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Old 11-27-2011, 12:14 PM   #1
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Non-Mechanic & Daughter - YJ Tear Down & Rebuild

OK, so I have spent the last 20 years as a computer jockey turned business man. I am not a gear head nor do I have a huge shop full of tools that would make a Nascar pit crew jealous.

I have always loved jeeps and for most of my life, I have drooled over the awesome jeeps that I see running down the road that have obviously been loved and built up. I never wanted a stock jeep I wanted one that was uniquely mine, that could turn a few heads of her own.

I want to do all the work myself (except paint) to show the everyday jeeper out there that this can be done by a non-mechanic with a little bit of patients and the ability to read. I also wanted to share this experience with my daughter. She is 15 and I do not want to send her out in the world without knowing how to turn a wrench, she loves it and it will be something that we will both remember forever.

Here is what I bought - 94 YJ - 4.0 with 100K on it - 5-Speed - Hard Doors & Hard Top - Stock (almost - PO was bit by the chrome bug).

I have had it for about 14 months and while using it as a daily driver have done a bunch of work to it.

Lifted 2.5 Rough Country
Pulled out Rough Country - put in Old Man Emu shocks
BFG 31's & wheels
Swapped the axels with rebuilt 4.10s stayed with Dana 30/35 for now
Added Soft Top and soft doors for the summer
Replaced Master & Slave Clutch Cylinders
New Iphone capable head unit
Repaired AC unit
Tuned up
Replaced the stock flares.

So now I had a jeep that was starting to look and run like I wanted, but when I did the flares, I realized just how bad the rust was getting and decided it was time to do it all and do it right.

So here comes the build.

After 2 weekends, she is ready for 4 burly guys to lift the tub off the frame. Everything is out disconnected, everything but the tub is ready for paint.

Here is a list of what we are going to do:

Body will be repaired in the rusty areas, and then painted a creamy beige

We will take out the RC springs and put in OME
Clean up the frame - remove all rust and clean and paint
Clean up and degrease the engine bay (we will see about painting)
Convert Gas tank to 20 Gallon
Replace brake lines
Possibly replace drive shaft. (Lots of ?'s here - Hard top, soft top, rear passengers... - never happy with the vibes since the lift)
Anything else we find on the frame and under-carriage

New seats in front from Pontiac Grand Prix
Front and back seats re-upolstered
Door panels/dash pad & console re-upolstered
Paint all plastic on dash
Upgrade speakers in sound bar & front dash (since it is already out)
Bedliner the floor
New Carpet - I want it since it is a daily driver.
Clean & Paint interior and exterior of hard top
Tint Windows of Hard top

New front and rear bumpers with swing-away tire.

I am sure there is manythings that I have forgoten that is on my list or that I may find as I go along, but the best part is that I have started it and I must say, that doing the work with my daughter and seeing the progress is way better than I expected. I can see how an addict is created!

I will keep the pics and the updates coming. If you have ideas or recommendations, please share them. Like I said, I am not a mechanic so share anything you care to pass along!!

I am off to drill out 4 broken bolts and to organize for the tub coming off.

Happy Jeepin - Chris
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Old 11-27-2011, 01:01 PM   #2
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Nice looking YJ.

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Old 11-27-2011, 01:10 PM   #3
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Thanks - hope it is much nicer lookin by Feb 1st.
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Old 11-27-2011, 01:39 PM   #4
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I think it is awesome that you undertook this project with your daughter. When it is all said and done, both of you can look at the product and know that all the hard work paid off and you can't pay anyone to get that type of feeling.

My 5 year old son doesn't know it yet, but the 95 I have will be his first car, if and only if, he has a hand in the rebuild (not necessary yet but I can't leave well enough alone). He won't actually find out until his 16th birthday and I can't wait to see the look on his face when he realizes that he rebuilt his own car.

Keep up the good work and enjoy the rebuild.
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Old 11-27-2011, 01:44 PM   #5
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Nice.

If I were you, I would definitely paint the engine bay. It makes all the pretty underhood toys and upgrades look so much nicer.
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Old 11-27-2011, 01:53 PM   #6
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Looking good

We have a 95
It has been a great project for my son and I
post lots of pic's!
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Old 11-27-2011, 04:45 PM   #7
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Ok, all the busted bolts are out and short of lifting the tub off the frame, disassembly is done. Now we start making forward progress.
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Old 11-27-2011, 06:04 PM   #8
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Yeah buddy. Looking forward to seeing your progress.

I would kill for a garage. Everything I do has to be done in the driveway. Sometimes I would like to spin a wrench or two and not worry about weather.
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Old 11-27-2011, 06:10 PM   #9
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great progress and very cool project.

