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Old 04-09-2014, 09:58 AM   #1
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90 YJ rebuild

I thought I'd start a thread on the build my son and I are doing on his 90 YJ. We purchased the Jeep in October of last year. It was in okay shape, the PO had just replaced the front floor sections (just the pieces by your feet) and it had fairly good tires and ran well with 108K on the 2.5. We knew it needed some significant body work around the rockers and under the front seats, and the drivers seat back was broken. On the drive home it was also apparent that some steering re-work was going to be needed, I could barely keep it between the lines on the interstate.

Here are the pics of it when we brought it home










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Old 04-09-2014, 10:02 AM   #2
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Welcome to the party. I'm about $1000 into my 90yj.
Love the center console mod. Lol

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Old 04-09-2014, 10:06 AM   #3
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The first thing we did once we got it home was decide that the work woudl be done right away. Since the steering was so bad it was unsafe to drive (in my opinion). We started by removing the interior (throwing away the broken drivers seat) and uncovering the rusted area's under the carpet. We cut out the rusted metal areas and discovered that the PO didn't do a very good job of welding in the new floor area's they replaced. We took out quite a bit of the body to get to good metal.





Drivers side interior floor, notice that the under floor brace that the body mount, seat, and roll bar attaches to is completely gone. Didn't find this out until we pulled up the floor. Also removed on both sides is the lower sections of the vertical support that the seat belt mounts to, a bit more on that later as I had to fab my own replacements for those.


Passenger side interior floor, the rear half of the under floor brace is gone on this side too.


Scrap pile after day one
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Old 04-09-2014, 10:23 AM   #4
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We started to rebuild the floor first, had to purchase the replacement floor pieces and the under floor brackets that hold the nuts for the center body mount, roll cage, and seat. We got those welded in and even had to fab up a piece for the outer section of the horizontal under floor brace on the drivers side, it was gone as well. Progressing nicely so far but lots of welding! My son has done most of it, I dabbled a little, been many years since I've done much welding. You can see that it's certainly not perfect, more of a frankenfloor but it will work.



Fabed horizontal under floor brace on the drivers side.


Passenger side under floor brace, same thing on the drivers side except we used the whole replacement piece. On this one we just needed the back half. Both sides got new metal on the transom where the roll bar mounts.


Floor being welded down




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Old 04-09-2014, 11:51 AM   #5
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Nice start, keep up the good work.
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Old 04-09-2014, 02:04 PM   #6
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Thanks! We got the rockers pretty much ready for paint, there not perfect but they will be covered anyway with a rock slider rocker cover so I'm not too worried about them being perfect. Still need to work on the "J" on the Jeep logo on the passenger side, the bottom of the J was where the rust stopped and I need to cast a J in some type of plastic and mount it on the rocker. I might cast the drivers side and then fill in the mold for just the part of the J I need and cast it in resin. Then I can just glue and screw it on from the inside. Can you tell I'm a prop & model maker too? lol

Drivers side rocker




Passenger side
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Old 04-09-2014, 02:07 PM   #7
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Welcome to the party. I'm about $1000 into my 90yj.
Love the center console mod. Lol
Ya, gotta love that big hole in the console, it actually went out in the trash with the drivers seat!

Doesn't take long at all to get $1K into a Jeep project, we're far beyond it now
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Old 04-10-2014, 08:21 AM   #8
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We have a 4" Rough Country lift installed now too. It wasn't too bad to install, worst part was the old nuts/bolts that either were rusted stuck or broke off. Lots of new grade 8 hardware You can see on the last photo that we did have to do some frame repair in the rear, the left side shock mount was in bad shape so we got a frame repair piece welded in. The other issue was the T-case skid plate, none of the bolts would come out. Those silly rivet nuts are a terrible way to secure things that will rust. To repair I cut a window in each frame rail and fabed a peice of stock with nuts welded to it and inserted it into the frame. We then welded each end of the new piece to the frame and closed up the windows, bingo... new nuts inside the frame!







Transfer case skid plate frame nut replacements.


