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Old 02-10-2015, 10:59 PM
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Ole Rusty

Hey guys! This is my build I have deemed Rusty. You'll find out why momentarily. This will be all of the work I have done up until now. It is a college student budget build. Hope you enjoy!

The first day I got the Jeep from my brother for FREE. It needed a few repairs...little did I know.
[IMG][/IMG

As you can see rust had its way with my Jeep while in its OPs possession.[IMG][/IMG]

I think my name should've been hack job right out of the womb.
[IMG][/IMG]


What was lurking under my rear carpet. It came up from the wheel well and rusted through the underside of the rear corner panel.[IMG][/IMG]

Passenger floor pan was worse than my drivers (no pic for that)[IMG][/IMG]
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Old 02-10-2015, 11:06 PM
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Time for some repairs! Half-assed of course. I am getting better as I go along and learn that is not the way to do things.

Covered everything up so I didn't get rust dust on my seats and dash
[IMG][/IMG]

Then hit each side with a little bit of rust converter. Still holding up 8 months later! [IMG][/IMG]

The hole in the rear corner panel made me worry about how stable the roll bar would be in the event of a crash. I later decided that since the roll bar doesn't even tie into the frame, the sheet metal wasn't doing much anyways.[IMG][/IMG] This has since been covered with fiberglass tape and BondoGlass, but is not flush with the tub.

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Old 02-10-2015, 11:12 PM
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This was possibly the worst day for Rusty and me. After I crawled under and poked those rust bubbles, I almost wish I had never looked.[IMG][/IMG]

After poking and prodding around even more I found the frame was even worse than what the pictures show. After exploring a few options I thought that I should have it welded up. Hundreds later this is what I had.

Mmmmmm...the smell of fresh welds in the morning can be refreshing

I found out a few months later that I wrangler that had a frame as bad as this either should have a frame swap or be junked. At this point I had around $2500 in for transmission work, some suspension work, break components, and welding.
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Old 02-10-2015, 11:16 PM
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With the Jeeps future in question, I decided to build it up slowly and methodically while keeping in mind that it could lose a control arm when I'm least expecting it.

I gave her a little wash down after some mud with the little nephew:


He liked helping out Uncle Pat until the mosquitoes got to him. I was a lone wolf from there on out.
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Old 02-10-2015, 11:17 PM
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Turned 170,000 in Rusty
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Old 02-10-2015, 11:25 PM
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My shocks weren't feeling too good so I decided it was time to replace them. This was the first time I took on a job like this seeing as this was my first car. I was pretty excited![IMG][/IMG] All the gunk build-up inside of the boot. Still trying to decide on taking off or leaving on my current boots

My first Jeep order

Clear coat on the SkyCrappers. I actually don't mind them. Rides better than OEM and I have had no problems with them yet.

After I finished everything up [IMG][/IMG]
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Old 02-10-2015, 11:26 PM
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Promptly after reading about high-lining hoods I saw a Jeep at the gas station with one. I talked to the owner and he sold me his 31x10.5 KM2s for $80..for all four...what a score! How could I resist this meat for $80. Way better than a filet mignon
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Old 02-10-2015, 11:29 PM
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Bed-Lined my front bumper with Rustoleum's extra strength bed liner. I sanded the old bumper down, cleaned it off thoroughly, and sprayed 3 coats of the bed liner on. Looked good for the first couple of months.

About 3 months later it started pealing. It no longer looks good and if I could do it again I would've just repainted the bumper to give it a new shine. I am not sure if I didn't give the bed liner enough to bite on but it looks like I'll be fixing my mistake come the spring.
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Old 02-10-2015, 11:31 PM
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A little doorless ride in the snow[IMG][/IMG]
A wee bit of no lift-snow flex
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Old 02-10-2015, 11:34 PM
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I got sick of looking at this and making the rip worse every time I got in and out of the Jeep so I decided to sew it up.

Before:

After:

I stuffed it up a little due to some foam loss. I should've used upholstery thread but so far so good. As long as it looks better than it used to I am happy.
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Old 02-10-2015, 11:40 PM
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I have been trying to learn a little bit of electrical lately and figured immersion was the best way. Put a little light in the center console with some Autozone White LEDs. The blue in the picture is not an accurate representation of the color or how much light they give off. They're great!



I later neatened up my wiring which I will edit in

Soldered and shrink wrapped my connections.

Now I am waiting on my switches in the mail and also trying to decide if I want to get an external fuse block to run my lights into. I'll be getting more auxiliary lighting and a CB in the coming months and want to have it neat.
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Old 02-10-2015, 11:43 PM
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Today I put poly-fill in the roll bar. I forgot to take pictures but there are a couple threads out there on it. Do I recommend it? Hell yeah I do! The stock roll bar speakers have amazing sound compared to what they used to. I am absolutely amazed with the difference. It took just $6 and 20 minutes and it was worth every penny.

