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97 TJ All in one RIG

179K views 313 replies 81 participants last post by  Tjohnson619  
#1 · (Edited)
Well, I have been in the WEROCK circle for a little while. It was fun and expensive like everything else. Tired of traveling long distances to just wheel for a few minutes. Thought about building up a trail worthy rig with highway roads accessible in mind. Sure I will still use the enclosed trailer to haul for long weekend getaways or small events.


What I got and some ideas..

-97 TJ 4cyl TUB Salvage Title, hmm Registering

-2002 5.3, Novak headers, wiring
-2002 4L80E, Advanced adapter with VSS
-Atlas 5.0 with 1300 flanges
-2002 Ford Superduty F350/F450 HP60 axles shortened
-Unit Bearings (TG)
-Rear Unit Bearing Pockets, Spidertrax
-ARB's, 488's
-17" wheels
-37x12.50x17 MTR Kevlars
-Tundra Brakes.. Secret
-Genright Rear Full Stretch Corners
-Genright Rockers
-Genright 05-06 Fuel tank, higher PSI for LS engine
-1998 Durango Steering Box
-4qty 16" FOA 2.0 remote res Coilovers
-7/8" heims, 1.5" DOM .250 lower links, 1.5 .120 upper links
-1 3/4" DOM Roll cage material
-Race Trim Seats
-2x3 and 2x4 steel tube frame .120 wall


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#5 ·
Waiting on chasis CNC tabs being cut for frame up and driveline/suspensions. 8 hours of auto cadd dimensions and designs off to hypertherm, where my buddy is an engineer. Why not cut useful parts rather than R&D parts that get tossed in the scrap barrel..
 
#6 ·
I have been lazy lately, buying Genright bolt on parts and making targets. Tired of that stock toyota crap kicking around. Thought I would use some spare axle shafts for small projects. I would rather use spare parts for my own projects than sell them at a slap in the face price from half of the people out there wanting a deal..


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#13 ·
Filler neck is from the Genright Rear quarter stretch kit. Relocates the filler so if you wanted to run a stock flare it will work. It's a super thin cheap plastic piece. The one I got that which I stuffed in the hole got crushed in the shipping, have to ask Genright for a new one, better since their crap isn't cheap..

Still waiting on Plasma parts being cut, always that favor that can slow you down. Sometimes full price gets the job done on time..

Ordered a filler tube and Pump lock ring from the dealer for the gas tank, rather cheap. Better deal than used parts on CAR-PART.COM.. Although I did get a used 05-06 fuel pump assembly with 20K miles for 85 bucks.

Wanted the fuel tank all set up so I can stuff under neath and make the frame around and incorporate the coilovers..
 
#21 · (Edited)
Another distraction, fabbing up a Rear ATV hauling rack, second reciever hitch to be welded onto hitch of truck for added stability.

Transfercase tucked up real high with future full flat belly pan across frame rails. Running into front driveshaft problems, potentially hitting 4L80E and floor pan. Moved drivetrain a few inches to the Passenger side. Might have to lengthen the axle tube on pass side, perhaps I shortened to much. Trying to make it slammed and some what leagal wheel base is really hard.
 
#22 ·
... Trying to make it slammed and some what leagal wheel base is really hard....
You can count on it. Badass build thou. In really interested in how you will address that front drivers support at the axle. I suppose you'll be cutting the center section a little.

Amazing supply of tabs you have there. Do you cut'm yourself? Whats the machine?

Keep on.
 
#23 · (Edited)
Actually, the tabs are R&D from a friend that is an engineer. I sent the DXF and he mails me test pieces.. lol His machine can cut upto 4" thick plate with .002" verticle tolerance and .002 for holes. The machine also uses gases rather than compressed air to cut, which means unhardened steel. Tap the holes directly from cuts.

The Diff upper link support, well I was going to run a 3-link and have the upper tower on the pass side. The lower link will be on tube and casting.

To much to do.. gotta stop writing and work..
 
#27 · (Edited)
I think I got $600 for the engine with 50K miles
$400 for two adapters, VSS and main 4L80E-Atlas
$300 for used tranny 65k miles
$200 for headers, which not really needed



About $1500 into it so far. Now the ancillaries, radiator, computer, tune, shifter, plumbing will add up quickly. Not to bad if I watch the deals out there. The wire harnesses are getting readily available and easier to understand. Stock OEM computers can be programmed, pretty nifty.

The 5.3 forum is real helpful, but scattered with info. Like to see it organized some how. Alot of great ideas. Small things like getting stock gauges to work, fuel supply, exhaust, ignition electronics, and other unforseen obstacles are overcome.

I am slacking, still doing some R&D on my ATV hauler. Everyone loves pics...
Had to weld another reciever hitch to carry the load, piece of mind with a 650lb ATV...

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#28 ·
Not a build for an amateur that's for sure but nice work - best thing I did a couple years ago was dump the big block powered rig for a 1997 TJ build with a 5.0L, Atlas, Dynatracs etc... Been wheeling more in the last two years than I did in the "cool" rig in all the time I had it and barely turned a wrench...
 
#29 ·
Really digging the build and thinking about the same thing. Just did the GR rear stretch and planning the front. BTW, I'm not that far from you but I never see those prices for motors and trannys. Please let me know if you run onto any more like that.
Bart
 
#32 · (Edited)
Been distracted with so many winter things. Easter Jeep Safari has me back up and running. Amazing when you have deadlines... Anyhow, Frame is together, the Gen right tank was a bitch to work around, to wide. Be interesting to see how the coilever fit in the rear without notching frame. I tried to use stock steering bearing and made a sleeve on the lathe, with heat from the header and being made out of plastic.. Think I might refit with a heim support. Steering box is a Durango box, see how that valves out for the hydro assist considering the ratio is way less than a stock TJ box. Sometimes the ram slows down you steering to much for the road. Poly bushings for the motor mounts and tranny supports. Stock TJ body mounts all around. Links should be in this week, bought some DOM.. 7 bucks a fricken foot.. OUCH! Oh, Shot an elk, pretty tastey.


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