You dont need to be super skilled just have the willingness to learn. I didnt know anything 10 years ago when I stated wrenching. I'm now knee deep in 3 jeeps and a toyota truggy project plus countless other projects for friends
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Old 11-27-2011, 06:41 PM   #10
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Looking good, I can't wait to get that deep into my YJ i just bought ..
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Old 11-28-2011, 01:06 AM   #11
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Nice build going so far how hard has it been for you to do all of this stuff? And sorry to be one of those people but I need some specs on those rims what kind are they and do you know the backspacing on them they are sharp looking.
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Old 11-28-2011, 05:46 AM   #12
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Quote:
Originally Posted by MoparMuscleFreak
Nice build going so far how hard has it been for you to do all of this stuff? And sorry to be one of those people but I need some specs on those rims what kind are they and do you know the backspacing on them they are sharp looking.
Considering the scope of what I am doing, taking a automobile apart and putting it back together, it is actually very easy. I am taking LOTS of pictures of the way it was assembled before I touch it. Like close ups of the way the door latches work. Pictures of what connectors are plugged into what before I unplug it. The other thing I am doing is using lots of ziplock bags. A new bag for every little area with a post it inside the bag of exactly where it came from written in sharpie. I am being very slow and methodical. I am also taping every bolt and screw back into the connector it came out of so it will make reassembly easier. Other than that the only hard stuff has been 20 years of rust and Torx bolts.

As for the wheels, they are Ion Alloy brand. I got them from quadratec about a year ago for about $90 a piece. I don't know the back spacing on them at the moment - I will find out but I did not order anything special so they are standard. Here is the link
http://www.quadratec.com/products/92616_5X0X_B_PG.htm
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Old 11-29-2011, 03:41 PM   #13
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Can't wait to see how this turns out.

Have fun with your project.
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Old 11-29-2011, 08:42 PM   #14
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i only have one suggestion...............................DRIVE THAT SUCKER TO MY HOUSE, PUT THE KEYS UNDER THE FLOOR MAT AND START HITCHHIKING. WOW, NICE WHEELS.
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Old 11-29-2011, 11:41 PM   #15
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Very impressive project. I bought my 92 a year ago as a project jeep with my 15 year old son. He is now 16 and a half and one month from getting his license. We spent the summer wrenching on it to make it mechanically sound to drive. Next summer, an AX5 rebuild. We bought yellow paint, just rust oleum but I figure some paint is better than no paint and it will look nice after cleaning up all of the rust spots. I also got some air brushes and an air brush compressor and touch up sprayer for bigger spots with a compressor for that too. We have been working on small painting projects this summer to get him used to the process of painting. Next summer we should be getting some paint on it. We are starting with a jeep body that is already in pretty good shape. What you are doing to yours, it seems, someone had done to ours some time ago. So now all we have to do is touch up the rough edges so to speak. This project looks awesome and I'll be book marking it and tracking it. An excellent father daughter project.
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Old 12-04-2011, 01:51 PM   #16
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Well - the tub is finally off and rust repair, clean-up and frame paint is underway. This week we will be sanding and cleaning up the bottom of the tub and getting it ready for the body guys. We did find that the rear body mount under the gas tank filler is completely rusted through and we will have to fabricate something there, any suggestions?? I forgot to take a pic of the mount so I will through that up later.
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Old 12-04-2011, 03:28 PM   #17
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Your project is fantastic! I can't wait to see if finished.

Take care,
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Old 12-04-2011, 04:16 PM   #18
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Good luck on the build! Ready to see it complete!


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Old 12-04-2011, 04:40 PM   #19
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Me too!!!!! I miss her so much. I am being punished, I see one everywhere I go, and I am stuck driving a minivan while she is laid up. Any idea how hard that is!!!!!
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Old 12-05-2011, 01:24 PM   #20
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Doors are just about done!!!!!!
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Old 12-05-2011, 01:30 PM   #21
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Looks awesome. Man I wish I had that kind of garage space!
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Old 12-05-2011, 02:05 PM   #22
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Quote:
Originally Posted by UMD_Jesse
Looks awesome. Man I wish I had that kind of garage space!
This was taken at the shop that is painting the jeep. I am actually working in a small space that I am renting for $200 a month just for this project. Hoping for three months start to finish so $600 is a small price to pay to be able to do this.
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Old 12-05-2011, 02:10 PM   #23
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Originally Posted by HUGICR

