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Old 07-14-2013, 08:59 PM   #1
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Tub replacement and restoration

I have a 2000 jeep wrangler 4.0. I recently swamped it out and my dad and i got it running good again, so now its time to work from top down and make it into the great jeep it can be! First off, The body is in bad shape rusting out at just about every body mount, so I picked up a new tub for just 475$ (which is a great deal!) it is rust free, the only problem with it is that the PO got in a wreck with his jeep so the front right body mount is a little off set. Other than that, which is a minor fix, it is in great shape! We are beginning to take off the old tub tomorrow and planning to work on it through the summer and put in a few new parts, along with a few mods(: ill keep a build thread and update it through the process(:

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Old 07-14-2013, 08:59 PM   #2
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Started taking off the body today. Got both fenders off, hood, grill, and all the dash along with seats. Not much left till the tub is off and it's only the frame! I'll have pics on here soon(:

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Old 07-14-2013, 10:05 PM   #3
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This is what we started with.

Attachment 272817

2000 Sport 4.0. Looks good in the pic but has a bad case of Michigan cancer. Picked up a southern 03 Rubi tub off CL for $475 so its time for a change.
Removing front clip.

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Attachment 272820



Attachment 272821

Removing steering column and dash.

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Attachment 272825

Chassis with old tub.

Attachment 272829

Chassis with new tub.

Attachment 272828

As you can see the tub was shot. All body mounts were rotted out.

Attachment 272837



Attachment 272841

We restored the frame last summer.
Stay tuned, TheJeepKing will outline some of the upgrades we will be doing during this project. BTW he is my 17 year old son.
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Old 07-14-2013, 10:11 PM   #4
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Looks kinda silly without the pics. Damn app.


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Old 07-14-2013, 10:13 PM   #5
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Old 07-14-2013, 10:24 PM   #6
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While we have the tub off, we figured now would be a good time to replace any parts that need it. We took out the transmission today so we can put in a new clutch. We are also putting in a new power steering gear because the one we have now leaks-_- we plan on taking the frame down to bear metal and painting it all in rustoleum bed liner to prevent it from rusting. The whole tub is also going to be painted in bed liner, I like the way it looks(; while the tubs off we're replacing any bushings that are worn out. Finally, we are ordering Metalcloak arched tube fenders and 6" fender flares to prepare my jeep for eventually running 35's and a lift.
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Old 07-14-2013, 10:29 PM   #7
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Now that's the easy way to pull a tranny. Literally 15 min. Lol
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Old 07-14-2013, 10:42 PM   #8
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We are also going to fabricate two new bumpers for my jeep, right now I'm running the stock ones and we need to beef em up a bit. If you look closely you can see the new bumpers in one of the pictures(:
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Old 07-16-2013, 10:21 PM   #9
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Got the clutch, power steering gear, and front axel u-joints today. Plan on painting the skid plate tomorrow and over the weekend get the power steering replaced. Stay tuned(:
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Old 07-17-2013, 11:09 PM   #10
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Took about 3 hours with a wired wheel getting the rust off the skid plate and painted it with rustoleum bed liner. Also my dad pulled the steering gear when he got home from work, pics coming soon(:
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Old 07-23-2013, 08:16 PM   #11
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So instead of going with the metalcloaks, we've decided we'll probably do a tummy tuck with a flat custom skid plate, and an SYE. Any pics or advice you could give me?
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Old 07-23-2013, 09:02 PM   #12
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Progress is slow because because I'm working 7-12s and the JeepKing works 40hrs plus football and other teenager things.
We did manage to test fit the new tub to the chassis.

Attachment 276641



Attachment 276642

Just wanted to be sure nothing changed in the body mounts between years. Everything lined up good. A few differences we have found are the sport bar mount flanges on the windshield supports are wider on the late model (LM), the hole for the lower shift boot is larger LM, and the rear seats mounts are different. Jeep must have changed the HVAC at some point because the passenger side fire wall EM has a hole for the blower motor

Attachment 276644

and the LM doesn't.
We will need to make a template and make our own hole with the plasma cutter.
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Frame off TJ restore project
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Old 07-23-2013, 09:05 PM   #13
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Quote:
Originally Posted by All Terrain TJ View Post
Progress is slow because because I'm working 7-12s and the JeepKing works 40hrs plus football and other teenager things.
We did manage to test fit the new tub to the chassis.

Just wanted to be sure nothing changed in the body mounts between years. Everything lined up good. A few differences we have found are the sport bar mount flanges on the windshield supports are wider on the late model (LM), the hole for the lower shift boot is larger LM, and the rear seats mounts are different. Jeep must have changed the HVAC at some point because the passenger side fire wall EM has a hole for the blower motor

and the LM doesn't.
We will need to make a template and make our own hole with the plasma cutter.
Damn app.

