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Old 04-18-2014, 06:20 PM   #1
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TK's Yellow Krait LJK Buildup

So as I update this I will copy paste the exact updated from Jeep forum onto here as well.

So I will start my build thread on here... incoming dump of pictures from the start of this LJ's career with me! Here we go folks, please keep all hands and feet inside your chair at all times, and enjoy the ride!


I just turned 17 and got my license. My parents gave me their yellow jeep. This was little over three years ago.



I really did not like the yellow, I felt like a girl driving this jeep. I was not familiar with the offroad world nor did I care at the time. I took care of my jeep keeping it clean and shiney.




I decided to test its offroad capabilities



Then my Dad asked me if I want a lift kit. I figured why not, not realizing what I was about to get myself into. Here is a stock jeep lifted 4".




Then came the tires and wheels, 33" KM2 and some platidip.



Then came the front bumber customized to my likeing



Then I went on my first wheeling trip with the guys over at wranglerforum. Went to Last Chance Canyon and had a blast. Figured I needed a OBA asap.

With the help from Jerry I was able to piece together a York and get it up and running on my jeep with air outlets in the front and back.




__________________
Yellow 04 LJ 4spd Auto:
-HPD30 w/ Aussie Locker, Alloy USA Chromoly Axles, RuffStuff cover, Reinforced Tubes, 4.88
-D44 w/ limited slip
-1 Ton Crossover Steering w/ Hiem Joint ends
-33" BFG KM2

My Build Thread
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Old 04-18-2014, 06:20 PM   #2
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Of course how can you forget the big air horns?!?!?




Then I got myself a smittybilt rear tire carrier and a winch up front, then went wheeling to Calico with wranglerforum.




All of a sudden loss of power. WTF. Drop the cats and discover this.




Went out wheeling with wranglerforum to Miller Trail starting in Frazier Park.




How she sat so far looking clean.



Summer shenanigans.





Then I ordered a set of Metalcloak Fenders because I was rubbing my fender wells in extreme flex. (I should have adjusted my bumpstops, oh well).



I did'nt like my custom smitty front bumper because of the ****ty approach angle and it being full size bumper, so I opted for a Poison Spyder Stubby.




Went out wheeling again to Last Chance Canyon with wranglerforum. The V-Notch was filling in with a bunch of sand and was a cake walk. I took the bypass the first time I went and really wanted to do it the second time, but the second time you didnt even need a spotter.



__________________
Yellow 04 LJ 4spd Auto:
-HPD30 w/ Aussie Locker, Alloy USA Chromoly Axles, RuffStuff cover, Reinforced Tubes, 4.88
-D44 w/ limited slip
-1 Ton Crossover Steering w/ Hiem Joint ends
-33" BFG KM2

My Build Thread
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Old 04-18-2014, 06:21 PM   #3
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New addition to the family. Dad dropped a Mercedes diesel in the Willys along with a suzuki samurai transfer case, he is in the process of restoring it still.

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Yellow 04 LJ 4spd Auto:
-HPD30 w/ Aussie Locker, Alloy USA Chromoly Axles, RuffStuff cover, Reinforced Tubes, 4.88
-D44 w/ limited slip
-1 Ton Crossover Steering w/ Hiem Joint ends
-33" BFG KM2

My Build Thread
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Old 04-18-2014, 06:22 PM   #4
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Went out to Gorman with some old High school friends who also has a Jeep and a Toyota 4x4. Testing flex on the staircase.



While we were out there, I was stupid and driving too fast on a sandy trail with aired down tires and disconnected swaybars and this happened. Not my favorite moment but a learning experience.





We had 10 people with us that day, so with 10 people we managed to flip over the jeep using just manpower. Only damage I had was my windshield frame got dented. Metalcloak fenders were spotless and the rear plastic fenders were dented. I did not roll, I meerly tipped over. Never doing that again.


Then I found a great deal on a HPD30 off CL. 4.88 gears, Alloy USA Chromo shafts, Alloy USA tube seals, Aussie Locker, Ruff Stuff Diff cover and Ruff Stuff steering kit. All for $500, the catch was that it was setup for coilovers so I had to weld on shock and coil buckets in order to mount everything up.





