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Old 03-02-2011, 07:31 PM   #1
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Rob's '89 YJ build thred

Hey guys I just thought i would start a build thread as a way to share and document my progress as I work on my jeep.

Brief history, I bought the jeep last Feb. for $2200. I had always wanted one, and my dad kept yelling at me for taking my 4runner off road (since it was my DD). So an old jeep seemed to be a perfect fit.

Image when bought:


Specs when bought:
  • 130,000 miles
  • 4cly
  • New 5 speed trans
  • Ford 8.8
  • 4.10 gears
  • Dynomax cat back exhaust (had cracked manifold)
  • Full doors
  • Hardtop
  • Bikini top
  • 33" tires
  • 4" fabtech suspension lift (not positive on this but there was a fabtech sticker on the jeep and after some research they made a 4" lift and that's what it looks like i got.
  • shackle lift (looks like 2")
  • Body lift 1"
  • Warn front Bumper with stinger
  • Best top trail max seats front and rear
  • KC lights on the windshield and on the bumper.


I didn't know much about jeeps when a bought it. I had a little bit of mechanical experience. So most of this has been a learning experience for me as well.
What I have done to date:
  • Purchased spare tire and wheel
  • Mounted Hi-Lift jack to rear bumper
  • installed radio and sound bar
  • Purchased factory half doors
  • Replaced front speakers
  • Replaced Starter
  • Replaced Water pump
  • Replaced Exhaust Manifold
  • Battery, Tune up ext.........

Its been a lot of fun so far and has been something that me and my father can enjoy together.
Our plans for the next couple months are:
  • Hurcurliner
  • Durango steering box
  • Drop down tailgate
  • Custom tire swing out
  • 35" tires.
  • 4.88 gears

Not much has changed as far has the outside of the jeep goes so no reason to post an after photo of the jeep. But ill use this thread to post photos of changes has I make them.

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Old 03-02-2011, 09:50 PM   #2
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Nice Jeep. Im shure your mechanical abilities are gonna grow by leaps and bounds. I know mine are.

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Old 03-05-2011, 10:42 AM   #3
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Nice jeep bro! I bought mine around the same time but paid $3200 for it. You definitely got the better deal because you had more upgrades. Looking forward to watching your progress so keep us updated!
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Old 03-05-2011, 10:33 PM   #4
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Thanks guys. The biggest problem I have had with it is some floor rust. I already fixed the big hole under the drivers feet. Still got a small spot to fix in the back.
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Old 03-06-2011, 12:30 PM   #5
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Thanks guys. The biggest problem I have had with it is some floor rust. I already fixed the big hole under the drivers feet. Still got a small spot to fix in the back.
Did you replace the entire front floor pan? I have the same problem. Thats the only place that is rusted out on mine. I have about a 4" whole right in the middle. I'm thinking the easiest solution is to just cut about 8" around and weld a new piece in.

Just curious how you fixed yours.
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Old 03-06-2011, 02:36 PM   #6
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looks like a good project. ur dads right tho its not fun to be breaking things on your DD this jeep looks to be in good shape tho and now u can have fun and not have to worry about you commute to work/school the next day
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Old 03-06-2011, 06:13 PM   #7
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Quote:
Originally Posted by n3rdmedia

Did you replace the entire front floor pan? I have the same problem. Thats the only place that is rusted out on mine. I have about a 4" whole right in the middle. I'm thinking the easiest solution is to just cut about 8" around and weld a new piece in.

Just curious how you fixed yours.
Nope I just wire wheeled all the rusted parts in the hole. Painted it with rustoleum. Sandwiched the hole with two 1/8" peaces of steal with bolts running through. And some sealer to keep the water from going in-between. So far so good! And it feels so strong!
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Old 03-06-2011, 09:49 PM   #8
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By the way all the brown in the photo above is dirt not rust!
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Old 03-08-2011, 10:53 PM   #9
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Looks like fun, please keep us updated!
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Old 03-13-2011, 10:17 PM   #10
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Today I fixed the problem I had been having with the steering box bracket. One of the holes on the bottom of the frame that the bracket connects to lost it's threads. It was still drivable with 3 bolts but wasn't safe and kept on breaking the other bolts that held the steering box on.

So I ratchet strapped the steering box in place and removed all the bolts that held it. I was then able to take the bracket off to get a look at the hole with no threads. It seemed my only options were to either weld the bracket on or run a bolt all the way through the frame, and since I don't have a welder you can guess what I did next. I drilled a 1/2 inch hole thru the frame, and picked up a 1/2" by 6" grade 5 bolt from the store. The stock steering box bolts are 7/16" so I figured the bigger 1/2" bolt would help out. I took it for a little test drive and it all stayed tight and no broken bolts! The true test will be on the trails.
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Old 03-16-2011, 07:16 PM   #11
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I lowered my windshield so that I could remove the dash and finally replace the drivers side speaker. While I had the windshield down I changed the cowl gasket.


