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Neal5280's Build Thread

10K views 71 replies 10 participants last post by  Neal5280 
#1 · (Edited)
Well since I just finished some of what I would call major enhancements I figured I start a build thread. I am a novice and have decent mechanical abilities. So enjoy, and if you have any questions let me know and I’ll try to answer them!
Got her last August, 2002 Wrangler X 4.0L 52,000 miles for $10,999 bone stock except for aftermarket rims and stereo. The day I brought her home didn’t even go inside before pulling the doors off!



First since I was broke I wanted to make her mine so slapped on some decals. Dog prints for the pups, Broncos vinyl sticker, ZORT and a few Pro-2nd Amendment for good measure.


Next I despised the “milk jugs” and my neighbor works for a Jeep Dealership and got me the end caps.

In December my wonderful wife picked me up a Warn VR8000 for my birthday.
Took until January to mount, just after mounting I also snagged a Hummer in front of my house.


I also changed the lights in the dash to a blue LED.

Next would be bigger mods, I spent a good bit of time and did a lot of research. I finally decided on doing the Metal Cloak arched fenders and 33s. I ordered my fenders March 15th! It took about a week and they shipped. Thru no fault on Metal Cloaks side, I had a hell of a time with UPS shipping the fenders. They changed dates and also stated they attempted delivery when they didn’t. Anyway once I had them in hand I was excited and ready to put a finish on them. I decided to use Rustoleum “bedliner” it is actually more of a slightly textured paint. I gave them a good once over with 220 grit and red scotch bright pads, washed them with acetone and 2 coats of Rustoleum dark grey primer and 2 coats of the bedliner. They are far from perfect but good enough I didn’t care to go any further.
Unfortunately with working graveyards it can be tricky to find time to do work like installing them, add into that the weather in Denver and the fact my garage is too small to do the work. It ended up being a couple of weeks before I could install them. Well Friday was my day, came home got a quick few hours of shut eye and started. My wife came home and I was at this point, she was a bit concerned but kept the faith!


I had to stop due to Friday night pool league. Saturday morning got right to it. I finished in about 4 hours on Saturday and went directly to Discount to get my 33” DuraTracs mounted and balanced. Here is the finished (for now) product and can’t wait to hopefully get out wheeling next weekend!
Finished with 31s


Finished with 33s



I am picking up a new stereo and new speakers tomorrow and will be installing them this week and have LED Tail Lights that I just need to find time to do.
Next up will be rockers, leaning towards Savvy, but need to save up some $$ first. And that will probably be it for this year for major mods.

Still to come 2.5 OME HD Lift, UCF Tummy Tuck, Dana 44/Ford 8.8, Currie Steering upgrades. I am happy she is where she is at for now but already looking forward to the other stuff too!
 
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#29 ·
So unfortunately I've had to put the 8.8 on hold due to some other financial responsibilities. Damn responsibilities... So it looks like I'm gonna test out how far my D35 w/3.73 will take me with 33's.

So I am going to go a head with the spring lift, SYE & DS, MC CA and Track Bar, UCF TT, Lopro mount and engine skid. In the last month I've also picked up a front Currie Anti-Rock and Novak cable shifter. I ordered a set of brown dog 1" MML. I ordered it 2+ weeks ago and had not heard a thing, so I sent an email last Wednesday for an update and they said it would ship in 12-48 hours but I have yet to hear anything back... Good thing they are advertised as the last MM you'll ever need.

I also ordered a front bumper from Barnes4wd.com and will finish and install that and the anti-rock ASAP.

I am hoping to get the new springs, TB, ZJ TR, MC CA's and MML (if it gets here) this next Saturday. Especially since my wife isn't liking my parts pile and I gotta keep her happy if I want to keep the upgrades going :flowers:

It will be a month or two before I can do the SYE and DS but as soon as those are in I'll be putting on the UCF Ultra High Clearance T-Case Skid and engine skid.
 
#30 ·
I really like the looks of your build. You and I have several similar parts and plans.
I am running BDS 2" coils front and rear with a 3/4" spacer up front. The spacer was to compensate for winch and bumper and it did that just fine. With the 8.8 installed, the back end is probably 1/2" higher.
I think your 3" front coils will do well once you get everything dialed in.
After I finish loading my jeep down with the remaining armor and spare tire, I will see if I need to make coil adjustments.
 
