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Old 02-15-2013, 05:32 PM   #1
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Post Building my YJ

After reading several threads from fellow jeepers giving advice and showing their cool mods, I felt it was time to give back to the community. Although im not starting from bone stock my goal is to help and inspire from this thread.
With major upgrades in sight now is a good time to start this thread than any other!
I have done a TON of mods already and unfortunately i don't have photo's of those projects but ill post some pictures and list what iv got done to the ZRV as she sits.....
1995 Wrangler SE 2.5L, Manual trans.
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So when I picked up the Jeep in a trade for my motorcycle I installed the 4" Rough Country lift, Put steel braided brake lines on the front and all new brakes front and rear. Got me some 33" swampers and thought I good with my setup.....so wrong I was...
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started playing in the dirt more and more working out all the bugs
Attachment 210219
After some time i tore all the carpets out, pulled the seats and belts out, all the foam padding came off and rhino lined the Entire inside. For kicks I put Zombie Response Vehicle on the sides and it has become know as the Wrangler ZRV. watched craigslist for a few weeks and found some racing seats for $50 that just needed to be cleaned up, since i was gong to abuse them anyways I took fabric paint and painted them black very heavily.
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It was now 2012 summer time and going to the lake almost every weekend so i ordered the Kicker sound bar with 6" speakers, a pioneer 500w deck and front 4x6" speakers to put inside the dash grills, lastly a 10" pioneer Sub in my homemade ported box running off a 400w amp. (Dont need anymore bump than that lol!)
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The jeep thankfully came with the front and rear rock crawler bumpers I just added lights and put 2 on the window. since i had the outside set up decent i needed motor mods!!! Im now running the 4.0 Throttle body (huge response difference!!) with the 5.0 fuel injectors from a ford. Exhaust has a magnaflow cat with Raptor muffler, on the intake im running the K&N cold air tucked as far over to the driver side as possible. iv also installed a flexalite Electric fan made for the 92 Fox body 5.0 mustang. Fan pulls close to 3k CFM to keep it plenty cool in this Arizona heat.

Attachment 210222

Iv also done the PM102 Heater Blower motor upgrade. For those doing it, id suggest having someone with you... make it 10X easier.
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Iv grown up building cars but they are obviously all different and in the auto work we never stop learning!!

My Biggest jeep building challenges are in the mail and i feel like christmas is coming!!!

Poison Spiders Hood louvers for the Yj
A cheaper set of 3" Flat tube fenders with the Side vents off Ebay
A Cowl scoop for the cabin air.
1 1/4" boomerang shackles front and rear.
Energy suspension polyurethane Shackle bushings

HOPEFULLY A shop owner/friend didnt sell it yet but an SYE kit and 4.88's for the front and rear... Will post photo's and keep updating this thread from here on out of ANY mod I do. Thanks for all the help from previous, present, and future Jeepers for posting their knowledge for us learners.

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Old 02-15-2013, 06:24 PM   #2
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get an 8.8 for the rear

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Old 02-15-2013, 07:01 PM   #3
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Quote:
Originally Posted by Tyler92yj View Post
get an 8.8 for the rear
Dont waste cash on gearing the dana 35 in rear! It wont hold up long, especially after gearing.
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Old 02-15-2013, 07:38 PM   #4
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jeep looks good!
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Old 02-16-2013, 01:51 AM   #5
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Originally Posted by YJ ALL DIRTY View Post
Dont waste cash on gearing the dana 35 in rear! It wont hold up long, especially after gearing.
thanks!! So iv been told.. ford 8.8 maybe? easy to find in az
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Old 02-16-2013, 01:35 PM   #6
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Looks like a great project. Lots of nice work.
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Old 02-16-2013, 05:11 PM   #7
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Quote:
Originally Posted by LowOutput2.5L View Post
thanks!! So iv been told.. ford 8.8 maybe? easy to find in az
you need the rear out of a 96-01 explorer or mountaineer. they have either 3.73 or 4.10 gearing i think and the plus side is you get rear disc brakes for your yj.
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Old 02-16-2013, 05:45 PM   #8
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Quote:
Originally Posted by LowOutput2.5L
After reading several threads from fellow jeepers giving advice and showing their cool mods, I felt it was time to give back to the community. Although im not starting from bone stock my goal is to help and inspire from this thread.
With major upgrades in sight now is a good time to start this thread than any other!
I have done a TON of mods already and unfortunately i don't have photo's of those projects but ill post some pictures and list what iv got done to the ZRV as she sits.....
1995 Wrangler SE 2.5L, Manual trans.