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Old 04-10-2014, 08:37 AM   #9
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Crap! I'm probably going to have to do that this weekend. I've been dreading trying to get that plate off. Now I can be pretty certain that it'll be a nightmare.
Thanks for the heads up and Easy fix.
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Old 04-10-2014, 08:49 AM   #10
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Crap! I'm probably going to have to do that this weekend. I've been dreading trying to get that plate off. Now I can be pretty certain that it'll be a nightmare.
Thanks for the heads up and Easy fix.
You're probably right, most will just spin from what I've read.

What I did was support the trans just in front of the skid plate with a jack stand, cut off all the heads that hold the plate and remove the plate. Then you can take a hammer and pound the old rivet nuts up into the frame. Cut your windows, two on each side, one large enough to slide the new metal in (mine were about 4"W x 2"H) and a smaller one on the other end big enough so you can get your welder in to weld down each end of the new metal so it won't move. You can get the old rivet nuts out thru these holes too. Clean up the inside as best you can and weld in the new piece. I coated the inside with that internal frame coating stuff you get from Eastwood after I closed up the windows (thru existing holes in the frame).

The other method is to cut the heads off and then drill out the old rivet nuts so you can install new rivet nuts. If the metal around the nuts is good enough you can do this, mine was not, the holes were too big due to the rusted metal.

If you can do the rivet nut replacement PM me, I have a bag of 1/2" rivet nuts I can send you for shipping plus a few bucks, I can't use them.
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Old 04-10-2014, 08:54 AM   #11
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Cool. Thanks again.
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Old 04-10-2014, 09:01 AM   #12
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OMG...this is about the same thing I'm doing now. Been at it off and on for a year now. Winter and non heated garage got in the way. I had to cut about the same amount of floor out. Rebuild supports under floor. Rebuild outside of tub in about the same places. One big diff...actually 4 is all four ends of frame are rotted. I've got the fronts fixed using donor frame, but back will be 1/8" flat steel. I'm doing tube fenders myself. Found Harbor Freight pipe bender and a youtube trick for bending tubing.

Couple years ago I rebuilt a 95 and had to do the same fix on the skid plate. Welded nuts to strip of metal and welded it inside of frame. Road salt is not a jeeps friend!!!!
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Old 04-10-2014, 08:43 PM   #13
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Seems like lots of us are rebuilding the same problem areas on these YJ's. Tonight we got the left frame rail POR 15'd. What a mess that is, laying under the jeep painting upside down to get the inner face painted.
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Old 04-11-2014, 09:26 AM   #14
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This weekend should be fun and filled with jeep work when we're not doing the scouting for food pickup or doing an electrical side job for a friend in town.
Last night while I did the driver side frame rail POR 15 job I also cut out the E brake cables, they were toast, so I ordered a set from Quadratec. Funny that they carry all the cables but not the equalizer bracket, found one for $4 on another site. I should be getting the new steering gear today so if there's time I can get the steering put back together.

The main plan is for Sunday, we're Monstalining the tub. Have it almost ready now, just need to finish prepping the front half of the tub, put the roll bar back in, and clean and tape off. It will be nice to be able to start putting the interior back together finally. I hope to have it back on the road by May. I ordered some new rims, Pro Comp 97's but it seems they are backordered. Might have to drive it for a little with the old tires/rims before we get the new ones on. We're putting 33x12.5 BFG TA KO's on the new rims.

Here is the tub getting prepped for the Monstliner.