Well, when I flipped my Jeep, I had to drive it off the trail with a small amount of ATF in the tranny, since it all drained out the dip stick. Turns out a couple months later my tranny died because of my stupidty in trying to drive it off the trail with little ATF. Here is the new 4-speed tranny with only 60k miles on it and here it is being swapped out in the garage. Took me and my Dad 8 hours to get everything to swapped. Those axles on the side are for the willys.


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Yellow 04 LJ 4spd Auto:
-HPD30 w/ Aussie Locker, Alloy USA Chromoly Axles, RuffStuff cover, Reinforced Tubes, 4.88
-D44 w/ limited slip
-1 Ton Crossover Steering w/ Hiem Joint ends
-33" BFG KM2

My Build Thread
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Old 04-18-2014, 06:23 PM   #5
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I have a lot of plans for electrical stuff and I didn't want to pay $500+ for a sPod even though I really liked their concept. So I made my own basic "sPod" I call the TKPod :laugh: I outfitted a box to have 14 fuse holders and 12 relays that will control 12 switches in the cab. All the wires will run as a bundle into the cab including all the power, ground and load wires for each switch. If I want to hook up an accessory to the box, all I do is connect the positive to the appropiate relay wire and connect the ground to the fuse holder ground spots, as well as adding the right fuse to the correct fuse spot and done. Really easy and really simple, it just took a **** load of time to wire everything.

In all I spend around $300 for everything + labor to set it up. In the end I have 12 switches that are independent of the Jeeps electrical system that so far has worked without any problems. Also if I ever get into an accident the switches will be imprinted in my passengers face :shhh:






Bumpstop, locker and flex test to make sure its all working.



Picked up some rocklights that I found people at pirate raving about. Spend $40 and got 25 LED pods in the mail. Also ordered a 10" light bar from lifetimeleds.



Went out to Calico again with the wranglerforum. It was a Meet N Greet so we had close to 80 jeeps at the meetup. We broke off into several groups and started hitting the trails. My passenger side coil kept falling off, so in the third picture I was going into the obstacle with a coil sitting in my passenger seat, and because of that I blew that shock out.






Got myself a new sound system along with a Sony headunit with bluetooth and Sirus radio.



How she sits now.





Hope you guys enjoyed reading the history of me and my Jeep. There were a couple mods that I did add but didnt have the pictures for and had no idea where it went in chronological order from oldest to newest. I will document my build jeep in this thread from here on out. Thank you for reading!

(Sorry if I spelled something wrong, I was trying to type all this out as fast as I could)
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Yellow 04 LJ 4spd Auto:
-HPD30 w/ Aussie Locker, Alloy USA Chromoly Axles, RuffStuff cover, Reinforced Tubes, 4.88
-D44 w/ limited slip
-1 Ton Crossover Steering w/ Hiem Joint ends
-33" BFG KM2

My Build Thread
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Old 04-18-2014, 06:23 PM   #6
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So I have big plans coming up this summer. I wanted to go to 37s and bigger in the future but I didn't really know when. So I finally decided that I will save up my money and do it all at once during the summer when I have no college. My jeep is my DD so I can't have the jeep sitting in the garage being built while im still going to school.

Here are my plans for summer:

- JKRubi Dana 44 front and rear
- Front Axle Beef Kit (Gussets, Clamshell, Clayton Bridge)
- Ruffstuff Panhard Kit
- Ruffstuff 1 Ton Steering Kit
- Clayton Long arm 3 Link Front
- Clayton Long arm 4 Link Rear
- 1.5" stretch in the front
- 1" Stretch in the back
- 37" MTR/K
- Coilovers
- Currie AntiRocks

So as of now I have the Rubi JK axles being shipped to me now from a doner rubi that was burnt. That I picked up for so cheap that it might be considered stealing.

Couple days ago I picked up 4 remote resi 14" King Coilovers for $1500. Person I bought it from bought these brand new but never got a chance to use it on his YJ. He had a pretty neat YJ project going in his garage that he was parting out.




I plan to use the Ruffstuff coilover tower front and rear and outboard my coilovers at the same time in the rear. With the width of the JK axles I should have enough room to squeeze everything in.