So when I picked up the Jeep in a trade for my motorcycle I installed the 4" Rough Country lift, Put steel braided brake lines on the front and all new brakes front and rear. Got me some 33" swampers and thought I good with my setup.....so wrong I was...

started playing in the dirt more and more working out all the bugs

After some time i tore all the carpets out, pulled the seats and belts out, all the foam padding came off and rhino lined the Entire inside. For kicks I put Zombie Response Vehicle on the sides and it has become know as the Wrangler ZRV. watched craigslist for a few weeks and found some racing seats for $50 that just needed to be cleaned up, since i was gong to abuse them anyways I took fabric paint and painted them black very heavily.

It was now 2012 summer time and going to the lake almost every weekend so i ordered the Kicker sound bar with 6" speakers, a pioneer 500w deck and front 4x6" speakers to put inside the dash grills, lastly a 10" pioneer Sub in my homemade ported box running off a 400w amp. (Dont need anymore bump than that lol!)

The jeep thankfully came with the front and rear rock crawler bumpers I just added lights and put 2 on the window. since i had the outside set up decent i needed motor mods!!! Im now running the 4.0 Throttle body (huge response difference!!) with the 5.0 fuel injectors from a ford. Exhaust has a magnaflow cat with Raptor muffler, on the intake im running the K&N cold air tucked as far over to the driver side as possible. iv also installed a flexalite Electric fan made for the 92 Fox body 5.0 mustang. Fan pulls close to 3k CFM to keep it plenty cool in this Arizona heat.

Iv also done the PM102 Heater Blower motor upgrade. For those doing it, id suggest having someone with you... make it 10X easier.

Iv grown up building cars but they are obviously all different and in the auto work we never stop learning!!

My Biggest jeep building challenges are in the mail and i feel like christmas is coming!!!

Poison Spiders Hood louvers for the Yj
A cheaper set of 3" Flat tube fenders with the Side vents off Ebay
A Cowl scoop for the cabin air.
1 1/4" boomerang shackles front and rear.
Energy suspension polyurethane Shackle bushings

HOPEFULLY A shop owner/friend didnt sell it yet but an SYE kit and 4.88's for the front and rear... Will post photo's and keep updating this thread from here on out of ANY mod I do. Thanks for all the help from previous, present, and future Jeepers for posting their knowledge for us learners.


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Very nice yj man. Here's mine. Gotta keep the black on black alive
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Old 02-17-2013, 01:06 AM   #9
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Thanks for the info, is the axle swap a direct bolt on?

jjusmc77 your jeep looks great! keep the black on black up!!
I do need some Opinions!!!
I want to keep the black on black and not be a mall crawler, so my general theme is non flashy.. HOWEVER!!!
After spending a grand in tax refunds i obviously am putting my own taste into. so here is my idea:
For my louvers i ordered them non powdercoated black so i can pain it myself, My jeep is ALL blacked out and there are TONS of those in Az, and after putting my zombie decals a year ago, and the popularity of walking dead, im seeing more and more vehicles with the zombie junk. Im think of taking the louvers and taking a steel brush to give it an edge look and just clear coating it. or do i go black and make it look stock?

