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DaddyJeep Rebuild

130K views 745 replies 70 participants last post by  daddyjeep 
#1 ·
Well... DaddyJeep is starting to show his age and is in need of a bit of a rebuild. I found out that the rear section of the frame was rotted out so I had to replace the last 18" of the frame rails on both sides.

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Since I had gone this far, I decided it was time to replace my completely worn out body mounts. Then again, since I had to do that I might as well just tear it down to the bare frame. That is where I am now...starting the tear down. This is going to be a very slow build since I work two jobs and am a Cubmaster for my son's Cub Scout pack. My free time is limited to an hour or two week, if I am lucky. My deadline is to have it ready for the Bantam Jeep Festival next August.

Just to make things a little more interesting...

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Thats right...5.2L V8 and 46RH tranny. I am having my local VoTech rebuild the 5.2 for me and need to find someone to go through the tranny for me. I am not much of a wiring guy so this might be a bit of a challenge next spring when it is time to get things back together and running.

If time and money allow there are several other things that I would like to get done during this build. I need to get my tube fenders built, similar to the Metalcloak ones. I need to build a real cage, which I plan on tying onto the tube fenders that will then tie into a front stinger. I want this thing completely wrapped in 1.5" DOM as one solid unit. Of course I have to finish my bumpers and tire carrier. Hopefully by the time all of this is done I should be getting pretty good with my welder.

Here is a pic of my current progress. I have the front clip off and just have a couple of really rusty body mount bolts to cut off and the tub will come off.

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I really need to get started on getting the engine out of the Grand Cherokee and get it over to the VoTech before the weather gets bad. My garage barely holds the Wrangler so I will be working on the grand outside. If anyone needs anything off of the grand let me know. All I need is the drive train. Notice those sweet 5 spoke Jeep wheels. I am sure one of you guys could give them a good home. Also, My current Wrangler drive train needs a new home. 4.2L with Howell fuel injection, only 96000 miles.
 
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#56 ·
Thanks, I can see the light at the end of tunnel. Fab work is almost complete. Just need to get my motor mounts and I can get the frame painted and start assembling. I hate to say it because I could jinx myself, but the deadline is not looking so unachievable.
 
#57 ·
I just ordered my ballistic fab shock hoops and shocks for the front today. Can you post a few more pictures of your front setup? I am looking on best ways to mount them up to the axle and best angles.

Jeff
 
#58 · (Edited)
I ordered the D44 brackets from Ballistic for the front and regular shock tabs for the rear. I have not mounted either yet. I have been focusing all of my energy on the frame so far. The D44 brackets are cool because they gusset the C's as well.

My hoops are leaning out 10 degrees and my shocks will be leaning in right around 10 degrees. I don't know if that is ideal or not, but that is where I am at.

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I don't know what else I have to show you. Let me know if you want something specific and I can get you some more pics. I have the dimensions I need for the bracket spacing so I can even get them welded soon if that will help.
 
#59 ·
I guess the only thing that would help is seeing where you are placing your lower brackets on the axle. I ordered some mounts for 4" axle tubes, but I may have been a little too anxious. I didn't see the D44 ones on Ballistic for whatever reason so I ordered these channel like ones off of a different place.

I also just found this for shock angles:
http://www.4x4review.com/Features/Tech/BeAGeniusShockAbsorbers/tabid/307/Default.aspx
 
#61 ·
81 Days until BJHF

That article on Pirate has it all. I have read that a couple of times, but ultimately the position of my shocks is where they fit best for my Jeep. I tried to keep them as close to vertical as possible and they do not lean forward or backwards.

I am pretty booked up with the kids for the next couple of nights, but hopefully will be able to get at least started on the shock tabs.

Here is a pic of the Ballistic D44 tabs in case you havent looked at them yet.

 
#62 ·
I agree that it does.

After you mentioned the BF D44 tabs, I went and looked at them. But I am not sure if they will work for me since it would put my shocks way out from the frame.
Plus I already have those others ordered. Thirdly, I am running a GM 10 bolt and I think the knucles are just slightly different from a D44.
 
#63 ·
Frame notch finalized. I welded angle iron to give the notch a little support.

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Shock tabs weled on to the front knuckles

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Got the pitman arm from the astro box mounted of the Jeep box. Once I get a reamer I can mount the drag link on top so I actually have room for my axle to move. I added a little color too. I plan on painting the engine the same color.