I also removed my front speakers which were blown in preparation for my speakers that I will be ordering in the next day or two
(P.S. That is not rust you see on the floor pan. The rust converter left an orangey film that has been a pita to get off)
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Old 02-10-2015, 11:50 PM
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Got some little mods that I ordered!

I got some generic grab handles for $13 off Amazon and I am surprised with how well they are made.

I got a couple of LED switches for some lighting I have planned in the coming months.

But the most exciting part is my light cubes! $25 for both off Amazon! Surprisingly great reviews and even if they break they were only $25.


I spliced, soldered, and shrink wrapped the connections between the lights and my wiring harnesses from my old smashed up fog lamps


Got them installed but my phone died before I could get any good pictures! Here is one, I'll get more in the morning.
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Old 02-10-2015, 11:56 PM
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I forgot to mention that I have 2" lift coils waiting to be installed. The guy who sold me the KM2s gave them to me for free when he upgraded! I am going to put 1" coil spacers on the front to get rid of some rake that I have going on. I will install the lift myself in the spring. I just want to wait until I am bringing it into the shop that way I can align it and do anything else the lift throws off all at once.

That's all for right now! I'll update with some pictures tomorrow.
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Old 02-11-2015, 06:44 AM   #15
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looking good, that was some nasty chassis, hard to look at haha. Poor jeeps all over hardly 10 - 15 years old and looks worse then vehicles from the 60's. I am repairing the upper control arm mounts for the rear. Keep a eye on it on yours. My chassis was half solid but it ripped the control arm mounts off.

Nice tires!
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Old 02-11-2015, 08:09 AM   #16
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You could get some new fenders off of craigslist and have them painted to eliminate the problem there completly. Looks good though keep treating her right!
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Old 02-11-2015, 11:32 AM
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Quote:
Originally Posted by Nlburden View Post
looking good, that was some nasty chassis, hard to look at haha. Poor jeeps all over hardly 10 - 15 years old and looks worse then vehicles from the 60's. I am repairing the upper control arm mounts for the rear. Keep a eye on it on yours. My chassis was half solid but it ripped the control arm mounts off.

Nice tires!
Thanks! Yeah the thing looked like swiss cheese. It's terrible how the frames rot unless they're protected from the start. I hope that it goes well. I'll take a look under mine as soon as I have the chance, thanks for the warning! I try to be pretty careful with how hard I wheel so I don't rip them off!

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You could get some new fenders off of craigslist and have them painted to eliminate the problem there completly. Looks good though keep treating her right!
My buddy found his brand new, painted black, for $100/each. I'm going to look into that. Thanks!
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Old 02-11-2015, 10:08 PM
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Here are some shots of the new LED flood lights. I haven't had that chance to zero in their aim but they're still looking good so far.

Mounting place on the bumper for now:
I may cut her down to a stubby in which case I'll move them in or put them up on the windshield.

The darkest place in the neighborhood. Can't get much better than this due to the snow blocking all dark paths. Here are no lights on for a reference:


Low beams:


LED floods:



Low beams and LEDs:



I need to do the high beam and fog light mod but my fingers freeze in the negatives we are getting lately. But for $30 after shipping
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Old 02-12-2015, 06:59 AM
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Had the chance to do a little work on my center console this morning before school. Learned some new soldering methods which helped a lot. If anybody has any tips on how to clean up my wiring, if I could've made it more simple, or any issues with the way I wired let me know!




Should've connected my wires a little more neatly, but they'll be under the console and were wrapped properly.


Connected to a battery and gave her a test. I would put the switch somewhere else if I were to do it again, it doesn't sit quite right.



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Old 02-12-2015, 12:14 PM   #20
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You got a lot done already! Looking good. Your soldering looks good from what I can see. A lot of people just use butt connectors so you are already ahead of the curve. Here's how I mounted my switches. Just an idea for the future.
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Old 02-12-2015, 12:57 PM
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You got a lot done already! Looking good. Your soldering looks good from what I can see. A lot of people just use butt connectors so you are already ahead of the curve. Here's how I mounted my switches. Just an idea for the future.
Thanks! I always go solder if I can. I figured this was a good project to gain experience. I love the way you mounted those. Do they sit flush?
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Old 02-12-2015, 03:17 PM   #22
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Thanks! I always go solder if I can. I figured this was a good project to gain experience. I love the way you mounted those. Do they sit flush?
Those type of switches don't sit flush but if you had flush mount switches it would still work.