#31 ·
Thanks man! I am about half way thru your build and it is awesome so far! It seems like we are taking similar roads :)

I am excited to get some of this going... Parts pile is crazy right now, I wish I had a garage like yours that would be awesome! Also I'd probably be a lot more tired too!

I look forward to finishing up your build thread.
 
#32 ·
So finally got the shipping notification from Brown Dog. Hopefully I'll have the MML in hand early next week. Hoping I get the front bumper soon I am waiting on installing my AR until I do the bumper at the same time.
 
#33 ·
Small update and some progress....

I've received the bumper and MML. I am taking my UCF t-case skid in for powder coating tomorrow got a killer deal on it, I was looking at it last week and didn't feel my painting "skills" would produce good coverage on the top side. I should have that back early next week. I am also set to paint my barnes bumper and UCF oil pan skid tomorrow. As long as everything looks good I'll be putting on the bumper and AR on Sunday. If I have time on Sunday I'll also put on the ZJ TR, also need to replace the TRE at the pitman arm and do the toe in adjustment & center the steering wheel. Then if it's decent next week I'll do the springs, MML, MC rear upper adjustable CAs and front MC track bar. Pics to follow hopefully on Sunday afternoon.
 
#34 ·
Well, baby steps... Got the bumper painted and installed with the anti rock. Initial impressions are that the bumper is perfect once painted it installed without any issue. The AR took a little longer than I thought but was very straight forward. It is set as short as it'll go and I didn't want to trim the rods because I will be putting 3" springs in it in a few weeks. I will adjust at that point. I don't notice much of a change in street behavior with the AR but took it out into some fields and it was a night and day difference, can't wait to get on a trail but no such luck today...

See it did happen :D






 
#35 ·
Antirock is one of my favorite upgrades. Did yours come with the bolt and washer to put on the outside of the arm?? Mine didn't, and last time I was out on the trail, my right side arm fell off.
 
#36 ·
Yea I actually like the feeling on road after driving more tonight. Yea they did bolt, lock washer and larger washer for both ends.
 
#37 ·
Well finally got to work on her a bit a few weekends ago. Got on the Anti-Rock, Barnes Bumper, 3in BDS front springs, 2in BDS rear springs & MC Track bar on and am loving it. I haven't put the winch back on yet hopefully I will get to that this weekend along with new front pads and rotors. I'm hoping to do my SYE/DS, rear adjustable uppers, Novak cable shifter and UCF Ultra HC Skid in the first few weeks of June. Now some pictures :)
Anti-Rock (pictures before lift so angle looks a bit high but is perfect now)


Barnes Bumper


MC Track bar


After lift
 
#38 ·
Did you have to drill anything for the MC Front Trac Bar? I get mine tomorrow according to my track #.
 
#41 ·
Yep have to do 5/8th on the frame side and 1/2 on the axle side. Use good bits the frame side was quite tough. The thing is stout.
 
#39 ·
Looks good man. Question about the Barnes bumper. Is there enough room between the bumper and the frame to drill two holes to mount a license plate??
 
#42 ·
You know I'm not sure when I take it off this weekend to re-install the winch I'll take pictures and post up.
 
#43 ·
Thanks! :beerdrinking: I like it and am going to have fun this summer. By next year about this time I do hope to be on 35s though. Will have to do some axle work before that for sure though. She sure is coming along though.
 
#47 ·
Mine are old but I know that they are carbide tipped. As far as brand I would think that most MAJOR brands will be ok, especially for how much use they'll get. 1/2 you'll use again probably but 5/8 may never get used again.
 
#49 ·
It's been a while but got some updates from the last week... Got the winch all mounted up and replaced all the torx bolts on the bumper. I also replaced the front brakes with centric rotors and EBC Green Stuff pads. The brakes were probably the easiest brake job I've ever done. My floor jack crapped out so I had to use the bottle jack and was done in about an hour from tires up to tires down. Although there are better upgrades for brakes I am very happy compared to what I had. I couldn't have finished sooner no rain was supposed to hit us but we got a hell of a storm less than 2 hours after I finished. No complaints on the rain however. Picture time :)






 
#51 ·
Had a good time yesterday running Twin Cone. Jeep did well, I was happy for the most part but I am really wanting to go up to 35s. Need an new rear end before I can do that... So for now just going to enjoy it and hopefully this winter/spring I can address a few things and be ready for 35s next spring. We leave a week from Wednesday for 5 days in Ouray, very excited for that.