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#64 ·
You should not even dick with the stock steering and just go full hydro. Its so nice.

But I think I'm going to have to go with those D44 knuckle tabs now that I see how they are mounted.

I got my hoops and shocks in Thursday.

The shocks are rough country for a mid 90s 3/4T gm pickup. They allow 14" of travel and are 29" long fully extended.

Do you have any pics of yours mocked up yet?
 
#65 ·
76 Days until BJHF

I wish I could go full hydro, but I would like to be street legal in PA.

I don't have shocks yet so no pics yet. I currently have a 2x2 for front shocks and need to cut another 2x4 down for the rear so I can make it a roller.

Indiroc, you say your shocks are 29" extended? mine are going to be almost 38", going with the 14" travel also.

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#66 ·
Damn, thats a huge difference, but you are going with coil overs, Im SOA and gas/nitrogen charged shocks.

Also, my collapsed length is only 18.5. Those show 23.79 so there is a bit of "scaling" for comparison.

However, I do know that the Pro Comp ES9000's that I was looking at were like 33" extended with 14" of travel. But for whatever reason I couldn't find them again. Oh well for the price I got these RC's for they should suffice for quite a while. They are just there to dampen the bounciness of the SOA.

I guess I will have to move them inboard a bit instead of using the knuckle mounts like you are.

Can't afford the great stuff currently. The army doesn't pay that good. LOL
 
#67 ·
76 Days until BJHF

Here is a shot for Indiroc showing the angle that my shocks will be. My axles are full width, 65 1/4" WMS to WMS. Shock hoops are 10 degrees out and the shocks are also 10 degrees out.

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I used my stock rear trac bar up front and it worked like it was designed to be there. The stock frame mount was cut off and moved back a few inches and I made a bracket for the axle end that bolts on where the coil bucket used to be.

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#68 ·
Great progress/ mock up!

Looks like I am going to be putting my hoops down on the outside of the frame seeing as how I am not running that long of shock. You are going to have some monster travel!

I need to pick up one of those tubing notchers from HF it looks like! And a whole saw kit.

What size tires are you going to run in the end?

Obviously I'm the #1 fan of your build. lol
 
#72 ·
Thanks guys...I don't know about the impressive welds. I have improved greatly through this build though.

I am running 35" Cooper STTs. I just bough them last year so I am going to abuse them for a while before I can go bigger.
 
#74 ·
Still going air shocks. Although it looks like I have a ton of room I really don't once everything is flexed. I need to flex it again to check clearances again and test the front trac bar.

Engine is supposed to be done this week but I won't be able to get over there intil next Thursday to get it.
 
#77 ·
I get out of the army in 3 months, and it amazes me the amount of places that only want to hire unreliable part time $10-$12 help. I can't work somewhere for that. I mean how is anyone supposed to support their family and pay bills for housing and other necessities ?
 
#78 ·
I know around here most companies have gone to hiring people as temps to avoid from having to give vacation and benefits. the job market is tough I hope you find something decent.

I did some more suspension cycling tonight to make sure my shocks will clear once and for all and to test the new front trac bar.

Shock clearance to frame at full droop. The shock body measures 2.25" so I will have about an inch between the shock and the frame.

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Shock clearance to tire at full stuff. I will again have about an inch of clearance.

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Track bar at full stuff on passenger side. Damn close to the diff, but it fits.

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Track bar at full stuff on drivers side. Again, damn close to the diff.

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One more shot of the suspension flexed to the max.

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I found the limit of the rear suspension...that sucks, I hoped it had no limit. The upper links twist and contact the frame brackets limiting my flex. I am about an inch short of maxing out my shocks at full droop. Looks like I need to get rid of the rubber bushings on the axle end to get the rest of my flex. That may be part of the next phase of the build due to the usual constraints... time and money.
 
#80 ·
69 Days until BJHF

The sun finally shone in Pa today. I took advantage by putting a couple of coats of POR15 on the frame. That stuff brushes on really nice and covers great. I did two coats on the frame and both axles and only used 1/2 quart. Once it dries good I will put it back on jack stands and pull all of the links and get them painted up as well as inside to link brackets.

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I didn't get a whole lot done this weekend because I went camping with this bunch. These are some of my webelos scouts. My boy is the one in the middle saluting.

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