I think Ill run out of funds by the time summer comes trying to pick everything up, I might have to roll with stock JK wheels/tires until I can pickup a set of 37 MTR/ks.
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Yellow 04 LJ 4spd Auto:
-HPD30 w/ Aussie Locker, Alloy USA Chromoly Axles, RuffStuff cover, Reinforced Tubes, 4.88
-D44 w/ limited slip
-1 Ton Crossover Steering w/ Hiem Joint ends
-33" BFG KM2

My Build Thread
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Old 04-18-2014, 06:28 PM   #7
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During the summer I'll have my front axle and rear dana 44 with limited slip up for sale. Great time to upgrade the front LP30 and D35 all at once!
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Yellow 04 LJ 4spd Auto:
-HPD30 w/ Aussie Locker, Alloy USA Chromoly Axles, RuffStuff cover, Reinforced Tubes, 4.88
-D44 w/ limited slip
-1 Ton Crossover Steering w/ Hiem Joint ends
-33" BFG KM2

My Build Thread
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Old 04-22-2014, 10:51 PM   #8
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Today my windshield light mounts arrived in the mail. I purchased two 6 LED flood lights....made in china... from a local swap meet for $30 each a week prior.

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Yellow 04 LJ 4spd Auto:
-HPD30 w/ Aussie Locker, Alloy USA Chromoly Axles, RuffStuff cover, Reinforced Tubes, 4.88
-D44 w/ limited slip
-1 Ton Crossover Steering w/ Hiem Joint ends
-33" BFG KM2

My Build Thread
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Old 04-22-2014, 10:51 PM   #9
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I ran into a little problem with fitment. The side bolts lined up just right. But the bolt in the front would not line up. The bolt kept going in at an angle and not catching any thread. So i had to wallow out the hole and repaint so it doesn't rust....

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Yellow 04 LJ 4spd Auto:
-HPD30 w/ Aussie Locker, Alloy USA Chromoly Axles, RuffStuff cover, Reinforced Tubes, 4.88
-D44 w/ limited slip
-1 Ton Crossover Steering w/ Hiem Joint ends
-33" BFG KM2

My Build Thread
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Old 04-22-2014, 10:52 PM   #10
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Got the light mounted

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Yellow 04 LJ 4spd Auto:
-HPD30 w/ Aussie Locker, Alloy USA Chromoly Axles, RuffStuff cover, Reinforced Tubes, 4.88
-D44 w/ limited slip
-1 Ton Crossover Steering w/ Hiem Joint ends
-33" BFG KM2

My Build Thread
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Old 04-22-2014, 10:53 PM   #11
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and some shots of my "TKpod" with 12 accessory spots. Look at the size of those horns...



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Yellow 04 LJ 4spd Auto:
-HPD30 w/ Aussie Locker, Alloy USA Chromoly Axles, RuffStuff cover, Reinforced Tubes, 4.88
-D44 w/ limited slip
-1 Ton Crossover Steering w/ Hiem Joint ends
-33" BFG KM2

My Build Thread
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Old 04-27-2014, 04:41 PM   #12
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So a very unfortunate turn of events... Unbolted the donor Rubi D44s and found out they were both bent. The rear axle has a nice smiley face and the front only has a bent long side tube. Also the axle shafts in the rear were bent a long with the front driver side shaft. All the ujoints, unit bearing, balljoints and calipers were toast.

Also, the stock lockers on the front and rear are toast. The solenoid on the rear locker has broken and the wires have vanished. The front locker still has its wires and solenoid but the locker will not lock or unlock when given power. Seems like a simple locker design, give the elctromagnet power and it pushes a ring that forces the locker to lock, turn it off and it pushes the ring away, however I don't seem to get any power to the locker magnet. Basically the rear axle is trash, and the front axle is rebuildable.

So today I went and picked up a JK Dana 44 rear with 5.13 gearing and a 1310 yoke installed already for $350. SO my rear axle is set, all I need are calipers.

For the front axle, I plan on retubing it in to get rid of the bent tube and to put in a much thicker tube. I will source a used OEM e locker for cheap and add that in along with 5.13 gearing. I will find or order a set of driver side axle shafts, and I plan on buying a used JK Dana 30 and taking all the balljoints, unit bearings, calipers and rotors and swamping them onto my housing. It will be cheaper for me to rebuild it that way then to purchase new everything. Then I will start replacing things that break with new parts as time goes on. And pictures:

So what do I gain and what do I lose from switching to a JK Dana 44 rear instead of a Rubi JK D44 rear? What I lose is the strength of a 8.8" ring gear and a pinion almost comparable to a D60, along with 32 spline axle shafts. What do I gain? I gain a axle that is a lot cheaper, stronger then a TJ D44, a wider selection of lockers, and an option to do a 35 spline upgrade like the Rubi44 in the future. I don't lose much except for strength, which quite frankly, I am not too worried with these axles under a LJ.




