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Old 03-31-2014, 03:41 PM   #1
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2 Weeks to EJS, Change of plans JcrOffroad JKU Build-up!

We've been working away on two Jeeps to take to EJS and Jeep Beach; Project Crusader and Project Maul Hauler. We finished Crusader, but we've been strung out on parts from a certain vendor and now we have to go with plan B. We have two weeks to get this Jeep ready for EJS and Jeep Beach and the 4800 mile journey.

Here's a behind the scene video of Plan B!

~Brian

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Old 03-31-2014, 05:31 PM   #2
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The lift we will be using on this Jeep showed up today! It's a pre-production J-Spec lift from JKS Manufacturing, which we were lucky enough to get our hands on and try out!



The coolest part about this new lift, are these super slick Dual Rate coil springs! I'm really excited to see how these suckers ride. We went with the 3" kit, which we are hoping to fit 37's with some fender trimming.



~Brian

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Old 04-01-2014, 04:04 AM   #3
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Those coils look sweet. Wonder what the price point is going to be for those kits. I know JKS can be pricey. Not sure about J-Spec.
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Old 04-01-2014, 05:14 AM   #4
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Those coils look sweet. Wonder what the price point is going to be for those kits. I know JKS can be pricey. Not sure about J-Spec.
We were given no more info then what it is and what it features. This kit was designed to be a high end kit.
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Old 04-01-2014, 07:11 AM   #5
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Probably would have been smarter to start with a Rubicon, but figured my wife didn't need it to haul kids to daycare! So out with the D30....



And in with this completely amazing Tera44 front housing! If you are not familiar with the Tera44 housing, they are awesome! The craftsmanship is top notch and Hand-Built right here in the USA. Kudos to TeraFlex for making such a great product! :thumbsup:



Now, it's time to get this front end back together and lifted!



~Brian
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Old 04-01-2014, 04:23 PM   #6
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We've got the TeraFlex Dana 44 housing hung, new ball joints installed.



Ripped out the rear axle, swapped with a geared Rubicon Dana 44:



More to come, going to be a long night!
~Brian
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Old 04-01-2014, 07:07 PM   #7
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Rear Rubicon Axle with 4.88's installed, along with the rear JKS J-Spec suspension lift! You can see the carcass of Maul Hauler in the background, some day maybe we'll get the parts needed to finish the LS swap. :endrant:



Added a TeraFlex rear diff cover to match with the front housing:



While Daryl is slaving away getting the drivetrain and suspension together, I decided to lend a hand by installing some JcrOffroad Classic Sliders! Probably one of the easiest things to install on this entire Jeep! haha. But hey, it all has to get done

Fresh back from the powder coater!


Easy Breezy!


Just to give us an idea of what this beast is going to look like on the 37" Toyo's, we put the front on jack stands and installed the rear tires! I hope is settles some, but we'll see once we get some armor and bumpers on it!





These Toyo Open Country MT's are some sexy tires! The best part, they are made in the USA!



Well, that's all for tonight! More to come tomorrow!
~Brian
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Old 04-01-2014, 07:11 PM   #8
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Looking good Brian!
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Old 04-01-2014, 07:16 PM   #9
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You are screwed??? Nope.....I am the one that is screwed! Ya'll are spending all of this time and energy to get ready for your trip that my Vanguard Bumper that is on order is probably not being made right now.......

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Old 04-01-2014, 07:16 PM   #10
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BTW - loved the video!
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Old 04-02-2014, 10:25 AM   #11
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With the Rubicon axles now installed, we only needed a Rubicon T-case to make this thing a full on Duplicon (or Doppelcon, Copycon)! Since this JKU is an Auto, the donor had to be 2012-2014 Rubicon with an Auto. Yep, good luck! Fortunately, I did have some very good luck and found a totaled 2012 Auto Rubicon at a Honda Import Junkyard! $1200 shipped, no core. Very happy with that.

Big goofy input shaft is what makes this not play with the previous Autos or Manual transmissions.




Took me just over an hour to get the old case out and the new Rubicon case in!


Next up; driveshafts and finish assembly of front axle!
~Brian
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Old 04-02-2014, 10:29 AM   #12
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You are screwed??? Nope.....I am the one that is screwed! Ya'll are spending all of this time and energy to get ready for your trip that my Vanguard Bumper that is on order is probably not being made right now.......

