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Old 04-21-2014, 01:40 AM   #1
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High School 98 Sahara Resto

On March 12 I bought a 98 Sahara with intentions to daily drive it. I knew the rear upper control arms were broken, but the frame seemed solid enough that i could patch and get away with driving for a while. Unfortunately some time with a hammer revealed that this was not the case.

The following week I started to tear it down for a whole frame swap. As always one thing leads to another. Being on a high school budget I haven't been able to get too crazy as I don't make a significant amount of money.

I bought it looking like so.


It has 107k miles and seemed to run well. Transmission seemed smooth for all 30 seconds I drove it.. Hopefully I don't run into any mechanical issues when it's back together, but if so we'll deal with them.
Found rust under the rocker guards (shocker)

Started the tear down.

Rust in the floor (now fixed)

Bought the new frame. Had to patch a little but otherwise extremely solid.


Painted it

Removed the body and patched rockers

The old



The one side of rails


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Old 04-21-2014, 01:42 AM   #2
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Donor tub


Brackets for coils were bad, I took the top one off the old frame, cut out center, and fit into the bracket on the axle, welded in.


Random mess photo

Small patch on drivers side.

Floor was bad under roll bar.

I used the section from the old tub. Not a perfect fit but close.

Old rails


One side is in. The other is will be done by the end of the week. Have to patch some floors on the drivers side first.

That's all for now.

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Old 04-21-2014, 01:47 AM   #3
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Having Daveys Jeeps under 10 minutes away is a giant advantage.
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Old 04-22-2014, 08:56 PM   #4
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One rail is painted

Going to paint the hole underside before it goes back together.
Driver side floor under roll bar is patched

I'm certainly no professional welder but I think they are pretty strong.
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Old 04-23-2014, 08:58 AM   #5
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Looking nice
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Old 04-23-2014, 09:16 AM   #6
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Davey's Jeeps is definitely a huge advantage. I would kill for something like that out west. Looks good so far especially on a high school budget. My high school budget was usually, "yeah, that's not getting fixed.... ever."
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Old 04-23-2014, 11:29 AM   #7
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Thanks
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Old 04-23-2014, 11:31 AM   #8
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Davey's Jeeps is definitely a huge advantage. I would kill for something like that out west. Looks good so far especially on a high school budget. My high school budget was usually, "yeah, that's not getting fixed.... ever."
Haha thanks. It is great. Unfortunately all my money from work goes toward the Jeep. Yeah i didnt really have a choice on this one
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Old 04-26-2014, 09:51 PM   #9
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Got the front axle on and swapped over motor, trans, transfer case.



Just need to take the bumper off and then off to the scrap yard.

Body may go on tomorrow.
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Old 04-27-2014, 08:52 AM   #10
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Geez those rusted frame pics make me wince.

Good job taking matters into your own hands getting your Jeep back to new. Keep the updates coming. We are looking forward to seeing the Jeep "healthy"
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Old 04-27-2014, 02:59 PM   #11
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Impressive. The good news is you know that jeep from the frame up. Hope you picked that up on the cheap, that's a lot of work.
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Old 04-27-2014, 08:49 PM   #12
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Geez those rusted frame pics make me wince.

Good job taking matters into your own hands getting your Jeep back to new. Keep the updates coming. We are looking forward to seeing the Jeep "healthy"
Thanks! It has been a cool project. Quite the learning experience.
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Impressive. The good news is you know that jeep from the frame up. Hope you picked that up on the cheap, that's a lot of work.
Thanks! Yes I there isn't anything I'm scared to tear apart now. One of the last vehicles I owned my dad and I rebuild the motor and transmission... Hopefully that knowledge isn't needed here.
I got it fairly cheap..... Not cheap enough really when you consider the work. On the plus side I have way under what it's worth into it... That is once it's finished.
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Old 04-27-2014, 08:57 PM   #13
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Got all my brake and fuel lines run today. Torqued all my suspension. I fabbed up the exhaust mount on the trans mount since I went from a 98 to a 2003 frame. I had to relocate one hole for the steering box since they are different between those years too. I got the body on today.

Old stuff ready to be scrapped
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Old 04-27-2014, 09:15 PM   #14
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I'm from Il and all about that nasty salt, you are doin some good work!
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Old 04-27-2014, 09:45 PM   #15
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I'm from Il and all about that nasty salt, you are doin some good work!
Ouch i bet it's bad there too. It's kind of crazy how fast they go. Thanks!
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Old 05-10-2014, 11:02 PM   #16
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Doesn't look much different, but a lot more hours in and it's running. Going to test drive it tomorrow.

No more rust.. exciting.
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Old 05-11-2014, 08:01 PM   #17
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Test driven today. Pretty much finished.

