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Old 02-20-2013, 12:32 PM   #31
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Well the rear sta-bar doesn't fit, at all, so after welding up the truss I cut off the sta-bar brackets on the axle and the frame and cleaned everything up. Finish welded the upper arm frame brackets as well. So basically the only stock bracket still on the axle are the coil buckets. I ordered a Currie antirock rear bar kit, so now I have to wait to paint the frame and axle until that comes in. I took some measurements for the driveshafts, rear has to get 9.25" longer, the front about 3-4" but I need to pull the front springs and cycle the suspension to be sure exactly how much, which is fine because then I can install my new front coils. I then started looking at the body and cut off some extra material from the new rear half, will do the final trimming once I get them closer. Also managed to clean up the garage a bit, so it's a little better to work in. So this week I need to run a wire wheel over the axle and frame to get them ready for paint, and hopefully get the shift shafts for the 300 back from the machine shop so that can be final assembled.

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Old 03-01-2013, 09:53 AM   #32
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More work, getting to it slowly. Extended the fuel tank wiring and routed everything for the t-cases. Got the holes drilled for the new body mount, 5" forward of the original and 1.25" higher (for the body lift).

Picked up a new toy, so put it to use removing the rear track bar bracket, some material at the front shock bracket that hit the arm at full droop and some of the LF control bracket that got bent during some event or other.




Also repaired some damage to the axle bracket from the control arm coming loose and wearing a groove into the bracket. I just filled it with weld and used the die grinder to smooth it back out.

Also got my new 3" AEV springs installed in the front and brought the driveshafts in for lengthening.

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Old 03-06-2013, 08:00 PM   #33
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So I'm officially pissed off at Savvy, I finally get a chance to open the box with what's supposed to be my rear antirock and what falls out is some heavy duty track bar and a pitman arm, grrr... Don't know what they are for, and don't really care, I've already paid the taxes for the antirock to come across the border and I can't get a hold of Savvy, even before 5 California time.


I did get a couple of things done though, cut a hole in my floor for the triple shifters, cut out a chunk of the center console to clear the shifters, welded on a new bracket to the shifter bracket so the cable for the 231 case can come in from the front so it doesn't do some weird S bend.


Started working on bracket for the 231 t-case cable mount too. I had a few other no Jeep projects to deal with too, like mounting my new drill press to my workbench, and making a bracket for my plasma to sit on my welded without it falling off as well as a hook for the cords.



Seeing as I was pissed and didn't want to deal with anything else I sprayed the entire inside of the frame with some Eastwood internal frame coating, used 4 full cans to do it, luckily I bought 5, so I have a spare. Now I need to stay out of the garage until tomorrow when the paint fumes die down.
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Old 03-10-2013, 07:56 PM   #34
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So I had cut a nasty hole in my floor for the shifters, not wanting to leave it that way I decided to bend up some sheet metal, I'm not really good at sheet metal, but I figured it'll be mostly hidden so I'll give it a go and get some practice before doing the body. Got a piece to fit most of the hole, just welding to the body, not the shifter plate, I want to leave that removable. Man I hate doing thin metal, but I played a little with the welder and go better as I went along.


One final piece for the last hole, sorry the pics a little overexposed.

I didn't bother trying to make it all fit flush, I didn't have that much patience, and my back was getting sore bending over the door opening.
While I had the seat out I also put the original seat risers back on, I had switched to a fold and tumble base, but with these shifters that's not going to possible anymore, oh well the kids will have to use the passenger side or go through the windows.
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Old 03-11-2013, 04:06 PM   #35
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Not sure why my previous post's pictures are not showing up, so I'll repost is, seeing as I can't seem to edit the post, not sure why??

So I'm officially pissed off at Savvy, I finally get a chance to open the box with what's supposed to be my rear antirock and what falls out is some heavy duty track bar and a pitman arm, grrr... Don't know what they are for, and don't really care, I've already paid the taxes for the antirock to come across the border and I can't get a hold of Savvy, even before 5 California time.


I did get a couple of things done though, cut a hole in my floor for the triple shifters, cut out a chunk of the center console to clear the shifters, welded on a new bracket to the shifter bracket so the cable for the 231 case can come in from the front so it doesn't do some weird S bend.


Started working on bracket for the 231 t-case cable mount too. I had a few other no Jeep projects to deal with too, like mounting my new drill press to my workbench, and making a bracket for my plasma to sit on my welded without it falling off as well as a hook for the cords.