Another question was i ordered clear LED tail lights that are the round sink ins. my stock ones i have now are blacked out, should i black out the new ones or leave them clear? maybe to flashy? just getting a feel on what other have seen or experienced, thank you!
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Old 02-17-2013, 10:03 AM   #10
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Nice to see another ZRT Jeep! Looks great man! I've got the RC 4" with 1 1/4" boomerang shackles and it looks SWEET!!!! I haven't had a chance to go wheeling with all the new springs and shackles yet. I'm looking forward to getting her off road and see.
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Old 02-17-2013, 10:10 AM   #11
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I think the brushed/cleared idea would be cool. Everyone paints or powder coats things. The brushed look would definitely be different.
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Old 02-17-2013, 10:12 AM   #12
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how big of a help were the 5.0 injecters? did you have to change anything else with that?
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Old 02-17-2013, 01:35 PM   #13
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how big of a help were the 5.0 injecters? did you have to change anything else with that?
huge throttle response my jeep runs a bit richer than i would like but id rather it be rich than to lean especially on the trails when they get hot. I highly recommend getting a 4.0 throttle body if your running the 2.5l motor.
Easy to do too! and while i was in there i cleaned everything down too. the injectors are a direct fit, but I will say this, your local auto parts store has a SINGLE injector rebuild kit for the ford injectors that run about 4 bucks. BUY the 4 or 6 kits you need for you injectors. I took the orings and caps off the jeep injectors thinking "hey they look almost new to me!" well they weren't and I got a vacuum leak on my third cyl. do it right the first time lol.

Quote:
Originally Posted by zombiechief View Post
I think the brushed/cleared idea would be cool. Everyone paints or powder coats things. The brushed look would definitely be different.
Very nice!! Im loving the custom stinger, I friend of mine owns an exhaust show and has roll bar tubbing from his person prject laying around, been thinking about building my own too. and since mine is all blacked out i didnt want the stock look and i didnt want to exactly paint it red or blue seeing how NOTHING is any specific color. So brushed steel it is.
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Old 02-17-2013, 11:42 PM   #14
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well as usuall i am an idiot and didn't read the whole posts closely enough.. i already hae a 4.0 so would 5.0 injectors work in it? would it make a noticable difference? if so what year injectors did you get?
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Old 02-18-2013, 12:39 AM   #15
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well as usuall i am an idiot and didn't read the whole posts closely enough.. i already hae a 4.0 so would 5.0 injectors work in it? would it make a noticable difference? if so what year injectors did you get?
It's all good, i feel like i wrote waaay to much as usual, but everytime i open this up there is so many more mods I should have mentioned. I actually just found someone on craigslist that has taken the ford 5.0 injectors out. i bought 8 + the fuel rails and had intent of trying to use the ford fuel rails for kicks but it was to much for the time i had. the injectors are a GREAT upgrade and i notice 2mpg better with the 4.0 and the injectors. The difference is that our injectors (stock jeep) have a single large nozzle on them and when opened the injector (quite literally) pisses a stream of fuel into the cylinders. this effect doesn't allow the fuel to atomize in the cylinder when the air/fuel is mixed. Therefor creating a pond of fuel and after detonation the cylinder dumps a good amount of unburnt fuel into the exhaust. this is one small reason why jeep from factory liked to run their motor's so lean.
So why ford injectors?
Jeep and ford used the exact same fuel injector design on their motor's. The design, the Ohm rating, and CC ratings, and even electronic connectors on the injectors are the exact same at idle and higher rpm's. The Ford Injectors have 4 Nozzle's and instead of a stream they allow for a MUCH higher atomizing level with the Air by taking 4 small nozzles and spraying the fuel in a fine mist kind of pattern.
I had a hard time believe ford could work in Chrysler until i looked at how exactly the same they are someone pointed this out.

