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Discussion Starter · #1 · (Edited)
Hello everyone. I've been a lurker for a while but thought you guys might be interested in my build. First it started with a stock 2004 Jeep Wrangler Rubicon that some lady drove and I'm pretty sure never once engaged 4WD. I took it from there and put a 5.5" long arm kit on it with 35" tires along with a couple other small mods:





After a couple years of that I wanted to get into more serious stuff and felt that I'd blow up my 44s if I went too much further so I decided to tear down and start a real build. The specs:

-Unimog 404 axles
-full interior cage with rear seat, all-new suspension seats
-front and rear bumper redesign with new mounts and front stinger
-rock sliders, high comp cut rear, and front tube fenders
-tubed rear chassis with wheelbase stretch
-double triangulated 4-link rear
-triangulated 4-link front
-14" ORI ST struts
-16.5" H1 double-beadlock rims with 39.5" Boggers for now

I'll keep posting updates as it progresses.
 

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Discussion Starter · #2 · (Edited)
I decided to start with the seats and cage first. Sent the Jeep up to Terra Traction here in Jacksonville, FL and got the cage built and seats put in:







 

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Discussion Starter · #3 · (Edited)
Axles acquired:





Full hydro and a couple other things were already built up on the axles. The previous owner took them right from the original vacuum-sealed boxing and flipped the front to work on his Land Rover. He ended up not really using them and they only hit the trails once or twice. I'm going back driver and will be using a spare housing I got with the deal.
 

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Discussion Starter · #4 · (Edited)
Right now parts are being ordered (struts too thanks to blacksheep10, Kelly, here on Pirate). I've got all the heims and everything else needed for the 4-link:



The Jeep is now axle-less and will start getting back-halved.
 

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Discussion Starter · #7 ·
Why didnt you bed line the interior before putting the cage and seats in?
I thought about it but there were better things to spend money on. I should still be able to paint one on without the seats there so I might do that in the future.
 

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Discussion Starter · #11 ·
Sorry, nothing special to report yet. Some trimming is still going on and the back-half tube chassis is being laid out. Making decisions on how high to cut the corners to fit the rear strut mounts and allow tire clearance. I'll try to get some pics in a few days.
 

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Discussion Starter · #13 ·
terra traction looks like they build some killer shit. Are all there cages one off, or do they make kits?
Yeah, David does some really good work. Each cage is custom-built and if you check out his gallery:

http://www.terratraction.com/gallery/projects

they all have unique qualities about them. He usually keeps his shop work to one or two vehicles at a time so he's not really making anything like a kit.
 

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Discussion Starter · #15 ·
Sorry, I'm sucking at getting new pics. The axles have all been cleaned up and are almost ready to get worked over for hydro steer and links. I'm buying some 2" tube in the next few days for the links and I'll try to get some photos then.
 

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Discussion Starter · #19 ·
The cage looks great. Just wondering if maybe there should be a bar connecting the tops of the C pillars? Looking forward to the rest of the build. Mogs are sweet.
Thought about it but checked some things and the way the cage should compress or have any weakness wouldn't be in that area. Having a bar there increases the possibilities for a head injury for the rear riders too so I stayed without it.
 

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Discussion Starter · #20 · (Edited)
Helped put together the front axle with its new housing while I was at the shop. All the fenders are off and it'll be saw time soon. Just discovered today that the engine will need to be shifted about 4" to the passenger side so now I'm in the market for a new fan setup. The struts should be coming my way in a little over a month.
 

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Discussion Starter · #21 · (Edited)
It's going to be a lot of work to get the pinions to fit. Should have a pretty long wheelbase; it's crazy wide, about 91 inches.
 

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Discussion Starter · #25 ·
Moving the engine over is a different way of doing things. I was thinking of that after the fact but it was a little tight with the Atlas back there. Cant wait to see how that turns out. What is your WB that your going for?
Even with pinion conversions it's just too long for me to want to do something else. The "fake" wheelbase mock-up for the front above is too much and it should be much closer to the frame, but compared to a stock TJ it'll be stretched some. The front will be a few inches and so will the back so my guess is between 100" and 110", probably closer to 110". Once we get the rear under for mock-ups some measurements can be made for links to see how everything will fit.
 

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Discussion Starter · #26 ·
Got the engine shifted over the maximum allowed of 2.5" before the transmission started getting too close to the body. Still not enough for the front driveshaft to really clear so I'll have to get something custom done there. Oh yeah, and the uptravel is too small based on how it rides now, so I'll probably end up having to get the front frame tubed out and a custom radiator put in so that I get what I want without it being sky high. It's gonna cost but I'd rather do it right and have it crawl well than to have it look like some monster truck which is what most of the 'mogged Jeeps look like.
 

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Discussion Starter · #30 ·
What size hiems did you get?
1.25". Pretty much this:

http://www.ruffstuffspecialties.com...l-rod-end-set-1-lh-1-rh-15-tube-id-p-383.html

Nice project..

If you could do it all over again, would you have mounted the axles first, then the engine and trans? I know they were already mounted but... Work with me.
I am in the planning process for my LJ build and plan to mount the engine and trans first, then the axles.
Since it is just 60's :flipoff2:, I can mount either first...

Thanks, Ricky
With 60s you shouldn't have the problems I'm having since their driver drop is pretty standard and keeps you far away from the engine. If I was a badass and started with just a frame I definitely would do the axles first, but I'm working with the stock Jeep drivetrain. Your LJ stuff shouldn't have any fit issues and you can do the engine first.
 

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Discussion Starter · #34 · (Edited)
Been buying a bunch of stuff lately. Ordered up a PSC 1600 series pump, larger pulley, all the related junk, and a new winch mount for the front:



The decision's been made to cut off the front of the frame and run it higher so that I can get more uptravel. The grille will be trimmed and I'll be putting in a custom radiator and fan.
 

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Discussion Starter · #37 · (Edited)
Can you just run a multi-piece front shaft with a carrier bearing?
That's part of the plan. We got the engine shifted over about 2.5" before the transmission started getting close to the body. This pic shows the issue, although this was before the shift so it's not as severe now.

I'll be putting some custom exhaust in to send the headers out of the way but now the problem is the transmission. Like you said I'll probably go with a two-piece front shaft. It seems like that's what most 'mogged Jeeps end up running.
 

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Discussion Starter · #44 ·
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