Seeing as I was pissed and didn't want to deal with anything else I sprayed the entire inside of the frame with some Eastwood internal frame coating, used 4 full cans to do it, luckily I bought 5, so I have a spare. Now I need to stay out of the garage until tomorrow when the paint fumes die down.
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Old 03-12-2013, 08:52 PM   #36
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Got a new package in today, Factory Ten axle shafts, they were a great deal and you'll see in the pics below why I chose to replace them, the pics are a little fuzzy but you can still see the twist, especially in the first pic. I ordered new retaining plates, so I'll keep these as trail spares.



Worked on the rear axle and brakes some tonight, I took the 3 way block off of the end of my procomp stainless line and then welded the bracket to the frame, and drilled a hole to mount hold the line near the upper frame mount.

Then used a hose clamp on the factory rear hose bracket to clamp it to the left upper arm, along with the stock original hose/tube and 3 way bracket mounted to the truss. Just had to bend the tube a bit to account for the angle of the truss.

Then the TJ disk brake tubes/hoses out to the ends with a little bit of tweaking.



Supposed to have my antirock on Thursday so then I can get that mounted and pull the axle to weld my locker air piston skid, the antirock brackets and drill and tap the hole for the 3 way block. Hopefully next week I can get the frame and axle sandblasted and then start work on mounting the body.
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Old 03-16-2013, 09:30 PM   #37
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Got the rear sta-bar mounted, so I pulled the rear axle and welded the brackets then made a skid plate for the air cylinder for the OX locker. I then picked up my lengthened drive shafts, unfortunately the front is too long by 1.5" and the rear is short by 2", so I need to take them back on Monday.





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Old 03-24-2013, 10:38 AM   #38
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A little update, decided I should do a little more to the rear axle, so I added a couple more brackets to it.


As you can see from the next picture what's it for, this should make loading and unloading a lot easier, especially when things are wet and muddy. There is lots of clearance to the gas tank too.

Also got the t-cases pulled, to get them finished up and painted the rear arms and crossmember.

Got a little frustrated last night while trying to assemble my rear shafts, the split collars wouldn't go on straight, so ended up ruining 1 bearing and 3 collars before giving up. Have done them a number of time on the stock shafts when changing seals, and never had an issue. I wonder if it's got something to do with hardened shafts, as the shafts don't have a mark but the collars keep getting gouged where they start on the larger diameter where they seat. The bearings went on fine, although they don't fit as tight and have a nice radius where they start. I may try cooling the shaft and heating the collars next time to see if I can get them started before putting them in the press, that or having a taper machined into the collars so they start easier. If anyone has any other ideas, let me know.
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Old 03-25-2013, 06:32 PM   #39
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Got the shifters in place and the center console back in. Also modified an existing bracket for 231 cable shifter and made a new shift lever for the 231.



Here are the shifters (the two nuts are to account for the thickness of the transmission), and some of the drain, vent and sight tube (at least the start of it).

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Old 03-30-2013, 04:18 PM   #40
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Ok, since I dropped off most of the Jeep at the sandblasters last week, and I won't be getting it back until Wednesday, or so I thought I'd get back to the rear body section. I pulled all the stuff that's been accumulating on it for the last couple of months off, removed the seats and seat frame and moved it to the working side of the garage. I then thoroughly scuffed up the surfaces with a red scotch brite pad and cleaned it top and bottom with POR's degreaser and surface prep, along with rinsing off with water, luckily the weather was great yesterday so I could leave the garage door open. Then this morning I coated the underside and wheel wells with POR 15 and then this afternoon I did the top with bedliner, Duponts Kevlar stuff. We'll see after everything dries whether another coat is needed.


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Old 04-05-2013, 10:13 PM   #41
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So I got the Jeep back from the sandblasters this week, so I pulled the rear axle back out again and re-assembled it, for the last time. Changed the pinion seal, painted and installed the diff cover and locker actuator guard, installed the new axle shafts and put the brakes and all the lines back on, plus filled it with fluid. Got the spring relocate brackets back on, as well as the shocks and new springs. Then the fuel tank went back in with the new rear antirock sway bar. For now I just have the upper arms attached until I get the t-cases back in, then I'll put the crossmember in and the lower arms. Still need to finish up the fuel line plumbing and wiring, and bleed the rear brakes, then on to the body work, but at least it's starting to get back together.