Ford 5.0 Liters, 8 cylinders
Cut it in half
Jeep 2.5 liters, 4 cylinders

That was all the motivation i needed to give it a shot.
SO i noticed a huge change in throttle response when wheeling (due to the 4.0 body) However with the more air flow the atomizing of fuel help with consumption and obviously the more fuel you can successfully burn, the more power you will have.
When i drove up north for the first time, going from an altitude of 2k to maybe 5500 or 6k i had a lot of issues with the jeep flooding and adjusting, so when we hit trails it was a joke to get it up a big rock since it lacked power and just kept stalling out. with the injector and body it gets better gas and when i went up north again i had almost no issues with the jeep and certainly no lack of power or stalling. Just my 2Cents. Lol, sorry for another long essay!!
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Old 02-21-2013, 02:25 AM   #16
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Update:
Got ALMOST everything done. My tail lights are stuck in NY due to storms so those will come later. Fenders are in with new light markers, SYE is in but waiting on the driveshaft shop. they promised me today. > All new bushing in 1 1/4 boomerangs ALL AROUND. (Write up on that later) Put the air damn on the cowl and a bunch more of little stuff, Have to re-adjust the hood tomorrow and push it back a little, as well has take the final steps in cutting the hood and installing my brushed louvers. Done a LOT of work in two days and captured over 100 photo's so far. Within the next week ill post a full write up with the best photo's i have!!!!
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Old 02-21-2013, 02:37 AM   #17
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Btw id like to post a link if i may to a friends shop. Without him doing all this would have taken a year or more and 5 times the cost. He goes to auctions to buy jeeps so he can and part them out to us! All his parts are tested before sales and is one of the friendliest jeep guys i have ever met. Anytime iv counted on him he has always come through, even on parts they dont make anymore. Check him out, he wont let you down.
his name is Michael, many of his parts are on craigslist for sale or you can see him at castlerock4x4.net
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Old 02-27-2013, 01:57 AM   #18
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Few of the Many parts, Was really impressed by shipping and quality of the fenders when i go them. i only paid 300.
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Poison Spider Hood Louvers.
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Old 02-27-2013, 02:35 AM   #19
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First and fore most was taking the lights off the plastic flares and taking the flares off.
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We put a 1" bead of tape to give us an edge to cut out and leave us the inside liner. Idea was good, we thought out measurements were good but we were wrong. Cut a piece of the old fender and tack welded a little on for the top to bolt up to.
This fender was the left side and a before image
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this is an after image as we got down to the last few corners and bolts we had to grind off to give it a cleaner look. quite a bit.
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Here is the major chunk of fender!!
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Old 02-27-2013, 02:44 AM   #20
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Adding a little metal for a good support.
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An idea of what all was cut from the sides. (sorry its not rotated)
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After a bunch of cutting and fitment the fender came with all the extra screws and nuts I needed.
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Image of the other side.
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Old 02-27-2013, 03:17 AM   #21
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So we pulled the Tranfercase to send it off to my good friend at Castlerock4x4.net. While I was on the phone with him he asked me if there was 5, or 6 bolts attached to the transfer. We thought there was supposed to be 6 and over time i had lost a stud however from factory jeep actually put a plastic plug inside one of the holes... After speaking with Micheal I found out that you can actually screw this plug out and add your own stud and add that much more support to the transfer.
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From Castlerock i bought the Cherokee XJ Drive Shaft and had it Shortened. So while the drive shaft was on one side of the town, the transfer was on the other; we decided to push forward and put the boomerang shackles on.
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I read many forums and although many people argue the boomerangs have absolutely no point on the front, i preferred the looks of the boomerang vs the straight. The point of upgrade is function and to me to be different. so boomerangs were the way to go.
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Old 02-27-2013, 11:17 AM   #22
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Well I had gotten my transfer back and installed it, looks beautiful. now if i could only get the driveshaft shop to have a little better service id have that back to.
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So we moved on to the Poison Hood louvers
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I HIGHLY recommend only peeling the corners.....or your left with this.
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But we made it work anyways and started cutting away with some Jigsaws.
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Installation was actually very easy, my only huge complaint is the screws they send you to hold it in place are very cheap and break, strip, and spin free.
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Old 02-27-2013, 11:28 AM   #23
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So after 3 DAYS of waiting for the shaft i must say the service i had over at T.A.D. was terrible. They promise "Same Day Service" and when I first spoke to them over the phone they told me 90 to just shorten it, or 125 to shorten balance and replace the joints. When i showed up i feel like they saw a young guy and decided to take me for a ride. The old man in the front rotated the joint and said these feel great i dont think you need to change them. I agreed and told them the measurements i needed and left with $90 in mind. After dealing with them for 3 days and arguing over the phone i finally get the call saying it's done. when i showed up a the younger mechanic came from the back and handed me the bill for 206.80. "because they painted it, replaced the joints (that they told me didnt need to be changed) and cleaned it up."
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So longstory short i walked out with it for 150 and was furious how terrible the service was.
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What didnt help my attitude towards the situation is that the XJ is a smaller yoke size being a 1310, my jeep runs a 1330. If you are doing this mod part number 353 is all you need!!! 353 is a Precision offset u joint that is more like a cross instead of a + sign. make it so you can fit this smaller shaft into the larger yoke.
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All in all we got her in and she looks great. cant wait for my first trip out with all the new mods. Plenty more to come!!

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