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Old 03-09-2014, 08:27 PM   #1
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Project Tomahawk Build

It's a long story, but it started May 2012 when I bought a 1992 YJ (4.0/Auto) that had several bad rust spots on the frame and tub. It's 3rd vehicle between my wife and I, so the plan was play around with it, enjoy the sun with the top off and work on it when I could. It turns out the frame was worse than I thought and I decided to replace the frame and tub.

I found a rust free frame with a nice tub and picked it up on a Friday. On Sunday, a 125 ft Maple tree fell and demolished my shop. After forever, I finally got the shop rebuilt (bigger and better), finished up so "honey-dos" that required significant space in the shop.

Last weekend we pulled the donar YJ in and I started dismantling.

I don't have pics of the "roadworthy" just at the moment, so these of the donor will have to do for now.

It's been setting like this in my yard for the last year plus.


It's finally in the shop!

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Old 03-09-2014, 08:43 PM   #2
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The short plan is to strip it down to the frame and treat the frame for rust prevention, I choose to use KBS Coatings Rust Seal. The tub needs some body work, a coat of paint, and roll-on bedliner inside.

Let the striping begin!




One of the leaf spring bolts was seized inside the spring and I couldn't get it to budge... so I cut.



First day junk parts pile


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Old 03-09-2014, 08:46 PM   #3
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Today with some help from my brother, I managed to get the tub off and started cleaning the frame.




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Old 03-09-2014, 10:03 PM   #4
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Hey Chuck looks like you are off to a good start, I will be watching as things move along. Keep the pictures coming
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Old 03-10-2014, 08:36 AM   #5
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Thanks Donny, and there will be lots of pics.
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Old 03-10-2014, 09:29 AM   #6
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I saw where you had posted a start on this in another thread and caught my interest so I clicked your link and looking forward to the build
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Old 03-10-2014, 09:37 PM   #7
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As promised, here are pics of the "roadworthy" Jeep, that I will be replacing the frame and tub on. It has lots of rust all the way around the tub and all of the undercarriage.

Body\Tub






The reverse rake stance comes from a combination of very worn rear leaf springs (almost flat) and 2.5 inch lift springs on the front. The PO took it to a shop for front springs and the shop used the lift springs and the PO didn't know any different.




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Old 03-10-2014, 09:42 PM   #8
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Here are pics of the frame and undercarriage. This part of the project is going to be a real SOB with all the rust. I'm sure there will be many broke, drill and\or cut bolts, busted knuckles, cursing\blessing and possibly a tetanus shot.











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Old 03-11-2014, 12:10 AM   #9
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the rear of your frame looks like mine before I did the repairs. Always lots to do with an old jeep
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Old 03-11-2014, 08:51 AM   #10
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Quote:
Originally Posted by Tim Stines View Post
I saw where you had posted a start on this in another thread and caught my interest so I clicked your link and looking forward to the build
Thanks, me too!


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the rear of your frame looks like mine before I did the repairs. Always lots to do with an old jeep
Yeah, I followed your build and noticed parts of our frames has similar issues. At first, I was going to go the same route as you with the Safe T caps , but there was just too much rust.
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Old 03-11-2014, 08:51 PM   #11
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I worked on cleaning the frame tonight, I'm about half done at the point.


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Old 03-11-2014, 08:54 PM   #12
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looking good
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Old 03-16-2014, 05:38 PM   #13
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I didn't get a lot done this weekend due to other projects. I did manage to finish the cleanup of most of the frame. I just have to get to the small tight places and I'll be done cleaning. I was missing a shackle hanger on the front, so I cut the other one off and ordered a new set from M.O.R.E.

At the moment, I'm trying to determine if I have a I4 or I6 donor frame. I know the motor frame mounts are in different locations, but i don't have measurements.
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Old 03-16-2014, 11:48 PM   #14
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Looking really good man keep up the good work.
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Old 03-19-2014, 07:23 AM   #15
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If the vin tag is still on the firewall of the tub you might be able to run it through a vin decoder and find out what motor it had. Never used it but heres the link to one in the stickies
VIN Decoder
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Old 03-19-2014, 08:45 AM   #16
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If the vin tag is still on the firewall of the tub you might be able to run it through a vin decoder and find out what motor it had. Never used it but heres the link to one in the stickies
VIN Decoder
Thanks, but there's o VIN tag or stamp anywhere. YJDave helped me determine that the new frame is a I6 frame by giving me measurements of his I4 frame.
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Old 03-21-2014, 09:30 PM   #17
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I had a good mail day today. I got new M.O.R.E front spring shackle hangers that I plan to get the Vo-Tech school to weld on next week... since I'm not real confident in my own welding. And I also got new front and rear poly shackle hanger bushing sets.

My wife and I volunteered to take pictures of homeless dogs tomorrow, so Jeep work may be limited, but I should be able to get a little done.