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Old 04-07-2013, 09:05 PM   #42
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Some more progress over the last couple of days, did a little work on the Dana 300, ran and bled the brakes, ran the fuel line, charcoal canister line and the fuel pump wires then started up the Jeep for the first time in months, didn't run it too long as there's no exhaust right now, but at least I know the fuel system works. Installed the 231 case and ran the shifter cable, it works real nice. Then finally lowered the body for the first time to see how much more trimming I need to do still.







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Old 04-22-2013, 09:17 PM   #43
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Did manage to get into the garage last night and put my new shift rails into the 300, ended up having the rear rail notched so I can go into FWD 4Lo and had a whole new front rail machined out of stainless bar stock. They made a pattern so if anyone needs one, I can get more made. I'll post picture later when I get home. Tonight I want to get the t-case finished and installed, but we'll see if time allows.
Pics from yesterday.

Also made a wedge out of one of the old shift rods to help put the detent springs in place

With the NWF shift plates mocked in place

Bolted in with loctite on the threads
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Old 04-22-2013, 09:22 PM   #44
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Got the 300 all done, although with a couple small issues, and installed. Put in the lower control arm crossmember and arms as well as adjusted them for length. Also put the rear driveshaft in place. So basically got the rear end buttoned up.
First the issue with the 300, the rebuild kit I got from Advanced adapters came with a new intermediate shaft, except that the shaft is a few thou larger and wouldn't fit in the case or in the intermediate gear without a lot of effort. Also as can be seen the o-ring groove is way too small to fit the supplied o-ring.

So I ended up installing the gear with the old shaft, which was still in decent shape, so not too big a deal.


Here is a pic of the single lip seal the kit comes with (right) and the double lip seal I bought (left). I ended up doubling up on the seals just to make sure I had no leaks with the single lip on the outside to act more like a wiper seal for dirt.

One

and two

Everything installed

Will have some interference with my old tranny crossmember and the shifters, so that's got to change, not exactly sure what I'm going to do, but I have a couple of ideas.

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Old 04-24-2013, 07:24 AM   #45
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Ugg, last night was a two steps forward 3 steps back kind of night. Put some better tube with qucik connects on the sight tubes for the t-cases, got the shifters for the 300 hooked up, although they are really stiff, but no oil yet so that might be part of it. Then I filled the 231 up and it started to drip back out between the 300 and adapter ring and then had a Homer moment when I realized I hadn't put any silicone between the ring and 300, so I took everything apart again. Tonight I hope to get it all back together, but first I'll peak inside the 300 again to see if there's anything preventing the shifters from working smoothly, although I've been told they are a little stiff anyway, so probably OK.
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Old 04-24-2013, 10:41 AM   #46
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wow great work can't wait to see more
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Old 04-25-2013, 03:51 PM   #47
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Wow, that is an impressive amount of work! I wish I had that much time and money on my hands. Lol

Great build so far!
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Old 04-30-2013, 06:26 AM   #48
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OK, so got the t-cases buttoned up, the rear suspension back together and no leaks this time. Driveshafts are in and the tranny crossmember is removed, just have to decide on what direction to go. The weekend was spent on installing the roll bar and various bars as well as putting the new Bestop NX softop on and making sure it fits.



Then I started welding up the body and fitting my corners.


It's not the prettiest but it will all get covered anyway.
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Old 04-30-2013, 08:13 AM   #49
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thats awesome!
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Old 04-30-2013, 12:46 PM   #50
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Quote:
Originally Posted by htkrph View Post
thats awesome!
Thanks, it's coming along, 2-1/2 weeks until Rausch Creek
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Old 05-05-2013, 08:14 AM   #51
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So got a lot accomplished the last few day. The body work is all done, got to be the worst part. The fenders are welded up and the center skid is modified to fit the doubler.






This week I've got to get the exhaust done, finish some painting, splice the electrical in and install the lights. Also the rear bumper and rear seats can go back in once I bed line the last of the tub.
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Old 05-06-2013, 08:47 AM   #52
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Looks good.
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Old 05-06-2013, 08:16 PM   #53
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Sunday I got the wiring mostly done, just two more wires to finish off and some wires to wrap up. Also got the bedliner done on the rest of the floor and then the rear seats installed. Put the back bumper back on and put the left fender on for the last time. Today I dropped it off at the exhaust shop to get that completed. Overall a very productive weekend. Not sure how much I can get done this week with other stuff going on, but I should have all of next weekend to work on it and get it finalized. 11 days and counting until Rausch Creek.


