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Old 12-04-2010, 11:09 PM   #1
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My daughters' 94 YJ

Hi Guys,
I'm relatively new here. First time posting pictures etc., so let me know if I should change anything.

I figured I post a project I've been working on with my two daughters.advised me that a quick body repair with crusher type corner covers would be the best route for a couple of teenaged drivers. That was the route I was travelling...until I came upon a almost rust free tub for short money then I jump off the edge!

A friend at work was getting rid of his Jeep and sold it to me real cheep for my girls. The 16 year old gets her learner's permit next week and the 18 year old is tired of driving my wife's old minivan. I planned on a quick clean up and let them drive it into the ground. A couple things changed (besides my obsessive compulsive disorder!). First, my daughters got real interested in the mechanical aspects and wanted to help with the repairs. Second, my oldest had just applied to College and might be interested in Mechnical Engineering. With both of these in mind we decided that a rebuild changing the rusty tub with a caved in rear quarter would be a good "bonding" project and a chance for them to get aquainted with some tools and basic auto knowlege.

We started by rolling the "new" tub on it's firewall and the girs got aquainted with the angle grinder with a wire wheel attachment. The underside was in really clean shape with much of the original undercoating in tact. We mixed up the coal tar epoxy left over from my boat's fuel tank project and they touched up as necessary.







We then made a wooden cradle to hold the tub, I shot a coat of red paint on the inside over the brown durabak the previous owner had applied. The girls then removed everything they could unbolt and we moved this all to the new body replacing heater core, etc as we went.









We then removed the old body and started to make a game plan to attack the running gear and any frame issues. There was a decent amount of rust to some cross members, behind the power steering box and some of the mounts. Then the devil on my shoulder found a sandblasted frame at a reasonable price and the project took another turn. The girls touched up the frame with the wire wheels and we POR-15'ed the frame. We removed all the running gear and suspension and started removing 16 years of New England rust. The motor, trany, and transfer case we pulled in one piece and placed on yet another 2x6 frame.






More to follow,
John

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Old 12-04-2010, 11:15 PM   #2
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Looks like a great start, and a great father daughter project too.

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Old 12-04-2010, 11:19 PM   #3
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Removal of the old bushings was a bear until I started drillin the old rubber out of the way, pushing the inner sleaves out, and using a cold chisel and (now broken!) screwdriver to pry the outer sleaves out. New bushing were presssed in.





The assembly of the chassis has actually went well. We replaced the ball joints, tie rod ends, spring bushings, brake lines, front end u-joints, sway bar and track bar bushings, etc. etc etc. Axels, track bars, springs were coated with 3M undercoating.










We encountered our first major snag when we started to re-install the drivetrain. The new frame was a 4 cylinder like our old one so we figured it would be a bolt in like everything else, but the passenger side frame bracket is 1" forward of the original.



I was considering cutting the bracket and moving (with the help of my brother who is a MUCH more talented welder than me) or fabricating a 1/4" plate on top of the mount with some gussets down the back side. I found another 2.5L motor for sale on ebay in a frame that matches our new frame. I spoke with the seller who measured his frame and it matches ours. I'm guessing the motor mount brackets on the motor itself might be different. He's pulling them and going to send them to me hopefully getting us back on track. We are hoping to mount the tub before the dreaded white stuff starts falling from the sky.

I'll update as progress continues. We are starting to fab bumpers while we wait for engine brackets pic's to follow soon

-John
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Old 12-04-2010, 11:32 PM   #4
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looks good and looks like your girls are having fun help building the jeep, but talk about a fun project.
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Old 12-04-2010, 11:41 PM   #5
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Looking good

I do have a tip that will help you though. Next time you need to remove a bushing like that, just set it on fire with a torch and let it burn out...then the sleeve falls out with a gentle tap. But, you will wanna do it outside
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Old 12-05-2010, 09:44 AM   #6
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Looking good

I do have a tip that will help you though. Next time you need to remove a bushing like that, just set it on fire with a torch and let it burn out...then the sleeve falls out with a gentle tap. But, you will wanna do it outside

Thanks,
I've done them like that, but I was trying to stay warm (little garage not heated) so we were working in the basement....wife just hates the smell of burnt rubber with smoke detectors going off!!! Burning them is deffinitely the quicker way to go.
-John
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Old 12-05-2010, 09:47 AM   #7
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LOL the smell is pretty tasty isn't it? I did two last week in the unheated part of my shop and it stunk the whole thing up
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Old 12-13-2010, 02:26 PM   #8
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After a tip from a very knowlegable Jeep expert, I found that Jeep changed the passenger motor mount bracket (on the engine) after 1990. Our motor had the 1994 one. I was able to get the one we needed. It relocated the engine mount forward and inch. It was narrower than the '94 one, so I had to cut the motor mount center down and inch and everything lined up as it was supposed to.


The steel unit is the earlier on (pre-'90) and the alloy one is the later one.