This was taken at the shop that is painting the jeep. I am actually working in a small space that I am renting for $200 a month just for this project. Hoping for three months start to finish so $600 is a small price to pay to be able to do this.
$200 a month isn't bad... I have a place around here that you can rent a bay for $50 an hour, course that's with a rotary lift and tool cart, I don't use it but it's nice to have around
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Old 12-05-2011, 04:59 PM   #24
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Very impressive project. I bought my 92 a year ago as a project jeep with my 15 year old son. He is now 16 and a half and one month from getting his license. We spent the summer wrenching on it to make it mechanically sound to drive. Next summer, an AX5 rebuild. We bought yellow paint, just rust oleum but I figure some paint is better than no paint and it will look nice after cleaning up all of the rust spots. I also got some air brushes and an air brush compressor and touch up sprayer for bigger spots with a compressor for that too. We have been working on small painting projects this summer to get him used to the process of painting. Next summer we should be getting some paint on it. We are starting with a jeep body that is already in pretty good shape. What you are doing to yours, it seems, someone had done to ours some time ago. So now all we have to do is touch up the rough edges so to speak. This project looks awesome and I'll be book marking it and tracking it. An excellent father daughter project.
Dude!!! don't pooh pooh the Rustoleum Paint job. I have seen some that look amazing. I did my buddy's Civic with a roller and it looks incredible. I am going to do my Jeep next summer once it warms up.

Check this out if you have not seen it yet:
Rickwrench, Alfa GTV, Falcon Squire, Corvair
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Old 12-05-2011, 10:11 PM   #25
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Dude!!! don't pooh pooh the Rustoleum Paint job. I have seen some that look amazing. I did my buddy's Civic with a roller and it looks incredible. I am going to do my Jeep next summer once it warms up.

Check this out if you have not seen it yet:
Rickwrench, Alfa GTV, Falcon Squire, Corvair
Wow, thanks for the encouragement. I am hoping for (worrying about) a good outcome. I've been spending a lot on mechanical and hoping for the best when we get to the paint. He did do a pretty good job on my rusty old wheel barrow. He picked yellow....that ought to be fun to watch because it is white now. I don't care really how it comes out as long as the rust is in check. I would be nice though is if looks good. I had a young man who worked for me when I was a Boy Scout camp director who painted his with a brush when he did a father son project. Whenever he found a bad spot, it was easy to touch up. I thought it made it look pretty trail worthy....and boy did he put that jeep through its paces in the woods. I had to rescue him once on the scout reservation! That's a whole other story though. I'm not an auto-body guy but I'm going to give a go with my son to get this done.

This project looks awesome. I'm not expecting perfection on my son's jeep but those doors look perfect. Something to shoot for I guess.
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Old 12-05-2011, 10:39 PM   #26
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Wow, thanks for the encouragement. I am hoping for (worrying about) a good outcome. I've been spending a lot on mechanical and hoping for the best when we get to the paint. He did do a pretty good job on my rusty old wheel barrow. He picked yellow....that ought to be fun to watch because it is white now. I don't care really how it comes out as long as the rust is in check. I would be nice though is if looks good. I had a young man who worked for me when I was a Boy Scout camp director who painted his with a brush when he did a father son project. Whenever he found a bad spot, it was easy to touch up. I thought it made it look pretty trail worthy....and boy did he put that jeep through its paces in the woods. I had to rescue him once on the scout reservation! That's a whole other story though. I'm not an auto-body guy but I'm going to give a go with my son to get this done.

This project looks awesome. I'm not expecting perfection on my son's jeep but those doors look perfect. Something to shoot for I guess.
You let him use it on your reservation? We aren't even allowed golf carts now
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Old 12-05-2011, 11:49 PM   #27
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You let him use it on your reservation? We aren't even allowed golf carts now
That was one of those situations....better to ask for forgiveness than permission. Our reservation is pretty big and has a county road through the center of it....that leads to a four wheeling paradise! That young man is in the army now and quite a soldier. Very proud of him.
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Participate in life....Keep movin'....Go there....JK'n it.........Do it! Jeep #1: Red Rock 08 JK Rubicon 4dr, 6 sp manual, Stock Mud Tires, MyGIG Upgrade, Hard Top, after sale BestTop SunRider Soft Top, Congo Cage Rack, Mopar slush mats Jeep #2 Black 08 JK Rubicon 2dr, 6 sp manual, both tops, some chrome...uggg (my wife's jeep) Jeep #3 White 92 YJ (my son's jeep) A great quote from a good friend: "All hail click clack and master jk'n." Click and clack are my idols!
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Old 12-05-2011, 11:59 PM   #28
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That was one of those situations....better to ask for forgiveness than permission. Our reservation is pretty big and has a county road through the center of it....that leads to a four wheeling paradise! That young man is in the army now and quite a soldier. Very proud of him.
Well that's good then, we got our four wheelers taken away, only side by sides, gators, and golf carts now and only on the fire access roads
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Old 12-06-2011, 01:33 AM   #29
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that is an awesome project for you and your daughter, and so far it looks ike you got a good jump on it
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Old 12-06-2011, 08:43 PM   #30
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Some in-progress pics.
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