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Old 05-09-2013, 09:42 AM   #54
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I picked the Jeep up yesterday from the exhaust shop, a little concerned with clearance over the axle, but it might work, otherwise they'll fix it. Has a code right now, but may be just because the rear O2 was unplugged at one point, I'll check it tonight. Got the right corner painted and holes drilled, have a little to do on the body side, hopefully tonight. Installed the main skid plate so I can measure for the cover between it and the crossmember. Also picked up the steel, 4"x2" 3/16" wall tube, for the side steps, which will be worked on this weekend. I can't wait to get it on the road for a test drive though.
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Old 05-10-2013, 06:12 AM   #55
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Got the right side corner all done yesterday and then took it for a bit of a drive, almost forgot to bolt the drivers seat down, but did do it. Drove nice, put the top on but left it down for a nice cruise, was good to get it out, now if I could only find my shift knob, it seems to have walked away. Was going to drive it in to work this morning but it was raining and I didn't want to get it all wet and then have to work on it this weekend, so I took the car. Found two codes, one for upstream O2 shorted to power and one for e-fan, which I don't have. Looked at the O2 and the connector was loose, the lock's broken, so I plugged it in and started the Jeep after clearing the codes and it didn't come back right away, so we'll see. I'll zip tie it together for now and see what happens, but otherwise I think I have another O2 that I can change out. Also did an oil change since it was warm, it was almost 2000 km since the last one, that was July of 2011, I've got to put more miles on this year, good thing I use a full synthetic oil.
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Old 05-12-2013, 07:36 PM   #56
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Got almost everything done this weekend, at least that's needed before next weekend, because a Jeep is never really done. Built and installed the sidesteps/rock guards, put the boot and knobs on the t-case shifters, put the hi lift on and spare tire, ran the wire for the CB antenna and re-installed the center console, soldered the wires for the backup lights but ran out of convolute. Tomorrow I'll get the last two pieces of steel I need so I can finish the skid extension and the rear cargo cover.






I did put labels on the shifters, but forgot to take a pic after that
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Old 05-16-2013, 07:09 PM   #57
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So all ready to head to Rausch Creek tomorrow, finished up loading and a few small final pieces. Got the last piece of 1/4" plate for a little skid plate extension under the 300, I may still make the transition smoother, but for now it should do. Also picked up some hood bumpers as I was tired of the metal on metal rubbing of my hood on the fender.



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Old 05-23-2013, 07:47 PM   #58
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Well I got some pictures from Rausch Creek. Unfortunately I am now in the process of pulling the t-cases as I couldn't get the front output to go into gear, it would partially engage but wouldn't stay engaged as if it couldn't get past the detent ball on the rod. I ended up running the weekend in rear wheel drive, so I had to skip some of the more extreme trails, but I rode with my buddies or walked along as a spotter. Did have a chance to see how the 4:1 worked and how the rear suspension behaved. It's amazing what you can still go through with a locked rear axle.
A little poser shot to check for any issues before the start of the day, the front is fully articulated but I still have 2-3 inches of travel left in the rear, most likely due to the rear antirock and no front sway bar.

The first obstacle were I realized I wasn't getting the front to engage.

Continuing on


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Old 06-21-2013, 01:44 PM   #59
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Well I discovered three things last night. First why the front output wouldn't shift on the 300, the set screw that I used to plug the hole for the 4WD switch was set a little too deep and the indent on the shift rod for the switch was hitting it when I tryed to shift . Secondly, that the stainless rod I had made doesn't have enough surface hardness and was wearing (already) where the detent balls run over it. I talked to a couple of buddies in heat treating and after I widen the machining for the 4wd switch and clean up the ball marks I'll have them surface harden the rod. So other than having to take everything apart again, the fixes should be fairly easy and I'll be ready to go wheeling again soon.
Thirdly, I learned that standing working on Jeep parts in a warm garage makes me queasy after donating blood and hour earlier, oh well good excuse to lay on the couch the rest of the evening.
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Old 07-28-2013, 07:00 AM   #60
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Well an update of my last wheeling trip, everything worked well, and a little news on what's coming. Decided to drive the Jeep to work on Friday, checked the tire pressures and topped them off on Wednesday and then noticed this when I came out of work, luckily I have OBA, so pumped it up and got home and ordered me a new set of shoes, hopefully they'll arrive before next weekend and Trailfest. If anyone needs two or three Goodyear Wrangler MTR's let me know, I'm keeping one as a spare. Two are good and hold air and the third is the one with the small cut, that just leaks when it's at the bottom, so would make a good trail spare (especially with a patch).


From the Saturday, when the weather was nice.


and Sunday heading up Greens, when it was a little wetter.




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