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Yellow 04 LJ 4spd Auto:
-HPD30 w/ Aussie Locker, Alloy USA Chromoly Axles, RuffStuff cover, Reinforced Tubes, 4.88
-D44 w/ limited slip
-1 Ton Crossover Steering w/ Hiem Joint ends
-33" BFG KM2

My Build Thread
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Old 05-15-2014, 01:20 PM   #13
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Placed my order with Ruff Stuff on Monday using their Mothers Day sale code of 20% off. All my coilover brackets, steering, and panhard kits come tomorrow!
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Yellow 04 LJ 4spd Auto:
-HPD30 w/ Aussie Locker, Alloy USA Chromoly Axles, RuffStuff cover, Reinforced Tubes, 4.88
-D44 w/ limited slip
-1 Ton Crossover Steering w/ Hiem Joint ends
-33" BFG KM2

My Build Thread
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Old 05-16-2014, 10:51 PM   #14
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Ruff Stuff package came in. 100 LB shipment! Thats a lot of metal! So I got my coilover towers, coilover axle side brackets, GM 1-ton steering kit with the high angle draglink ends, and the panhard kit for the 3 link. Those TRE's and tubes are BEEF, I dont see much that will bend those!



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Yellow 04 LJ 4spd Auto:
-HPD30 w/ Aussie Locker, Alloy USA Chromoly Axles, RuffStuff cover, Reinforced Tubes, 4.88
-D44 w/ limited slip
-1 Ton Crossover Steering w/ Hiem Joint ends
-33" BFG KM2

My Build Thread
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Old 05-17-2014, 08:51 PM   #15
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Today, my Dad and I decided to try and straighten the bent long side tube on the D44. We went to our metal warehouse and bought 3"x.25" Steel tubing to retube the long side and create a clamshell for the shortside. Here are some pictures of the results and how straight it looks.

We cut the bent section off and left some tubes on the ends. Here is the bent section.. it was really crazy bent.




Axle tubes cut with around 3" of tube left and grinded down.




My Dad is in the process of grinding down the tube on the inner C.



The DOM tubing we used.



Using some heat and a BMFHammer we pressed the tube into the stub.



Same concept for the other side.



Made sure the inner C on the long side was at the same angle as the inner C on the short side. We only retubed the long side, the short side will get a clamshell.



Visual check and it is straight.

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Yellow 04 LJ 4spd Auto:
-HPD30 w/ Aussie Locker, Alloy USA Chromoly Axles, RuffStuff cover, Reinforced Tubes, 4.88
-D44 w/ limited slip
-1 Ton Crossover Steering w/ Hiem Joint ends
-33" BFG KM2

My Build Thread
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Old 05-18-2014, 05:08 PM   #16
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Today we took off all the brackets from the JK D44 rear and welded the tubes on the front JK D44.



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Yellow 04 LJ 4spd Auto:
-HPD30 w/ Aussie Locker, Alloy USA Chromoly Axles, RuffStuff cover, Reinforced Tubes, 4.88
-D44 w/ limited slip
-1 Ton Crossover Steering w/ Hiem Joint ends
-33" BFG KM2

My Build Thread
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Old 05-19-2014, 03:54 PM   #17
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Damn nice build. Keep up the good work.
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2000 Jeep Wrangler 2.5L
-Paramount Offroad Zero Flare Front Fenders
-4 33X12.50 Discoverer Cooper S/T
-Fabtech Front Prerunner Bumper With D Rings
-Dana 44 Rear Axle With Upgraded 4.88 Gear Ratio
-Rough Country 4 Inch Suspension Lift
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Old 05-19-2014, 04:02 PM   #18
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Quote:
Originally Posted by luisf14 View Post
Damn nice build. Keep up the good work.
Thank you!
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Yellow 04 LJ 4spd Auto:
-HPD30 w/ Aussie Locker, Alloy USA Chromoly Axles, RuffStuff cover, Reinforced Tubes, 4.88
-D44 w/ limited slip
-1 Ton Crossover Steering w/ Hiem Joint ends
-33" BFG KM2

