King Of the Hammers or Bust TJ Build

[KarlVP]

Been a while since I have posted up here. You folks out at T4W were the start of my wheeling adventure so I figured I would show you what I was doing to my poor beat TJ.


For those that don't remember, this is what we are starting with.







Getting it ready for the trip to KOH next month. Been working on it since I got off of deployment in October.

What's in these boxes?




I do believe that is an atlas 4 speed transfer case.



Removing belly pan for cleanup.



Installing new T-case.

[KarlVP]

A note for those installing a 4 speed on thier 4cyl TJ.

The stickout at the transmission mounting of the t-cases are way different.

4 speed stickout.



NP 231 Stickout. Cleaned this up with a ring from AA.

[KarlVP]

Building Crossmember for transfercase.








The rear axle was bent from me jumping the jeep and all around shenanigans.



Also the pinion nut kept backing off on me Causing the axle to leak.




A little help from a grinder to cut a groove in the pinion and all is well.


Skid plate cleaned up.

[KarlVP]

My coils were hammered so I ordered some new RE coils.



Old RE control arm bushings.



Gas tank and such pretty beat up.




Passenger side body pretty beat up.



After some straightening, turned out pretty nice.

[KarlVP]

Removing erroneous parts.



Whoops, something fell off.





Straightening tailgate.

[KarlVP]

Before.



After.




New Frame section.

[KarlVP]

Transfer case brace done.




Frame 4 link cross member. Took forever to build.






Plating the frame for the crossmember.



First control arm Joint fabbed.

[KarlVP]

Link mounts being fabbed.









Rear axle from the bottom.




Same from the top. Shows the trusses pretty good. We took a while straightening it and reinforcing it for go fast or jumping situations.

[KarlVP]

What am I going to do with all these levers?




The shifters BARELY fit in the jeep.



Roark support ring installed on the crossmember.



Belly pan back in for fitup.

[KarlVP]

Putting the frame link mount into place.



Axle in place.



First fitup of control arms, shocks and coils.



Easily accessible grease zerks.

[KarlVP]

With the front 3 link that I made last year, I didn't like the angle on the bushing, so I drilled out the D30 mount and sleeved it.





Removal of stock frame cross member.






Top hat coil spring retainers in the rear so if I get some "cheater droop" the coil won't fall out.

[KarlVP]

Rear 4 link fitup. I really like this picture.






Straps on the lower control arms. The joins are reset so the control arm has a flat bottom to slide over rocks and such.



Reused the stock coil buckets.

[KarlVP]

Built a new driveshaft and painted the top hats for the coil retention.



Fitting the brakes on the rear.



New hard lines on the axle.




Painting/priming the control arms.



Coil bucket reinforcement.

[KarlVP]

Trying to get the body back right to fit the tailgate.



Not going to happen so we broke out the sawzall. We are going to make it into a fold down "pickup truck style tailgate".



Plating the front of the frame.



Tying the body into the bumper.



More frame plating photos.



Axle painted and ready for install.

[A "CJ"]

Looks really good Karl.... keep the pics coming.

tim