Don't worry Jancie! We have a shop full of Worker Bee's! This build doesn't slow down our manufacturing at all!


~Brian
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Old 04-02-2014, 11:55 AM   #13
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Walked about to the garage after the last update to find that the Magnaflow Exhaust we order was here!!! This is a complete exhaust kit from the cats back!

The stuff on top is for replacing the goofy 2012-2014 exhaust loop.



Here is what is in the bottom box! The rest of the exhaust! A resonator AND a muffler! This stuff is sooooo nice and best part; MADE IN THE USA!



To install the front kit tubes, you will have to cut the down pipe on the driver side. 3" down from the weld on the cat.



Here is all the stock crap, heading to the dumpster, to be recycled into something worth while!

[img]http://www.jcrpics.com/jcrrigs/DogHouse/21.jpg[img]

The front kit installed, much better!



The resonator and mid pipes installed:


Axle over pipe and muffler!


They make another kit that relocates the muffler up under the Jeep. But since I don't want to be in the dog house forever, I thought the milder sounding exhaust system would be the better choice!

[sarcasim]I bet Amy will love the way this sounds! [/endsarcasim]

The entire exhaust system took me just under an hour to install! The quality and fit of this kit is unsurpassed, Magnaflow has this dialed in! If you had to do this by yourself in your driveway, I would say around a 3 hour job to take out the old exhaust and install the new Magnaflow stuff.

Allllllight.....now onto getting the driveshafts installed and front end wrapped up!
~Brian
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Old 04-02-2014, 01:44 PM   #14
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Installed a set of RCV front axles into the Tera44 housing. It's like these are meant for each other, such a beautiful couple!



Stole this image off our FB page as well, same shafts went into Project Dog House!



Bonus, check out this awesome hat RCV sent!!! Hahhahahhahahahaha too funny! The back of the hat says "What's under the orange dome?" I can see this being used for JCR videos in the future! hahaha



For Driveshafts we went with Adam's Driveshafts from Henderson, NV. If you haven't heard of these guys, you need to check them out! Welcome to Adams Driveshaft and Off Road | Henderson, NV We are very picky about our quality around here and it's obvoius they are as well! The craftsmanship on these shafts is like nothing I've seen before. These guys do damn good work! These shafts are out of Maul Hauler and we lucked out that they work in Project Dog House! I've already informed Daryl that Maul Hauler is SOL on Driveshafts! I'm keeping these Adams units!

Stole this from our FB page to show the quality! Note the piece of paper stapled around the shaft, that is James (the owner of Adam's) person email address! Talk about first class customer service!


Rear Driveshaft, comes with both replacement yokes needed (Tcase side, Axle side):



Front Driveshaft, comes with a replacement yoke needed for Tcase skid:



Up next; finish the front end, install some JCR Skids and flex it with a fork lift!
~Brian
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Old 04-02-2014, 02:05 PM   #15
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awesome build
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Old 04-02-2014, 03:11 PM   #16
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Front end back together! It's awesome looking!


Tossed on our Tcase skid and Engine skid, I'm guessing we'll need these in Moab!





While Daryl was taking a break on the front end, I install some Truck-lite LED Headlights. These things are super easy to install, should take you less than 30 minutes! Huge upgrade over the stock headlights!



Installed! Look awesome with the Billet color!



Low Beams:


High Beams:


Now to get this thing down on the ground and outside for a test drive!
~Brian
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Old 04-03-2014, 10:55 AM   #17
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We were able to get the Jeep outside to test drive and check for clearance issues:





Going to need to trim the fenders to run these 37's!

[img]

[img]

[img]

~Brian
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Old 04-03-2014, 12:38 PM   #18
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That is sexy. Keep up the great work.
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Old 04-03-2014, 01:55 PM   #19
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Sweet! Nice work! Where are the bumpers?
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Old 04-03-2014, 03:00 PM   #20
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Sitting at my desk wrapping some things up for Manufacturing and UPS shows up with an overnight package. The box was from Active Grafix, it was a JKU Jeep wrap kit designed for the Jeep! Check them out! https://activegrafix.com/main/



Laid out:


I installed these wraps on Project Crusader:


As well as on our trailer:


So I had plenty of practice! This material is very easy to work with and very forgiving. You can actually stick it down and pull it back up.