Another piece of advice for what it's worth. If you use relays, mount them inside the cab. Weather, mud, dirt, etc. beats the Sh%% out of them under the hood. Mounted mine under the steering column on the metal plate that is behind the dash trim. I don't have any pics. Depending on the year TJ there might not be a plate there. Buy a thin piece of sheet metal and use that.
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Old 02-13-2015, 04:53 AM
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Quote:
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Those type of switches don't sit flush but if you had flush mount switches it would still work.

Another piece of advice for what it's worth. If you use relays, mount them inside the cab. Weather, mud, dirt, etc. beats the Sh%% out of them under the hood. Mounted mine under the steering column on the metal plate that is behind the dash trim. I don't have any pics. Depending on the year TJ there might not be a plate there. Buy a thin piece of sheet metal and use that.
That is a great tip and I good spot to mount them! Thanks
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Old 02-17-2015, 05:07 PM
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Finished up the center console light today. Here are a few pics



I actually don't mind where the switch is. Where it is it won't get accidentally get switched on and left on while the Jeep is off since it's wired direct.


It gives off some good light!


Update: I opened up my dash after my heat stopped working for the past two weeks. It had happened before but I had made some temporary fixes. My speed switch finally melted, but I decided I am going to add in relays for the two high speeds, a new speed select switch, and probably a new blower in the spring. I still need to flush the heater core though.
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Old 02-17-2015, 06:36 PM   #25
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Flushed mine with CLR, freakin awesome. It's ok if you let it sit for 10-15 mins and flush it ALL out. (Some say it will eat the aluminium otherwise). My heats hotter than hell now.
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Old 02-17-2015, 09:04 PM
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Flushed mine with CLR, freakin awesome. It's ok if you let it sit for 10-15 mins and flush it ALL out. (Some say it will eat the aluminium otherwise). My heats hotter than hell now.
This is great to hear! I had heard the CLR trick but shied away from it after I heard it could eat the aluminum. Did you just flush it with water multiple times after you used the CLR? I can't wait to have some good heat! Or heat at all really. We haven't been above freezing in the past month and I want to drive my Jeep. Thanks for the info!
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Old 02-17-2015, 09:19 PM   #27
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This is great to hear! I had heard the CLR trick but shied away from it after I heard it could eat the aluminum. Did you just flush it with water multiple times after you used the CLR? I can't wait to have some good heat! Or heat at all really. We haven't been above freezing in the past month and I want to drive my Jeep. Thanks for the info!
I flushed it back and forth about 10 times with the hose, poured the CLR in and
let it sit for 15 mins, and again flushed it back and forth 10 more times. Topped off coolant and let it idle to running temp to get rid of air bubble and had HOT heat again!
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Old 02-18-2015, 01:12 PM
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I flushed it back and forth about 10 times with the hose, poured the CLR in and
let it sit for 15 mins, and again flushed it back and forth 10 more times. Topped off coolant and let it idle to running temp to get rid of air bubble and had HOT heat again!
Hot heat is something I dream of! Thanks for the tips! I am getting started on fixing my melted wiring today and then I'm headed to the store to buy stuff for the radiator flush
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Old 02-23-2015, 10:17 PM
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Just an update:


I ordered a speed select switch and some relays for my HVAC fix that should be here tomorrow. If I have time I will run to the store and get the right sized spade connectors and the right gauge wire for the job. As soon as I can I will start wiring in my relays so that I can run my heat.

Once that is all set up I plan to flush my heater core. However, since it is in the single digits here on average I will probably just blow it out with the compressor for now and then use CLR once it gets warmer. It's impossible to work for long out in these temperatures.

Once it gets a little warmer and I have some extra money I will buy a new blower so I pull less current. After lots of research I have decided that the best way to do things is relays and a new blower as opposed to just building a harness that can handle more current/heat.

This weekend I may be picking up a best top soft top 100% complete with tinted and clear windows for $200. It looked good in the pictures just as he said it was but I hope this kid isn't BSing. Lightly used, maybe it's just a good deal! Either way mine leaks like a siv and new QTec skin will run me $309 so we'll see how this goes!

I'll try to get some stuff done this week and over the weekend!
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Old 03-02-2015, 01:10 AM
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I've been pretty busy lately with school but have had the chance to get some wiring done. I have the heat 80% wired up and I am hoping to get it finished tomorrow. I got my new speed switch yesterday which means my wiring can continue! I also scored a used pair of kickers from a buddy of mine for free that I'll put in the dash. I was going to run 5.25" but I got these for free. Not sure if they're 4x6 or not as they came out of an 03 and I'm not sure whether or not those had the same size speakers.

If anyone has any questions on the HVAC wiring just PM me. I think I have a fairly good understanding of it as of now! I'll try and post up some pictures I have tomorrow.

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