My Build Thread
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Old 05-21-2014, 08:12 PM   #19
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Im having a hard time figuring out what locker to throw into the front JKD44. I can get the stock E-locker used for around $400 with low miles, or I can choose the other 30 spline alternative and spend around $1000 and grab an OX locker with the electric actuator. What do you guys think?
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Yellow 04 LJ 4spd Auto:
-HPD30 w/ Aussie Locker, Alloy USA Chromoly Axles, RuffStuff cover, Reinforced Tubes, 4.88
-D44 w/ limited slip
-1 Ton Crossover Steering w/ Hiem Joint ends
-33" BFG KM2

My Build Thread
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Old 05-25-2014, 07:35 PM   #20
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For sale post is up for my tires, and axles!

HPD30/D44 w/ goodies & 33x10.5R16 BFG KM2 w/ wheels! Lotsa parts!
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Yellow 04 LJ 4spd Auto:
-HPD30 w/ Aussie Locker, Alloy USA Chromoly Axles, RuffStuff cover, Reinforced Tubes, 4.88
-D44 w/ limited slip
-1 Ton Crossover Steering w/ Hiem Joint ends
-33" BFG KM2

My Build Thread
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Old 05-29-2014, 01:58 PM   #21
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Damn, had me worried there. I thought you were going to sell your wrangler for something else.

Quote:
Originally Posted by tkfx View Post
Im having a hard time figuring out what locker to throw into the front JKD44. I can get the stock E-locker used for around $400 with low miles, or I can choose the other 30 spline alternative and spend around $1000 and grab an OX locker with the electric actuator. What do you guys think?
I would go with the OX locker. Do it once and do it right.
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2000 Jeep Wrangler 2.5L
-Paramount Offroad Zero Flare Front Fenders
-4 33X12.50 Discoverer Cooper S/T
-Fabtech Front Prerunner Bumper With D Rings
-Dana 44 Rear Axle With Upgraded 4.88 Gear Ratio
-Rough Country 4 Inch Suspension Lift
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Old 05-29-2014, 02:04 PM   #22
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Quote:
Originally Posted by luisf14 View Post
Damn, had me worried there. I thought you were going to sell your wrangler for something else.

I would go with the OX locker. Do it once and do it right.
Haha no I dont think ill ever sell this. As far as locker goes thats what ill be doing. I decided on the OX just to do it right the first time. Id want to go ARB but I dont want to upgrade to 35 spline shafts.

My dad posed a good question... "why do people replace the stock locker?" Basically telling me to rethink buying a used factory locker and going for a new replacment.
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Yellow 04 LJ 4spd Auto:
-HPD30 w/ Aussie Locker, Alloy USA Chromoly Axles, RuffStuff cover, Reinforced Tubes, 4.88
-D44 w/ limited slip
-1 Ton Crossover Steering w/ Hiem Joint ends
-33" BFG KM2

My Build Thread
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Old 06-05-2014, 02:36 AM   #23
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So it seems like I wont have enough time to save up for beadlocks by time turdhurdler's event rolls by, so I will be buying some stock JK rims and mounting the 37" MTRs on them instead until I can get some beadlocks. I might also need to get some spacers because the stock JK rims have like 6" backspacing.

Also decided on going with the OX locker for sure. I will be buying the electric actuator for it so I can hook up the locker straight to my switch in the jeep and not have to find a mounting place for the mechanical switch.

As soon as my finals are over for college I will be taking my axles and tires/wheels off, selling them, and buying the remainder of my parts which include: clayton kit, 37" MTRs, and some JK rims off CL. Hopefully I can get this all done for Big Bear.
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Yellow 04 LJ 4spd Auto:
-HPD30 w/ Aussie Locker, Alloy USA Chromoly Axles, RuffStuff cover, Reinforced Tubes, 4.88
-D44 w/ limited slip
-1 Ton Crossover Steering w/ Hiem Joint ends
-33" BFG KM2

My Build Thread
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Old 06-09-2014, 02:15 PM   #24
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I run the factory e-locker in mine and personally I love it. So easy to use/wire up and has not failed me. I'm curious to see how it holds up with the 40s though.

Are you going to run the jk wheels with your current setup? Or with the jk axles. Because if with the jk axles it'll set you roughly back to 4" bs because of the width of the axles.

