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54K views 197 replies 51 participants last post by  staybrutal 
#1 ·
So I had gone the 4 Door Jk route in late 2010 and loved my jeep. However, I was beginning to grow tired of seeing every soccer-mom on the road driving a lifted JK on 35s. Here is a picture of my mall crawler...



I now had a decision to make...lift the JK more and upgrade the driveline or go with a custom build to ensure no one else on the road would have a jeep like mine. Well since your reading this its probably evident the path I chose.

Here is what I started with...a 1999 TJ 2.5L 5 Speed with a 4" Rough Country lift and 33" Falken Wildpeaks




As soon as I got it home I stripped the interior and anything else I thought I didnt need.



Since it was a 2.5L 4 cylinder I immediately took it to my buddy Scott at SBC Offroad for some 4.88 gears.



Once re-geared, Scott and I headed for the mountains for some fishing.



Here is what my first few rides resulted in...



Then I went to Jeep Fest in Jasper, GA and saw a few things in person that got me thinking of a direction for my build...



Seeing this in person, meeting Matt from GR8TOPS and seeing the halfcab jeeps they build in person, and following the threads of chop110 and MCE Jason on this board (along with the other TJ-6 builds) gave me the needed boost to start my build.
 
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#3 ·
Using LJ belt rails as a guide and measuring off the rear of a GR8TOPS extended half cab it took a 24" stretch to get to the JKU WB.



24" extension utilizes sections of TJ frame rails.



Mocking it up...



Overall WB mockup...



Borrowed a 35 off a 10th Anniversary Rubicon to see how it looked. I like it but I'm thinking 37s.

 
#5 ·
Meanwhile back at my place...I picked up this dirty fuel burner. A 1985 Mercedes 300D OM 617 5 cyl Turbo Diesel.

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And started tearing it down for a re-seal and cleaning.

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You can see the garage full of parts accumulating for this build.

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Next up body work and some Poison Spyder parts.
 
#9 ·
Can't wait to see the finished product.
 
#12 ·
This is one of my major inspirations...
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Well I told y'all I wanted 37s...found some Baja Claw TTC on CL for a deal. They will work just fine to kill these stock axles and make way for the JK upgrades.
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Poison Spyder stuff showed up from Northridge 4x4...dont know how they sell it so cheap?!


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Trimmed the rear factory bars off for the half cab.
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#13 ·
Got some 2013 JK Rubicon wheels and adaptors for the lug pattern till the JK axles go in.
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SBC got some body work done...18 gauge sheet metal to match the factory thickness.
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Factory tub top rail sections grafted in with factory LJ belt rails to keep it all looking like it came from the factory this way.
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#14 ·
Dropped off a set of well used TJ Sahara seats at the upholstery shop for a custom re-cover. All the green sections will be replaced with a new dark tan and dark brown tweed to match the jeeps final paint scheme.
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The diesel I bought came with an AX-15 and NP231 I'll be using for my swap. However, they are in need of cleaning and I'm converting the AX-15 to an external slave setup. BTW if your going to convert your AX-15 from internal slave to external be aware you need not only the bell housing but a new front imput shaft cover that accepts an external slave style throwout bearing (this is the extremely brief version!)
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A good bit of my time has been consumed with trying to degrease this diesel and making sure its ready to be put back together and be dead reliable and look good when the hoods opened. After all what good is a cool engine if it looks like crap when you open the hood? Got a pile of seals, gaskets, water pump, thermostat, and hoses ready for it. The aluminized paint I got from the machine shop that cleaned the parts for me works wonders.


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#19 ·
Getting the body work completed.

Inside the cab floor section.
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Custom cab close out and inner fenders. The entire tub will be covered in LineX.
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Underside shots...frame section fabbed up for support.
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Top off...
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#21 ·
More to come.

Custom roll bar in the bed.
Poison Spyder Defender front and rear fender and flare install.
Poison Spyder corners.
Custom full length side armor.
Custom front bumper.
LineX tub.
Desert tan paint.
Install 37s.
Get interior back in it.
Add some Rigid LED lights.

All in the next 3 weeks before RBD at Morris Mountain, AL the weekend of NOV 29-DEC 1 2013!
Hope to meet some of y'all Wrangler Forum guys there!
 
#24 ·
Well I deliberately waited to start posting until some real progress had been made. It will slow down a bit now. I understand slow builds but it does kill me to wait forever on some of these builds! Mainly because most of them are super innovative and I enjoy all the new ideas they share with the forum.
 
#26 ·
Well the template for the side armor is coming along. Armor will be made out of aluminum, run the full length of the side, and wrap under the body with a tie in to the body mounts. The rear corners will be modified Poison Spyder Trail Corners.
The body around the wheel wells will be trimmed to accommodate the 37s with minimal lift.
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