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Old 05-12-2014, 06:52 AM   #18
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Nicely done. It's good you can now get to the fun part of owning a Jeep
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Old 05-12-2014, 02:06 PM   #19
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Nicely done. It's good you can now get to the fun part of owning a Jeep
Thanks! Looking forward to it. I need to figure out something for the door switches. I think i want to get a switch for the dash. It may have some little bugs but seems good so far. Before i started driving my transfer case was almost empty. Will have to keep an eye on it
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Old 05-12-2014, 02:42 PM   #20
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Thanks! Looking forward to it. I need to figure out something for the door switches. I think i want to get a switch for the dash. It may have some little bugs but seems good so far. Before i started driving my transfer case was almost empty. Will have to keep an eye on it
Definitely check the fluids and then make sure you don't have a bad seal. That would suck since you just rebuilt the damn thing.

For your doors, honestly, I would just stick with the good old manual locks. You should do a dash mod
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Old 05-12-2014, 10:14 PM   #21
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Definitely check the fluids and then make sure you don't have a bad seal. That would suck since you just rebuilt the damn thing.

For your doors, honestly, I would just stick with the good old manual locks. You should do a dash mod
Yeah would have been easy to look at the tcase then... oh well. It hasn't leaked any yet. I checked every other fluid. Seems the rear end may be popping... wondering if it needs additive for trac-lok
Oh I meant for the dome light so I can turn it off.
I actually got an ok photo of it.
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Old 05-12-2014, 10:40 PM   #22
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Great work young man....you should be proud of yourself for sure!! Good job from one buckeye to another!
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Old 05-13-2014, 06:58 AM   #23
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Yeah would have been easy to look at the tcase then... oh well. It hasn't leaked any yet. I checked every other fluid. Seems the rear end may be popping... wondering if it needs additive for trac-lok
Oh I meant for the dome light so I can turn it off.
I actually got an ok photo of it.
Some trac-lok will make it run smoother usually. Do you happen to know if you have synthetic gear oil? Reason I ask, is because most synthetic differential fluids have a limited slip/trac-lok already added. If that's the case, you may want to pop open your rear axle and check that everything is running smooth with no signs of grinding and wear.
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Old 05-13-2014, 08:00 AM   #24
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Great work young man....you should be proud of yourself for sure!! Good job from one buckeye to another!
Thank you! I am very happy with it!
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Some trac-lok will make it run smoother usually. Do you happen to know if you have synthetic gear oil? Reason I ask, is because most synthetic differential fluids have a limited slip/trac-lok already added. If that's the case, you may want to pop open your rear axle and check that everything is running smooth with no signs of grinding and wear.
Not sure what's in it. I'm going to probably change it at the end of the week and go from there.
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Old 05-13-2014, 08:11 AM   #25
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Not sure what's in it. I'm going to probably change it at the end of the week and go from there.
RP 75-90 or 75-85 is some good stuff. Expensive but you are paying for quality and efficiency.
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Old 05-13-2014, 09:38 AM   #26
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mighty damn impressive! i'm very close to you too, I got my 98 about a week ago, already been to Davey's and planning more trips out there soon!
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Old 05-13-2014, 03:12 PM   #27
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RP 75-90 or 75-85 is some good stuff. Expensive but you are paying for quality and efficiency.
I'll look into the Royal Purple.
Thanks!
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mighty damn impressive! i'm very close to you too, I got my 98 about a week ago, already been to Davey's and planning more trips out there soon!
Thank you! Where are you located? Davey's is a great place and he's a great guy to do business with.
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Old 05-13-2014, 06:55 PM   #28
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I'll look into the Royal Purple.
Thanks!

Thank you! Where are you located? Davey's is a great place and he's a great guy to do business with.
I'm in Youngstown - but I work in Salem
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Old 05-13-2014, 09:36 PM   #29
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I took it on a trip today with the top and doors off. The rear diff is definitely making the noise. It has to be the LSD. Will get new fluid in it Friday. That's the only issue I have found. Suspension and steering are tight. It may need an alignment but working at a dealership will help me get that done I still need to get the rocker guards on and get the A/C charged. I'm going to have the interior detailed this summer. I'm also going to get new fenders, get the flairs repainted, and fix the back corner rust and get corner guards painted body color.
Davey at Davey's jeeps thought mine was lifted until he looked at suspension. I'm not sure why it sits higher than most.




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I'm in Youngstown - but I work in Salem
Awesome. It's great being so close to so many jeep parts!
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Old 05-13-2014, 09:56 PM   #30
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It's probably exciting listing all your future mods you want to do after taking so much time to fix that frame rot

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