With that headache out of the way, we now can move forward and hopefully get the body mounted this week if time allows. I have to finish up a rear bumper I'm making and we have to run new e-brake cables first (too cold to lie on back this time of year to work. We also just picked up a hardtop for $75 that need a little glecoat repair/paint job next spring but will keep the girls much warmer this winter

More updates to follow.
-John
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Old 12-13-2010, 02:46 PM   #9
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looks great. will you adopt me and work on mine too?
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Old 12-13-2010, 04:47 PM   #10
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i love them gambler rims.. had em on my jeep before i replaced em.. now they are on the xj i shared with my mom.. def makes a jeep look a lot nicer with em on

just saw this today on another forum.. i like what he did with em.. in case they may want some black rims and new ones are outta the question.. black rims on a jeep are always nicer imo
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Old 12-13-2010, 09:03 PM   #11
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i love them gambler rims.. had em on my jeep before i replaced em.. now they are on the xj i shared with my mom.. def makes a jeep look a lot nicer with em on

just saw this today on another forum.. i like what he did with em.. in case they may want some black rims and new ones are outta the question.. black rims on a jeep are always nicer imo

Exactly what we had planned on for the spring. Probably with red center caps to accent the red body. I was trying to decide if I would tape off the rivets like those or just media blast the whole thing and paint satin black. I think I like the silver rivets.

Toshpate, Already have 4 kids....no more room at the inn...and another Jeep project the wife will throw me out...but I do have a set of Dana 44's that will fit a CJ frame....
-John
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Old 12-13-2010, 09:06 PM   #12
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Exactly what we had planned on for the spring. Probably with red center caps to accent the red body. I was trying to decide if I would tape off the rivets like those or just media blast the whole thing and paint satin black. I think I like the silver rivets.

Toshpate, Already have 4 kids....no more room at the inn...and another Jeep project the wife will throw me out...but I do have a set of Dana 44's that will fit a CJ frame....
-John

eww no red center caps lol.. my ex painted hers pink (worse than red i know) but it looked like crap.. black and silver are the way to go.. especially on a red jeep..

but then again.. thats just my opinion lol
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Old 12-13-2010, 09:51 PM   #13
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Black with silver rivets looks awesome, but like the previous post, red center caps would look terrible in my opinion.
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Old 12-13-2010, 11:12 PM   #14
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That jeep will look brand new when you are done. Looking great so far. Gotta cj7 I'm going to do like that soon.
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Old 12-14-2010, 12:14 PM   #15
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Looks awesome!
Wish I could of came across a better tub before I started my Lifelong build :P

Goodluck giving the keys away to your daughters :P

Luckily you can just give them your car and keep the jeep
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Old 12-14-2010, 05:52 PM   #16
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wow great work so far !
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Old 12-15-2010, 08:33 AM   #17
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These builds are fun to watch. Lookin' good. Can't wait for the updates. Cheers.
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Old 12-15-2010, 08:46 AM   #18
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sweet project!!
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Old 12-18-2010, 10:46 PM   #19
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Looks good keep up the good work! Least you know it will last that much longer now!
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Old 12-19-2010, 12:03 AM   #20
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I wish my dad would do projects on my jeep with me. But instead he wants me to run it till it dies and scrap it. He hates what I'm doing to it. (well see how he likes it in the summer time when I'm all done )
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Old 01-06-2011, 07:20 PM   #21
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It's been a couple of weeks since an update guys. A week before Christmas, the white stuff started falling in Mass, but not before we got our tub mounted on the frame. The plan was to spend Saturday and Sunday finishing some brake lines, mount our newly fab'ed rear bumper, and tie up a few loose ends and then mount the body. The weather man changed our plans slightly when they predicted a possible Nor-east winter storm for Sunday. We where under the gun on Saturday to try to button up what we could.

We have had the rolling frame in the tiny garage/"shed" that sits 8' away from our house. The body has been on a cradle behind the shed on a patio. Once the loose ends were finished up, we rolled the frame into the driveway. I gave the girls a rolling jack and told them they would have to "skid" the rear end over to line it up for the roll up the yard (they've done this with me several times during the project). I went down to the basement to get the new body mounts and wanted to see how they would do on their own. They surprised me when I came up. They had their 10 year old sister and 13 year old brother help and they had the frame rolled around the garage and almost lined up with the body. Amazing how they can fight like cats and dogs then put it all aside and work like a team when necessary!







If you look closely, you can see the engine lift behind the body. I tied it to the roll bar and my wife manned the hydraulics. We lifted the front up and slid some 2x4's under the tub and supported with saw horses. I climbed under with my chainsaw and cut the cradle out of the way then we rolled the frame under. We had a couple of old body mount bolts that refused to budge. I used an angle grinder to cut access flaps in the floor and removed the factory "nut". We replaced with large washers and nylock nuts on the new bolts. I will tack the flaps down later and seal with seam.



