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Big Blue Makeover...YJ to Juggy Build

4K views 18 replies 5 participants last post by  wildman128 
#1 ·
During Big Blue’s last ride at Rush Offroad Park in 2013, we encountered some mechanical problems that was gonna put her on the shelf for a while. The 4.3L Vortec was already having fuel injection issues and was trying to kick the bucket, the 700R4 transmission gave out and a brake line got ripped out of the caliper. It was a long ride home. Every time I looked in the rear view I could see my baby on the trailer. All I could think about was that her recovery was gonna take a while. I unloaded her into my shop, Murphy Custom Fabrication, and just looked at her for a long time. Every day that I walked into the shop, she would be sitting there looking all pitiful and depressed. After a month or so, I talked to the boss (my wife Nicole) about doing some upgrades to Big Blue. I figured that if she was gonna be down for a while, I might as well take this time to make her better in every way possible. That is when this journey began. This is what she looked like on that dreary day in August 2013 when she took her last ride.
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#2 ·
New motor and custom headers

First order of business was to get rid of her sick heart and get a transplant. When removing the old motor, I knew that I was gonna try to sell it and needed to keep the harness intact. I removed everything together without cutting a single wire. At this time, I also removed the entire dash, heating and AC components (which I donated to Matt to help fix his), steering column and everything else connected to the firewall. I sold, donated, and scrapped most everything that I removed from the front of the jeep including tube fenders, radiator, grill, stringer and winch mounting plate. Next, I removed all brackets from the front section of the frame and repaired where needed.
I made a few calls and about 3 weeks later the heart transplant arrived at the shop in the form of a 2004 Chevrolet LM7 5.3L Vortec with a mild build that dyno’d around 400hp at the flywheel and a standalone wire harness. Shortly after unpackaging the motor, I removed the factory air intake, exhaust manifolds, and AC bracket that came shipped with the motor. I did some cosmetic touch ups on the plenum to give it that MCF feel and Big Blue appearance. I also ordered an LS Swap Water Pump Heater Core Bypass Hose from Ebay.com since I removed the factory heating system. Next, I built new motor mounts and installed the new heart. Due to the size of the motor and the limited space left inside the frame rails, I decided that a set of custom headers would help with fitment and sound. Less than a week later, UPS showed up at the shop with a box of tubing, collectors, O2 sensor bungs, flanges, header bolts and gaskets from Speedwaymotors.com. After a lot of measuring, cutting, trimming, welding, sweating and some frustration, the headers were complete. They are 1 ¾” primaries into 3” collectors. This was the first set I have ever built and I think they turned out well. I had to remove the rocksliders and front body mount to make room for the headers to run outside the frame. The headers were also connected to Schoenfeld Mufflers and turndowns from Summitracing.com.
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#4 ·
New dash, radiator, front hoop with radiator supports and guards.

I built a new dash using ¾”x.095 wall square tubing and 12g sheet metal. I used the tubing to frame and support the dash. The sheet metal was used for the face plate. All the gauges, switch panels, speakers, and the master power switch will be on the new dash. Behind the dash and mounted to the dash frame will be the stereo amplifier, drive-by-wire control module, and other electronics.
A call to Summitracing.com and UPS quickly arrived with a Griffin Dual Pass radiator built for LS Swaps and a Proform 16” electric fan. I built radiator supports to mount the new radiator. Then, I built a front hoop with radiator guards to protect the radiator.
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#5 ·
removed cage,rear tub section,built rear tub wall, fuel cell and battery relocated.

Now was the time to decide exactly how I wanted to design the new look of Big Blue and the new cage style. After much deliberation, I removed the windshield frame, old roll cage and the rear section of the tub with the ever-so-handy Miller Spectrum 875 Plasma Cutter (so much faster and cleaner than a torch or saws-all). I shortened the frame 6“ (I had modified it a while back to stretch the rear). I used 2” tubing to build a new cross member at the rear of the frame. I also built a platform to hold the fuel cell, which I moved 15” closer to the tub. Behind the fuel cell platform, I built a section to hold a cooler and/or toolbox. This also reinforced the frame. Next, I built a battery box to relocate the battery behind the passenger seat. Then I framed up the rear tub section with 1” square tubing and used 12g steel to build the rest of the rear tub wall. The wife didn’t like the idea that the rear tires could throw rocks and mud into the back of her head and every off-roader knows that an unhappy female passenger makes for an unpleasant ride.
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#6 ·
I needed a place to mount a transmission cooler/fan and a fuel filter/pressure regulator. The place needed to be out of the way of other moving parts, somewhere safe and free from flying debris, and the fuel filter/pressure regulator needed to be close to the fuel cell. I used 1”x.120 wall square tubing and some nutserts to make the mounts. Then, I welded the mounts to the rear tub wall in front of the fuel cell. Everything is protected by the fuel cell.


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#9 ·
I won't be use the stock grill. The hoop and radiator guards on the front will have a few more braces added to them. The hoop will be tied into to rest of the exo-cage. There will be expanded metal between the radiator guards and a 12" LED light bar. Haven't decided if I'm going to keep the hood or not yet either. It's going to be more of a rock buggy style than a factory jeep look. We wheel pretty hardcore trails and protection is the main key to this build. Hope you continue to follow the build.
 
#14 ·
Awesome project and damn nice fabrication on those headers! The cage work also!! You've clearly got some great fabrication skills and I wish you the best of luck!

I too and in the process of a big project like this, where I'm installing a built Chrysler 440 / TF727 / NP231 / Ford 8.8 into my 1995 YJ, so I know what you're going through. http://www.wranglerforum.com/f330/95-yj-w-chrysler-440-a-1465473.html

I haven't been on this board long, but it doesn't seem like too many folks are doing engine swaps like ours' around here for whatever reason, so I'm sub'd to this thread to watch your progress.

Forge on mate! :thumb:
 
#15 ·
Thanks jeepdad95. I am new on here also. Not many on this forum seem to do a lot of builds as extensive as this. Thought about deleting the post because no one seemed interested. I like to share the builds I do so others can get ideas if they are looking to build also. I own a small shop in Eastern Ky where I build rock crawlers, cages, tube fenders, and other mods. Thanks for subscribing to the thread, I will continue posting my progress. I will stay tuned to yours as well. Good luck.
 
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