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Frame off TJ restore project
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Old 07-23-2013, 09:37 PM   #14
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Cool thread, lotsa work ahead but looks like you are nailing it out. A couple suggestions. Por 15 would be a great product for the frame to prevent rust. As much Berliner as you are planning on doing, you would save a ton of money and time buying a kit that comes in gallons or quarts with a gun to spray it. There is a company or two in the vendor section advertising their products. Good luck and looking forward to more.
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Old 07-23-2013, 09:48 PM   #15
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Quote:
Originally Posted by Jeepfixer1 View Post
Cool thread, lotsa work ahead but looks like you are nailing it out. A couple suggestions. Por 15 would be a great product for the frame to prevent rust. As much Berliner as you are planning on doing, you would save a ton of money and time buying a kit that comes in gallons or quarts with a gun to spray it. There is a company or two in the vendor section advertising their products. Good luck and looking forward to more.
Thanks! We are actually hoping it will only take about 3-4 cans of bed liner to do the frame, there's not too much surface to it! The real expensive part will be bed lining the body!
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Old 07-23-2013, 10:02 PM   #16
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The tailgate looks good on the old body! hahaha

Where di you find a new tub at?
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Old 07-23-2013, 10:10 PM   #17
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Found one on CL near my area... It wasn't easy finding a tub that was in good shape. We had to go with the 03' because it was such a good deal and we had been looking for a while
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Old 07-23-2013, 10:23 PM   #18
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I have been/and am still looking for one for a trailer project. Its rough, good find on your part through! Enjoy the rest of the project!
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Old 07-27-2013, 12:53 PM   #19
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Well I couldn't wait any longer to see what this bedliner is gonna look like on my jeep! So I painted one of the doors today, pics coming soon(:
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Old 08-06-2013, 12:23 PM   #20
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Got my passenger door all painted, painted the interior black and the outside with bedliner. Love the results!
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Old 08-06-2013, 12:45 PM   #21
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While he was working on the painting I started on the upper coil buckets. As you can see they are toast.

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I cut that mess off and cleaned up the frame.

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It's now ready for the custom buckets we are fabbing.
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Old 08-06-2013, 01:02 PM   #22
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Old 08-09-2013, 06:10 AM   #23
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Had a good day yesterday. We both finally got a day off together and were able to work on it.
We took the old coil bucket and removed the rusted mounting flange. Then took the original coil cups and welded them to 7" round X 1/4" plates.
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Old 08-09-2013, 06:20 AM   #24
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We then welded 1/4" plates on each side of the frame rail. The new coil buckets were welded to these. Everything was wire wheeled and painted.

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This picture shows how extensively we had to repair the frame.

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Some of it is using Safety Cap pieces and some pieces we have fabricated. Today we're going to fabricate frame tie ins for the rear bumper then the frame should be complete.
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Old 08-11-2013, 07:19 AM   #25
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We fabricated the frame tie ins today.

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3X3X1/4" angle iron welded to the frame and cross member with a 1/4" gusset. Now that the welding is done we were able to finish priming frame. We also got the new clutch installed.
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Old 08-14-2013, 07:00 AM   #26
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Frame is completed. All fabrication is done. The whole thing was stripped to bare metal, primed, and sprayed with several coats of Rustoleum bed liner. Took about 4 cans of BL.

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We have to replace the front axle ujoints, install the new steering gear, trans and gas tank then the chassis will be finished.
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Old 08-20-2013, 07:48 AM   #27
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We were gonna install the trans today so we could finish the the exhaust. Of course when I removed the clutch bearing arm the retainer spring broke. Had to order from dealer.
So we started prepping the tub. As mentioned earlier the LM tub is lacking a couple holes necessary for the EM parts. We made some templates and JeepKing cut the holes in the firewall with the plasma cutter.

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Grinding smooth.

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Fit perfectly.

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Now that the mods to the tub are complete it's prep and bed lining.
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Old 08-20-2013, 08:13 AM   #28
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I recently upgraded to 35 MT/RKs on my rig so swapped my lightly used 33" Duratracs for his lightly used 31" Duratracs. I sold the 31s to a forum member.
To clear the 33s he will need flat fenders. We were originally gonna use Metalcloaks but this build is being done on a 17yro with summer job budget. We were able to get a pair of Smittybilt (:0) XCR no flair tube fenders for $300 shipped from Baseline 4X4.
He also bought new unit bearings and Spicer 5X760 ujoints for the front axle. The rear axle (he's lucky...D44) pinion seal is leaking and the yoke is grooved so he bought a new yoke and seal.
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Old 08-21-2013, 10:42 PM   #29
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Got the new tub all painted today. First I took our palm sander using a fine grit paper to scuff the factory paint up just enough to get the shine off. We then rubbed the whole thing down with isopropyl alcohol. Prep is essential to getting great results! Then my father and I painted the tub in two thick coats. Being sure to get a really thick coat on the floorboard to prevent from wear and tear . I used roughly 11 cans of rustoleum bed liner to cover every inch of the tub, including the underside. Very pleased with the results of the product, so far I have about $105 worth of paint after doing the frame, tub, and doors. Still have the grill, fenders, and hood left. So far I looks great!
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Old 08-22-2013, 07:04 AM   #30
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Received the retaining spring for TO bearing so we installed the trans, tcase, skid and gas tank. Got the exhaust welded up too. Relaced passenger axle ujoint and unit bearing. Looks sweet with those 33s.

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Roads? Where we're going we don't need roads!
Frame off TJ restore project
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