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Old 03-24-2014, 08:35 PM   #18
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good luck on your project!
nothing like building Jeeps.

I've been enjoying my Tomahawk for about a year now.
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Old 03-24-2014, 09:36 PM   #19
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good luck on your project!
nothing like building Jeeps.

I've been enjoying my Tomahawk for about a year now.
Wow! That's nice! I don't suppose you're a Braves fan, too? And nice hood decal, where did you get it if you don't mind telling me? Do you have a build thread? I'd like to see how it came together.
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Old 03-24-2014, 10:52 PM   #20
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not much of a pro baseball fan - but the name idea did start with an Indian name (Cherokee) but that's a long story.

made the decals myself on DIYlettering.com:
Vinyl Lettering | Custom Vinyl Lettering

here's my build link, I started out with Dodge trucks/Ramchargers years ago before I discovered how much fun Jeeps are:
"Tomahawk" - 1 ton Magnum YJ - Dodge Ram, Ramcharger, Cummins, Jeep, Durango, Power Wagon, Trailduster, all Mopar Truck & SUV Owners. Dodgeram

Eric
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Old 03-25-2014, 01:57 PM   #21
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Thanks. I'll have to check that decal site out.
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Old 03-31-2014, 07:43 PM   #22
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Over the weekend I was able to get some welding done on the frame. We welded new front frame shackle mounts and some touch-up welding on the rear crossmember support. I hope to cover the frame with KBS rust prevention and paint next weekend. I also sanding on the tub a little.


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Old 04-05-2014, 10:29 PM   #23
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I was in the shop from all day today and had a productive day. I got some fab and welding done on the frame (rear crossmember) and started putting applying KBS rust prevention system. The KBS system is a lot of work, but hopefully will be worth it in the long run... more on that later. Tomorrow, I plan to finish coating the frame.

And I'll add pics of the process and finished product.
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Old 04-05-2014, 10:34 PM   #24
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Looking good you are making good progress
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Old 04-06-2014, 06:34 PM   #25
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Looks like you've been working pretty hard on this...if you get a chance can you post some pictures of the frame coating process...I'm still trying to decide what product to use on my frame...any suggestions would be great...thanks!!
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Old 04-06-2014, 08:59 PM   #26
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I finished the frame coating today, but I still have to apply a 2nd coat of paint.

The KBS Frame Coating System starts with Aqua Kleen, then Rust Blast to smooth out rusty surfaces. Next you apply Rust Seal (the actual coating). And last, if you choose, Blacktop, which is a chassis paint. The Rust Seal is not UV resistant and even though the frame will not get much sun, I choose to apply the Blacktop chassis paint.

I was really happy with the easy application of the Rust Seal, it went on smooth and was a good consistency. It dries smooth as glass and is hard as a rock. Rust Seal Comes in several colors, but I choose gray since I was painting over it anyways.

The Blacktop was harder to apply, but still turned out nice.



Here, I am applying the Rust Seal.



Finished with the Rust Seal coat.



Close-up



And finally, here is the Blacktop Chassis Paint after the first coat. I still have one more coat to apply.




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Looks like you've been working pretty hard on this...if you get a chance can you post some pictures of the frame coating process...I'm still trying to decide what product to use on my frame...any suggestions would be great...thanks!!
Gunny,
All in all, I liked the KBS System. If I was to use it again, I would probably save a little money and use a good rattlecan paint instead of the chassis paint. The prep sucks, because you have to wash the frame after using the Aqua Kleen, let it dry, apply Rust Blaster, wash again and let dry, then apply the Rust Seal. But as long as it does what it supposed to, I'll be happy.
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Old 04-06-2014, 09:11 PM   #27
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I hope to apply the 2nd coat of chassis paint sometime this week. After that, I guess my next move is install the lift kit and axles.
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Old 04-07-2014, 08:15 PM   #28
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I managed to slip out of work early today and finish apply the second coat of paint. Over the next few days I'll be spraying PB Blaster (every time I think of it) on the "roadworthy" Jeep to make it a little easier to get the axles off this coming weekend.
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Old 04-13-2014, 10:20 AM   #29
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This weekend I pulled the Jeep in the shop and started the tear down, starting with the D30 and D35. I got a little spoiled when I since I started working on the rust free (mostly) donor Jeep first. I managed to the the front end out and almost finish up with the rear end before I had to call it a day. I hope to finish removing the rear end this week.

Running out of shop space





By the end of the day, I had a mess.

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Old 04-15-2014, 02:13 PM   #30
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I got the rear end out yesterday evening after work. Now, I'm going to work on cleaning both axles up and make them pretty, but not too pretty since I've talked myself into doing an 8.8 swap later down the road... when time and money allows. This coming weekend I'm planning to install a 2.5 inch lift.

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