Installing Driver side first...




One side complete.


Amy will probably like this addition! Probably will be the only addition she'll like! haha
[img]http://www.jcrpics.com/jcrrigs/DogHouse/47.jpg[img]

Time to get the other side done!
~Brian
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Old 04-03-2014, 03:01 PM   #21
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Sweet! Nice work! Where are the bumpers?
That's the easy part! haha. We'll get them installed today or tomorrow!
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Old 04-03-2014, 05:23 PM   #22
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We were able to get the Jeep outside to test drive and check for clearance issues:


Great build!

Wish I could make it all the way to EJS!


Total noob (well, lift noob) question here:

Doesn't the rear axle need to be moved back? It looks out of alignment now.
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Old 04-03-2014, 05:59 PM   #23
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The stuff on top is for replacing the goofy 2012-2014 exhaust loop.
There seems to be a few varying opinions on those goofy loops. Any concerns running without the loop?

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Tossed on our Tcase skid and Engine skid, I'm guessing we'll need these in Moab!
These look like they cover pretty good; maybe ill finally get some JCR gear on my rig.
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Old 04-03-2014, 08:59 PM   #24
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There seems to be a few varying opinions on those goofy loops. Any concerns running without the loop?)
It's said to balance the exhaust length from both sides. But if you open up the exhaust in the back, it will hardly matter. One less thing to get bashed up, won't may enter with the Supercharger installed.
~Brian
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Old 04-04-2014, 10:25 AM   #25
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Nice Brian ..
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Old 04-04-2014, 05:16 PM   #26
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Making some more progress....

Hood decal:


This box of goodies showed up!




Daryl got rolling away installing the RIPP Supercharger....



Getting there...


Needed some surgery to fit the 37's!



Ripped all the rear flare and inner wheel wells and painted everything black:


Started cutting!


We are running our Vanguard Full Width bumpers on this, so we needed to trim the flares to still look good with a Full Width bumper!


Cutting the Rears:




Back to work!!!
~Brian
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Old 04-04-2014, 06:55 PM   #27
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Sitting at my desk wrapping some things up for Manufacturing and UPS shows up with an overnight package. The box was from Active Grafix, it was a JKU Jeep wrap kit designed for the Jeep! Check them out! https://activegrafix.com/main/



Laid out:


I installed these wraps on Project Crusader:


As well as on our trailer:
I had plenty of practice! This material is very easy to work with and very forgiving. You can actually stick it down and pull it back up.

Installing Driver side first...
One side complete.
Amy will probably like this addition! Probably will be the only addition she'll like! haha
[img]http://www.jcrpics.com/jcrrigs/DogHouse/47.jpg[img]

Time to get the other side done!
~Brian
what front bumper is that!? I want it!!!!
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Old 04-04-2014, 08:07 PM   #28
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Old 04-04-2014, 08:28 PM   #29
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Wow I love it.. that's the exact bumper I'm looking for my 2010.. wish I could afford that!!!! Beautiful !!
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Old 04-08-2014, 08:21 AM   #30
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Wrapped up the installation on the RIPP Supercharger. They also sent us a High Boost pulley, which is only 1 of 3 Pentastar's running it! It makes more RWHP than a 6.0L LS motor!






For the front bumper, we went with our Vanguard Front Full-Width bumper. Figured this would be the best all around bumper for Amy when she gets this back and takes it on urban adventures (read; Grocery store, Daycare, Mall)



Installing the rear Vanguard Full Width bumper, with a pair of cube LED lights!



We installed the Shield Carrier, this way Amy can have one hand operation on the tailgate!



Here is the rear tire stuffed when the fenders trimmed:



Here's a side profile of the Jeep. Rear Bumper installed with Carrier, Wrap done, Fenders trimmed and the suspension slightly settled! We have the front bumper temporarily bolted on, waiting on the Warn winch to shadow our doorstep!



Last part of the update, we installed a Kenwood Nav unit. This will be nice to have on the trip to EJS and then to Jeep Beach!



That's all for now....~Brian

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