Sorry no pics of the mounted body. As the afternoon wore on the sun set, the temps dropped 10 degrees, and the threat of snow grew closer so the camera was put away. We rolled the Jeep back to the driveway and it fit in the tiny garage with 1/2" of clearance between the hardtop and the door opening. All is tucked away out of the snow. Now that the holidays are over we'll have to plan our attack. We may just put up a "blue tent" on the front of the garage with portable heaters on warmer days or try to move to a larger garage to work (couple options possibly available from some generous Jeep enthusiasts). Worse case we pick away at it this winter doing what we can and finish in the early spring.


We have the battery tray, radiator support, power steering pump, etc in the basement shop and will be cleaning and painting as necessary. Santa brought a console with a stereo mount and some d-rings for the new bumper . We'll be mountin the stereo and probably making a plate for the stock dash radio location to mount a CB.

We'll get some updated body mounted pictures next time it rolls out into the light from it's tight hide-away.
-John
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Old 01-11-2011, 06:48 PM   #22
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This is a great build. I am following with jealously.
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Old 01-11-2011, 08:56 PM   #23
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Fun stuff - I'll have to show this thread 2 my daughter I'm lucky 2 get her 2 help wash a car!!! LOL
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Old 01-14-2011, 09:42 AM   #24
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I like it. Nice job (and I guess the time spent with the kids working on it are priceless). And this started as a quickie fix for the girls to run around in.
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Old 01-14-2011, 04:46 PM   #25
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Tell the daughters they are doing a great job! Teaching them this stuff at a young age will simplify they're lives when it comes to future vehicle maintenance. Even if they grow up and do not do they're own work, they will at least understand what it is being done and will not be pushed over by any certified parts replacers who don't troubleshoot.
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Old 01-14-2011, 11:25 PM   #26
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Thanks for the possitive comments guys. There's been times when I've had to carry the project to keep it moving, but the girls have really shown interrest in the process and wanted to be involved with more than just the "fun stuff". We're stripping and painting odds and end brackets and pieces from under the hood as well as stripping minor rust and priming the front fenders in the basement. Plan is to pick away at project and hopefully have assembled for paint in spring. We'll keep you updated.
-John
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Old 01-17-2011, 12:04 PM   #27
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I can't wait until I have kids, that way I can do a father/kid project like you. The work looks good so far. Keep it up!
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Old 01-22-2011, 11:31 PM   #28
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Tell the daughters they are doing a great job! Teaching them this stuff at a young age will simplify they're lives when it comes to future vehicle maintenance. Even if they grow up and do not do they're own work, they will at least understand what it is being done and will not be pushed over by any certified parts replacers who don't troubleshoot.
I totally agree with every word of this and second it.

Further more I mothion for 94YJ to be considered as DAD of the year.

Pretty awesome.
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Old 02-12-2011, 12:19 AM   #29
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Thanks for the kind words guys sorry we’ve been absent here lately. The New England weather and the schedules of 2 high school daughters has made “Jeep Time” difficult. We have managed to scrap out a couple of projects to move the YJ along.

My body work has previously been bolt on replacement parts and bondo. It was time to pull out the welder and give it a shot. The tub we bought was mostly rust free. There are only 2 areas that needed attention. The first was on the passenger side lower near the firewall. We cut a patch panel out of a donor fender with the 90* bend still intact. It was scribed over the damaged area and the grinder made quick work of the removal. I welded the piece in, ground it down and faired it will some filler. The patch was primed to protect it until the planned spring paint job









Sorry for the picture quality…or lack there! Not sure why they came out so bad but I was too happy to see the repair work than to worry about my photographic skills. The patch is not perfect, but since it will be covered by a rocker guard I figured it was a great place to practice.

We cleaned up the greasy rusty brackets for the radiator and washer bottles, the jack mount, horn bracket, etc and the girls shot them in the basement with rattle cans.


One day a couple weeks back it reached a whooping 34* out and my oldest had no swim practice so we decided to spray the insides of the used fenders we had been sanding and self etch priming in the basement. We hung a drop cloth in the opening to the small garage that is housing our red project. We warmed the fenders by the woodstove in the house then brought them out one at a time and sprayed them. They were then carried down to the basement shop and hung from the ceiling to dry. This was my daughter’s first time with a spray gun. She did well.
First we shot the dupont primer.




After the primer flashed, we switched guns and laid on the red on the inner fenders and all the mating surfaces and jams. The outsides will me sanded again after assembly before we shoot the rest of the body.



Now I just picked up a pipe bender from HF and we are messing around with scrap pipe trying to decide our plans for the front bumper...more to follow!
-John
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Old 02-12-2011, 09:36 AM   #30
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Good to see you back on the jeep and nice job on the patch. The weather has been unbelievably cold this year. Never mind all the snow.

I'm sad to say I'm heading for the garage now to see if I can get mine into prime. I'm dragging my feet because I just don't want to paint. Normally I'm there by now.

Throw the body on a trailer and bring down the shop and get it painted. Then you might get some warmer days to start on the interior.

60 days to warmer weather.

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