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Old 10-25-2009, 09:44 AM   #1 (permalink)
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=-Rocky-= TJ Build

Hey all, a couple pirate friends talked me into posting up my build thread here to let you all check it out and get ideas if need be. Well I will catch you up to where I am at today. I started with a semi built 03’ wrangler and decided that it was about time for the Jeep to catch up with my driving. Having a small off-road fabrication company on the side last year allowed me to collect many of the tools I have now to do everything myself which was nice.
Well, here is the Jeep before I started.


Here it is torn down in my 2 car garage.


The D60 front and D70 rear.
When I got it

Now

When I got it

Now
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Old 10-25-2009, 09:45 AM   #2 (permalink)
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Some Parts:
Atlas 10:1 4spd with HAD 1350 drive flanges


42” Iroks 17” softies and Offroad overstock beadlocks

QA1 Rock Hard rebuildable joints.

Axle parts: Seals, Kingpin rebuild kits, Front a rear ARB’s, 35 spline d60 outers, and 5.13 gears.

RCI fuel Cell with Kore fuel pump ring.
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Old 10-25-2009, 09:46 AM   #3 (permalink)
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OK enough of that, on to the fab work.
Here are axles built and setting at their new wheel base (108”).

Front suspension tacked into place.


Rebuilt the front of the frame and straighten it out



I then redid the back half by following the bottom of the tub all the way back.
Before with the body already cut.

After (with the rear Antirock tube in place)

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Old 10-25-2009, 09:47 AM   #4 (permalink)
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Skid plate that I fabed up to be removable which will be skinned with 3/4” UHMW.



The D70 all trussed up with a triangulated 4 link.


Front 16” and rear 14” fox coilovers with King springs




And here it is finally off jack stands.
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Old 10-25-2009, 09:47 AM   #5 (permalink)
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On to the cage. I wanted to still fit the factory soft top which made it quite hard but was able to get everything to fit perfectly.







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Old 10-25-2009, 09:51 AM   #6 (permalink)
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This bring us up to the present with getting the seats installed and getting the cage tied into the frame. Here are the front seats (Race trim) installed and am currently working on getting the rear 48” race trim seat installed since I have three kidos that will need to be riding in the back. Wow what a tight fit it will be but oh well just about everything on this build as been a tight fit.


The front is setting about where I need it but I still have to add some more weight to the back to adjust the rear coilovers perfectly. Here is how it sets now.


Also here is a link to all of the build pics if you are board and want to check them out.
http://s632.photobucket.com/albums/u...Rocky%20Build/
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Old 10-25-2009, 10:10 AM   #7 (permalink)
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NICE work!!! realy dig that skid/crossmember you built, you've got some skills man!
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Old 10-25-2009, 10:14 AM   #8 (permalink)
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Looks good, I like to simple straight forward aproach. What material is the xmember made out of, and how much does it weigh?
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Old 10-25-2009, 10:27 AM   #9 (permalink)
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Looks good, I like to simple straight forward aproach. What material is the xmember made out of, and how much does it weigh?
Thanks guys. I built the frame sections out of 4x2 3/16" and braced it with 1.5 1/4 wall and .120 wall tubing. The back half wieghts about 30lbs more then then stock section I cut out with out the back bumper welded on. The center skid I built out of 1.750 and 1.5 .120 wall and is still light enoght for me to hold up and built in place (I never wieghed it sorry).
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Old 10-25-2009, 10:30 AM   #10 (permalink)
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NICE work!!! realy dig that skid/crossmember you built, you've got some skills man!
What Wally said! Very impressive work. Hope to see you out on some of the Texas trails.
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Old 10-25-2009, 01:49 PM   #11 (permalink)
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Great build up. Fab work is top notch!
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Old 10-25-2009, 01:58 PM   #12 (permalink)
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It's about time you posted it here slacker! Can't wait to see it on the trails with us again!

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Old 10-25-2009, 02:14 PM   #13 (permalink)
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Nice job, what are you doing for mounting harnesses?
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Old 10-25-2009, 02:25 PM   #14 (permalink)
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That's a beautiful rig you have there. Nice work and I can't wait to see the end result.
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Old 10-25-2009, 02:28 PM   #15 (permalink)
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Thanks again Twisty, OkLaHoMaYJ, and JCTJ. I hope to have it finished up by the end of the year but you know how that goes sometimes. After that we just may see you JCTJ.

Yeah, Yeah doggyhouse, you need to get back over here and give me some motivation.

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Nice job, what are you doing for mounting harnesses?
Thanks, I should have some tabs coming in this week from Copperhead fab so I can install my RJS camlock harnesses that came in the other day. I will also be putting on some Crowe harness pads which match the gray harnesses.

Last edited by =-Rocky-=; 10-25-2009 at 02:29 PM.
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Old 10-25-2009, 02:58 PM   #16 (permalink)
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Nice build!
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Old 10-25-2009, 03:35 PM   #17 (permalink)
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Where did you get all your suspension brackets?
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Old 10-25-2009, 04:50 PM   #18 (permalink)
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Very nice! Some day I hope my jeep grows up like that one.
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Old 10-25-2009, 04:51 PM   #19 (permalink)
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Looks like ruffstuff brackets.

Jeep looks good. Whats the frame height and top of cage?
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Old 10-25-2009, 04:59 PM   #20 (permalink)
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Tube work looks incredible. One question though? Do you plan on using your receiver hitch? How are you going to get a through pin in the behind the bumper with the two side bars on each side. It may have any easy answer, I was just curious.
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Old 10-25-2009, 06:45 PM   #21 (permalink)
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Cool to see your build on pirate! It still blows me away how fast your build is going! Keep it up!
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Old 10-25-2009, 06:55 PM   #22 (permalink)
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Looks good man!
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Old 10-25-2009, 07:07 PM   #23 (permalink)
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Sweet build. How long have you been working on it ?

Looks like Green Acres in atleast one those prebuild action shots.

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Old 10-25-2009, 07:40 PM   #24 (permalink)
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Slick lookin man! Would you mind getting a better picture of the trans mount?
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Old 10-25-2009, 08:55 PM   #25 (permalink)
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I was wondering how long it would take before you posted your build on pirate. JR and I were talking the other day about possibly giving you a hand on the weekend of the 21st and we could set the gears in my new front axle at the same time. Keep up the good work.
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