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Old 10-30-2013, 09:51 PM   #1
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'04 Unlimited, 4bt Cummins Build

Hey everyone, I thought I'd share my build with you guys. Its an ongoing project that has taken over a year so far, as I am a full time student and I work part time, so progress can be very slow at times.

I've had a few jeeps in the past, a wrangler, scrambler, and cherokee, but I've wanted to do a diesel swap for a while now, and I decided to go with an LJ for my base. I scanned Davey's Jeep's for a while and finally found a rolled 04' that was mechanically sound, and only had a little body damage, save for the hood, fenders, grill, and roll bar. I ended up selling my cherokee in a hurry and getting the wrangler for a little under 4k







I drove up from Tennessee to Ohio with my good friend and trailered it back down here, getting 12mpg up, and a solid 9mpg back down with his Powerstroke f550, haha.

The overall plans for the build are as follows:

- Cummins 4bt out of a bread van
- Chevy NV4500
- Chevy NP205
- 14bolt and Dana 60 with Detroit lockers out of a CUCV truck
- Clayton Pro series long arms, with 5 inch springs
- H1 double beadlocks, recentered, in 37 inch Goodyear Mt's
- Tube fenders, or Hi-line tube fenders
- Poison Spyder Customs full cage.

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Old 10-30-2013, 09:55 PM   #2
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When I got it home, I began stripping it down, both internally, and externally.



I completely removed the interior, save for the dash.





I'm going to be painting it Metallic Green, one of the colors of the JK. So the body will be stripped to the metal and prepped again to be freshly painted. I also will be eventually have the interior linex'd.

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Old 10-30-2013, 10:00 PM   #3
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This sounds like an awesome build, I'll definitely be watching this one
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Old 10-30-2013, 10:02 PM   #4
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I took out both axles, and sold them for $900 on craigslist.

Sold the engine for $1000

Sold the transmission and tranfercase for $350




I sold the wheels and tires, roll bar, and just about everything else I didn't need, coming close to breaking even with the original price of the jeep.

My cousin has a construction company in VA, and he had his crane down here in TN, helping remove some of the downed trees during the tornadoes here last year. I got lucky and was able to use it to remove the body









Got the two separated, ready to begin work. I'll post a lot more when I get back to my other computer that has all my other pics on it
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Old 10-30-2013, 10:03 PM   #5
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Next up you'll get to see the breadvan extravaganza and how that turned out haha
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Old 10-30-2013, 10:11 PM   #6
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This jeep sounds similar to your plans! Has a Dana 60 rear, 37"s poison spyder goodies
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Old 10-30-2013, 11:23 PM   #7
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Quote:
Originally Posted by wmeyer116 View Post
Hey everyone, I thought I'd share my build with you guys. Its an ongoing project that has taken over a year so far, as I am a full time student and I work part time, so progress can be very slow at times. I've had a few jeeps in the past, a wrangler, scrambler, and cherokee, but I've wanted to do a diesel swap for a while now, and I decided to go with an LJ for my base. I scanned Davey's Jeep's for a while and finally found a rolled 04' that was mechanically sound, and only had a little body damage, save for the hood, fenders, grill, and roll bar. I ended up selling my cherokee in a hurry and getting the wrangler for a little under 4k I drove up from Tennessee to Ohio with my good friend and trailered it back down here, getting 12mpg up, and a solid 9mpg back down with his Powerstroke f550, haha. The overall plans for the build are as follows: - Cummins 4bt out of a bread van - Chevy NV4500 - Chevy NP205 - 14bolt and Dana 60 with Detroit lockers out of a CUCV truck - Clayton Pro series long arms, with 5 inch springs - H1 double beadlocks, recentered, in 37 inch Goodyear Mt's - Tube fenders, or Hi-line tube fenders - Poison Spyder Customs full cage.
nice can't wait to see the final build
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Old 10-31-2013, 08:28 AM   #8
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I waited and scanned all the local craigslists, but no breadvan was found. almost all had the gm diesels, or 350's.

I heard of a website through 4btswaps.com, a place called dovbid.com. They have auctions of vehicles, equipment, etc, and I found several on there. I ended up finding one and getting it for $1800 out the door, not knowing if it ran or what needed to be done. I drove 3 hours with a buddy of mine and low and behold, it started on the first crank, and ran flawlessly



On the way back though, I blew a rear tire, thinking that the engine had blown. But I was pleased to find it was just a rear tire. However, the bolts were seized up and we had to drive 30 minutes to get a cheater bar at a hardware store. We finally got it home though, and I began surgery to get out my prize, the 4bt



Took out the engine and trans, which was an sm456. Then I cut up the entire body in strips, because it was aluminum, and its a pretty good scrap price. Between the frame, axle, and body, and wheels, I ended up getting about $900 for everything at the scap yard. I wend through probably 20 sawzall blades lol.
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Old 10-31-2013, 08:30 AM   #9
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This is the after I started tearing it down. It ran perfect when I drove it home, but since it is already out of the frame, I thought I would go ahead and do a master rebuild kit on it, which isn't too expensive for some peace of mind.

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Old 10-31-2013, 08:35 AM   #10
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The body had some surface rust underneath, and the frame had some pretty bad rust in certain places, as well as trapped inside the rails. It amazes me how some people literally never wash their frame once when they live up north and drive through salt constantly

I began by almost completely stripping the frame of all the brackets and etc, and grinded and sanded most of the rust off. I bought a couple quarts of chassis saver, which you can paint directly over rust.





