of a TJ? I know you can get those corny little bolt on gizmos- I was just planning on running those big blocks for D rings through the front, but those arent considered bolt on and wont pass tech around here so what do you guys do? I need some ideas...

[Rugger99]

Originally Posted by HULK

It's hard to tell who looks more stoked in this pic, you or the little guy.... Cool build, keep us posted with the progress.

[drewguere]

I really like this build, everything is all in a theme which is great

Keep it coming

[clemsonjeep]

nice build man...lovin the seats...gonna look killer with the OD paint!!

[slvrjp00]

Great build. Keep the updates coming. The stock mounting point for TJ tow hooks is the on the frame it would be were the factory bumper bolted to. Should be two bolts per side on the frame. Most people when they build a front bumper just add some kind of D-ring tab into it.

[ky scrambled]

Lookin good Josh.



Did Scratch leave ass cheek marks on that windshield!!!!

[HULK]

Originally Posted by ky scrambled

Lookin good Josh.



Did Scratch leave ass cheek marks on that windshield!!!!

Probably- you know how he is about everyone seeing his ass....

As for the front pull points, I am going to put some weld through mounts on there for when I am actually pulling, and I am going to put on some bigger bolt on ones on the top to appease the tech inspectors...