But if not you'd need spacers anyway with the bolt pattern being difference. I'm sure you know that though.
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Old 06-09-2014, 02:25 PM   #25
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Quote:
Originally Posted by NYGLT56 View Post
I run the factory e-locker in mine and personally I love it. So easy to use/wire up and has not failed me. I'm curious to see how it holds up with the 40s though.

Are you going to run the jk wheels with your current setup? Or with the jk axles. Because if with the jk axles it'll set you roughly back to 4" bs because of the width of the axles.

But if not you'd need spacers anyway with the bolt pattern being difference. I'm sure you know that though.
Id run the factory locker but I cant find any for cheap. At the price im seeing id rather buy a OX and be done with it.

I plan on running the rims with the JK axles. Ill be adding spacers so I have room to mount the coilovers front and rear. The rims will be semi temporary until I can find some beadlocks with 3-4" BS.
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Yellow 04 LJ 4spd Auto:
-HPD30 w/ Aussie Locker, Alloy USA Chromoly Axles, RuffStuff cover, Reinforced Tubes, 4.88
-D44 w/ limited slip
-1 Ton Crossover Steering w/ Hiem Joint ends
-33" BFG KM2

My Build Thread
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Old 06-09-2014, 02:39 PM   #26
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Quote:
Originally Posted by tkfx View Post
Id run the factory locker but I cant find any for cheap. At the price im seeing id rather buy a OX and be done with it. I plan on running the rims with the JK axles. Ill be adding spacers so I have room to mount the coilovers front and rear. The rims will be semi temporary until I can find some beadlocks with 3-4" BS.
400 vs 1000 though.

And I see. Yeah it's tight in there with 4" BS on jk axles with COs. The jk wheels will bring you back to Tj width with 4" BS.
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Old 06-09-2014, 02:40 PM   #27
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400 vs 1000 though. And I see. Yeah it's tight in there with 4" BS on jk axles with COs. The jk wheels will bring you back to Tj width with 4" BS.
In the rear anyway. The front has plenty of room.
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Old 06-09-2014, 02:41 PM   #28
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Location: La Crescenta, CA
Posts: 872
Yesterday I picked up 4 JK rims w/ tires from a guy off JK forum for $75! Ill use the tires as rollers until I get the 37s mounted on. Its a shame that these rims have 6.5" BS because I like the look of them.

Also picked up front JK calipers w/ the frame and pads off a guy from JK Owners. My front axle was missing the brake components and my rear is missing the calipers w/ the frame. So I still need to find a set for the rear.

This build is almost ready to start, ive been collecting parts for 2 months now. The big stuff left to get are the clayton arms, 37 MTRs, and some small things here and there.

Soon™


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Yellow 04 LJ 4spd Auto:
-HPD30 w/ Aussie Locker, Alloy USA Chromoly Axles, RuffStuff cover, Reinforced Tubes, 4.88
-D44 w/ limited slip
-1 Ton Crossover Steering w/ Hiem Joint ends
-33" BFG KM2

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Old 06-09-2014, 02:48 PM   #29
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Join Date: Aug 2012
Location: La Crescenta, CA
Posts: 872
Quote:
Originally Posted by NYGLT56 View Post
In the rear anyway. The front has plenty of room.
I can't find them for $400. All the ones I have found were already sold. Ive been searching forums and CL and have not had any luck. The ones im able to find now are going for 600+. Ive also read people having problems with the lockers not unlocking or locking or the locking plate wearing out ect. so im opting for the OX as an aftermarket replacement.

Also like you mentioned the rear will pose a problem with coilovers since I plan on outboarding the shocks. I'll most likely be returning the rear shock towers I bought from RuffStuff and picking up a set of Poison Spyder rear shock outboard kit which will cut into the frame, that should solve any clearance issues in the rear, and like you said the front has plenty of room to play in.

http://shop.poisonspyder.com/TJ-Uppe.../14-51-010.htm
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Yellow 04 LJ 4spd Auto:
-HPD30 w/ Aussie Locker, Alloy USA Chromoly Axles, RuffStuff cover, Reinforced Tubes, 4.88
-D44 w/ limited slip
-1 Ton Crossover Steering w/ Hiem Joint ends
-33" BFG KM2

My Build Thread
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Old 06-09-2014, 03:35 PM   #30
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Join Date: Jan 2010
Posts: 244
I never realized they were that expensive. I made all my towers. You should opt for custom ones.

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