These are some bad quality pictures but you get the idea





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Old 10-31-2013, 08:37 AM   #11
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I ordered a 1 inch body lift with new body mounts to go on it, as well as the Clayton pro- series long arm kit, brackets from Ruffstuff specialties, Ballistic fab, and an axle bracket kit from Clayton. Some of the pics show that stuff lying on the floor.
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Old 10-31-2013, 08:43 AM   #12
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Here are the axles I picked up. I had to get a chevy dana 60 because the chevy adapter plate on the engine, as well as the transmission, will only allow a chevy np205, which is passenger side drop. But oh well, I'll make it fit.



Beginning of prep work for the Clayton truss, and the other brackets.

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Old 10-31-2013, 08:45 AM   #13
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This jeep sounds similar to your plans! Has a Dana 60 rear, 37"s poison spyder goodies
That jeep is beautiful, who's is it?
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Old 10-31-2013, 09:18 AM   #14
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This looks really exciting. I can't wait to see it play out.
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Old 10-31-2013, 10:36 AM   #15
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That jeep is beautiful, who's is it?
A guy from mahomet Illinois last name parker
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Old 10-31-2013, 12:29 PM   #16
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I will follow this build. Looks like it will be great when you finish it. Looks like you are paying attention to every detail.
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Old 10-31-2013, 02:42 PM   #17
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Thanks guys, I hope it turns out well also. My good friend, the one who went with me to get the jeep and the van, is a diesel mechanic at Peterbuilt, and has a few diesel trucks and toys, so he knows his stuff. I have him for backup, lol.

Anyway, I started work on the rear axle, getting it down to bare metal, and measuring, remeasuring, and finally welding the truss on.



The thing is a beast. I am thoroughly satisfied with the quality of Clayton, and their customer service. I had free shipping , and it was here 3 days after I ordered the kit altogether.


Here is the body as of now



I'm completely new to welding, I bought the Hobart 190 mig welder last year, and a bunch of tools to boot. my welding skills are lacking, but I'm learning. Its quite entertaining
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Old 10-31-2013, 02:45 PM   #18
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The axles are also in pretty good shape. They have the Detroit gov lockers, and the 60 has Warn lockouts, so that was a nice upgrade.

My steering kit from ruffstuff just came in the mail today. Its the 7/8ths kit with Heim joints. I also have a track bar kit coming as well. since I ground of the old trackbar mount, I got one that mounts to the outside of the frame, and has an axle offset pointing forward to make room for everything else.

Also, I have a passenger side histeer arm coming in the mail as well from ballistic fab.
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Old 12-12-2013, 09:21 PM   #19
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Sub'd! All I can say is "Intense". Looking forward to your future updates here.
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Old 12-13-2013, 12:19 AM   #20
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This is beyond intense!! Def ready to see this build and the outcome! Big props to you man.
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Old 12-14-2013, 10:05 AM   #21
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Oh man it's been a long time since I've updated and i have gotten A LOT done.

The suspension is almost completely done, and soon the body is going back on. The tires are here, and i have them on the axles as well.

Also, the engine is torn down, the rebuild kit is in my garage, and its going to my friends shop to be re-machined and honed.

And lastly, I'm ordering the cage tomorrow from genright. That's going to be my next step until I get the Cummins back to work on.

Ill pics if the progress either tomorrow or Monday!
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Old 12-28-2013, 09:46 AM   #22
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Well here is the progress so far.












I still have to go through and torque all the hardware, grease the joints, and generally align it. But for the most part the suspension is done now.

I'm not sure yet if I like the Ballistic Fab adjustable shock and coil towers, but I guess I'll find out. I also still need to set up the steering linkage, but I don't think that will be too hard.

I ordered the full cage kit from Genright a couple weeks ago and it won't be here until the first or second week in january they said, so I'm looking forward to that.

The next step is to get the engine off to the shop to get remachined, and to get the body on the frame so that I can start setting the ride height and weld the cage in
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Old 12-28-2013, 09:47 AM   #23
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I do love the wheels as well, they are great quality, even if they did take well over a month to get here...
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Old 12-28-2013, 09:51 AM   #24
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I don't know if I posted this but I picked up a np205 transfer case off of craigslist, the passenger drop chevy round pattern with the spacer, the hardest to find. Boy, the thing is a beast. I already have the nv4500 and bellhousing, so when I get the engine back all I'll need is the clutch, master and slave cylinder, and pedal kit, some motor mounts, and driveshafts and the drivetrain will be set in.
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Old 12-29-2013, 01:24 PM   #25
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Old 12-30-2013, 10:04 AM   #26
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Subscribing. This build is awesome. Keep us posted, it looks great!
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Old 12-30-2013, 11:45 PM   #27
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Got my goal done tonight. I wanted to get the suspension finished and the body back on the frame.









I figure with the weight of the drivetrain, roll cage, and the rest of the interior, it will sit around 3 inches lower in the front and about 2 inches lower in the back. But with the Ballistic fab adjustable shock towers and buckets, I can set it wherever I want. Its sitting pretty damn high right now lol, a little too much for my liking.

But I'm going to California with my girlfriend for New Years and when I get back I start school again. My goal is to have it done, finished, complete, by June.

I gotta lot of work to do. Thanks for the compliments guys!
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Old 12-31-2013, 09:52 PM   #28
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I'm already so jealous ...can't wait to see how this build turns out.
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Old 01-01-2014, 04:53 PM   #29
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Looks great!!
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Old 01-02-2014, 11:23 AM   #30
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Great work so far!

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