Twin Cone 7-12-14 Photos by neal5280 | Photobucket
 
#52 ·
Got back yesterday from our trip to Ouray, CO. What an amazing area, jeep did great!

Trails:
Black Bear
Imogene
Yankee Boy Basin
Hurricane Pass
California Gulch
Corkscrew Gulch
Treasure Mtn
Picayne Gulch
Engineer Pass
Cinnamon Pass
American Basin







More Pictures: San Juans 7-14 Photos by neal5280 | Photobucket
 
#53 ·
Hey all!

Finally found a TJ rear d44 that isn't priced like it's made of gold (picking up in Kansas) to swap and wanted to ask a couple of questions. I've read a good may posts/articles but am left with the questions below. I'm not going to throw in in right away, because I want to go over it all and make sure thing are kosher. It has the same gearing as my front so I am good there. Over the rest of winter and spring I will be piecing together a locker, alloy shafts and will have it geared in the spring. Then the 35's get slapped on and it's time to play!

Questions:
Is there any difference in DS length?
From what I can tell it is really as simple as control arms breaks then parking break... Anything else to be aware of?

While I have it out and accessible I am going to wire wheel it and repaint and replace the diff cover.

Anything else that I should pay attention to or replace?
 
#55 ·
Thanks Patrick good to know. Well 1041 miles, 17 hours and a d44. Everything spins great no slop in the pinion. Has the sway bar, track bar and the parking brake hardware. The only things I know it needs are a 1 new wheel stud, brake hardware freshen up and fluid. I'm going to start by cleaning the thing up in the next week or so and pulling the shafts and draining the oil. If everything looks good I'll have the new wheel stud pressed in, paint it and sling it under the jeep.

 
#57 ·
Thanks man I appreciate it. I think I found a HP30 for 100 bucks in good working order. I am considering picking it up and making it my winter project but not sure since they are plentiful around here, I may hold off and just wait till spring to grab one. Unless I find a local built one then I'll hop on it... Looking forward to getting this part of the build done, LOL.
 
#58 · (Edited)
Well finally tore into the d44 oil looked recent, gears were correct and not beat up, axle shafts are in good condition. Looks like all I need to do is redo the brakes reassemble and she'll be ready to toss under the jeep ddc4d So now I need to do the SYE and will do the TT at the same time and I'll be ready to put her under the jeep and get a driveshaft. I'll do the ZJ tie rod upgrade next weekend and replace the ends on the drag link and hopefully that'll do it for the mechanical upgrades for this spring. Once this is all done, hello 35's! dde1c I'll finish up my rocker guards and oil pan skid and I'll be ready to rock n roll! Looking forward to a fun summer!





 
#59 ·
Finally getting nice enough to put some work into the Jeep!

I was mildly stressing about the SYE I lined up to have it installed which I thought would be best. One of my buddies talked me out of it and had me come to his shop and walked me thru it, it wasn't nearly as bad as I thought. It took us longer as he was talking me thru it. Also got my MC adjustable rear uppers in.

Next week will be the Novak shifter cable, UCF Lopro mount & UCF UHC skid. Once that's done then I can swap in the rear d44 and be ready to get out and enjoy Colorado!



 
#60 ·
Looking good. What gear ratio are you gonna go with for the 35s?? Our Jeeps are pretty similar..you're just building yours faster than I am!
 
#61 ·
I am going to do 4.88 with ARB or Eaton E-Locker, but I've promised the wife I'll wait till either the end of this year or next spring because of the cost. It may be a rough rest of the year without 5th gear... After the work in progress and the 35's I'll probably be done with it except for maintenance...

We are hoping to be able to move into a bigger house, we've outgrown the house we bought 5 years ago so that could factor into it. But bigger house means having room to do some of this stuff too!
 
#62 ·
Well got the 44 in yesterday. Not too bad all in all took about a half day or so...

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