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Old 04-12-2014, 04:56 AM   #15
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have the tub lined! I had my 1990 Rhino lined 10 years ago, still in great shape just hose it out!
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Old 04-12-2014, 09:07 PM   #16
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Spent a few hours getting the tub ready today. Got the final areas prepped, the worst was scraping off the plastic entry guard crap at the doors, that's nasty to get off. We installed the roll bar and got the tub all cleaned up and taped off. Just have to clean it once more with MEK tomorrow before we install the Monstaliner.
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Old 04-13-2014, 08:27 PM   #17
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To cold here to put on the Monstaliner, says it needs to be at least 50 degrees for 12 hours after its on, we would not have that today or tomorrow! Maybe in a few weeks it will get warmer.
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Old 04-16-2014, 09:02 AM   #18
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Hee hee...I have the same shock mount broken. Wonder in 20 years how the new TK style will hold up? My daughters 02 TJ already needs a windshield. Frame looks good still.
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Old 04-16-2014, 10:09 PM   #19
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I like knowing I'm not the only one trying to repair a rusted yj. We put in new floor pans, replaced body mounts, and have to put on shock mounts. Next thing is tackling the interior and getting it sanded and probably monster lined.
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Old 04-19-2014, 09:29 AM   #20
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I like knowing I'm not the only one trying to repair a rusted yj. We put in new floor pans, replaced body mounts, and have to put on shock mounts. Next thing is tackling the interior and getting it sanded and probably monster lined.
Sounds like we're on the same path! We tried to do the Monstaliner last weekend but it needs to be 50 degrees for 12 hours after installing it and we were to cold so we'll try next weekend.
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Old 04-23-2014, 10:46 AM   #21
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Haven't done much on the jeep in the last week due to traveling for work and then traveling for a family wedding. We did receive a few packages though, check these out!





This weekend is the local swap meet so we're heading there to see if we can score some rubber to put on them. Looking for 33 x 12.5's, hopefully we can get a good deal on a set.
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Old 04-23-2014, 11:02 AM   #22
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Haha too funny! I was just checking this out. Looking good! Nice weld/ Metal work.
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Old 04-25-2014, 02:02 PM   #23
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Not a lot of work went on this week on the project. But I did get a few things in the mail.
I have one issue though. We started to replace the lower steering shaft and am having a terrible time getting the upper U joint fitting to slip on to the column shaft. We greased the new fitting and the existing shaft, tried to spread the new fitting as much as we could but it still won't go over the shaft. It looks like there is only one way that this fits on, there are two sides that are rounded, one is flat, and one looks like it almost has a rounded keyway on it. Anyone have experience in replacing this piece?

Here are the new goodies for the weekend, rock sliders from E-Autogrills on ebay. We are also hitting a local swap meet to try and find some tires tomorrow.



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Old 04-26-2014, 10:11 AM   #24
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Haven't done much on the jeep in the last week due to traveling for work and then traveling for a family wedding. We did receive a few packages though, check these out! This weekend is the local swap meet so we're heading there to see if we can score some rubber to put on them. Looking for 33 x 12.5's, hopefully we can get a good deal on a set.

Nice
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Old 04-28-2014, 08:28 PM   #25
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We did get a good price on a set of 4 BFG TA KO's 33x12.5x15's at the local swap meet last weekend. We also picked up a set of black lug nuts and a used Alpine CD player for the jeep. This weekend we also got the brakes all done and the steering! Changed the transfer case, transmission, and rear diff fluids. I found that installing the new steering shaft I needed to remove the clamp bolts completely to install the rod, I tried without with no success.
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Old 05-03-2014, 06:35 AM   #26
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Tires and rock sliders on! Monstaliner tomorrow.
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Old 05-04-2014, 08:42 PM   #27
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Got the Monstaliner put on. Went very well, waited 6 hours between coats. Only issue we had was what to do with the rollers and pans in between coats. Didn't have enough roller covers to just toss them and use new so I remembered the freezer trick for oil based paints so we tried it with the Monstaliner. Put the rollers and pans in bags and put them in the freezer after the first coat, took them out for the second and they were in perfect shape to use again.



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Old 05-06-2014, 09:32 AM   #28
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Just thought I'd post a few update photos of the tub all lined. Turned out great! We should be able to get some time this weekend to get the seats back in and maybe even drive it a little (without a windshield).





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Old 05-12-2014, 08:50 AM   #29
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It was a good day on Saturday, we got everything tightened up and took the jeep for it's first drive since tearing it apart in October. Still no Windshield yet but no leaks and nothing was loose. The new steering system is awesome and the brakes work just as they are supposed to. Still a lot to do to get it completely ready for the road but it sure was fun to drive it around town a little.

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Old 05-13-2014, 09:06 AM   #30
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Got the new windshield frame painted last night. Maybe on Thursday I can put in the glass and get it ready to install on the jeep.


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