But while working on it the plastic dash cracked so I had to use plastic weld to peace it back together. Also some of the metal under the windshield was rusted so I used a wire brush and rust-oleum spray paint on it.


after I was all done I went to raise the windshield and found out that the hinge cracked at some point during the fix....when working on the jeep you always have to expect to do something unexpected.



So I removed the old hinge... pain in the butt! and replaced it with a new one that I was able to pick up from the jeep shop. When putting on the new hinge on I swapped out the torx bolts with flat phillips heads.



I also painted the side mirrors since I had taken them off the replace the hinge.


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Old 03-16-2011, 10:11 PM   #12
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looking good. i've always been afraid to drop the windshield because of the whole breaking the bracket factor. i'm sure the windshield has never been dropped and i don't want to be the first haha.
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Old 03-17-2011, 08:35 AM   #13
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Quote:
Originally Posted by hotshotjus
looking good. i've always been afraid to drop the windshield because of the whole breaking the bracket factor. i'm sure the windshield has never been dropped and i don't want to be the first haha.
Yea I should have used some wd40.
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Old 03-17-2011, 08:58 AM   #14
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I soaked my hinges with some PB Blaster first and let that sit for a couple of days. They were still a little stiff but they moved.
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Old 04-07-2011, 07:14 PM   #15
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Took the sway bar off for good....
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Old 04-17-2011, 10:53 AM   #16
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I'm working on modifying my tailgate to drop down rather then swing out.
First i decided where I wanted the new hinges to go, and I drilled the holes for these before removing the old hinges. I did it this way since I already knew that the gate was lined up with the striker and would close smooth.
So far I removed all the old hardware tire carrier and rubber tire bumpers. Im using bondo on these holes so that it has a smooth look.

I'll post more pics when I have more progress.
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Old 04-17-2011, 06:14 PM   #17
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Done painting.. It turned out pretty good for my first time doing "body work"
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Old 04-17-2011, 06:24 PM   #18
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looks good so far!
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Old 04-17-2011, 06:49 PM   #19
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Can't wait to see how that tailgate turns out!
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Old 04-18-2011, 04:45 PM   #20
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It is looking good!
Please tell me what the deal is with using a Durango steering box. I have not heard of it and I'm about to put a lift on my YJ and am going to have to switch to power steering.
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Old 04-18-2011, 05:11 PM   #21
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Quote:
Originally Posted by Dudeadam
It is looking good!
Please tell me what the deal is with using a Durango steering box. I have not heard of it and I'm about to put a lift on my YJ and am going to have to switch to power steering.
Thanks!
It's suppose to be a direct bolt on. It's more responsive. it's bigger and stronger so you can turn larger tires easier. Its also cheaper then a jeep steering box. I found out about it on google. The only thing that worries me about it is that it's only held in by 3 bolts rather then 4. I have already had problems snapping the bolts that hold in the stock steering box.
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Old 04-19-2011, 07:00 AM   #22
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Thanks!
It's suppose to be a direct bolt on. It's more responsive. it's bigger and stronger so you can turn larger tires easier. Its also cheaper then a jeep steering box. I found out about it on google. The only thing that worries me about it is that it's only held in by 3 bolts rather then 4. I have already had problems snapping the bolts that hold in the stock steering box.
Have you thought about using a steering box brace that connects to the other side of the frame? I'd be interested to know if this works with the Dakota box as well.
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Old 05-27-2011, 11:17 AM   #23
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I have been wanting to hurculiner my tub for a while but I knew I had some rust to fix first. After removing the roll bars it was a lot worse then I originally thought it was...
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Old 05-27-2011, 11:34 AM   #24
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I took it to a welder down the street since I can't weld. I ordered some replacement floor pans offline and he took care of the rest.
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Old 05-27-2011, 11:37 AM   #25
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Now that I have good floors I can finally hurculiner the tub.... First coat is on!!!
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Old 05-27-2011, 12:46 PM   #26
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I'm guessing that Herculiner is about the same thing as Line-X??? We use Line-X exclusively at the mine I work at and it's the toughest stuff I ever saw. Great for floorboards or bedliners. Great thread and great pics, guys! I will be reading it anxiously to see the progress!
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Old 05-27-2011, 02:35 PM   #27
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I have used HercuLiner of wrecker beds before. It's pretty cheap and lasts a long time. Tractor Supply sells it.
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Old 05-27-2011, 07:15 PM   #28
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I'm guessing that Herculiner is about the same thing as Line-X??? We use Line-X exclusively at the mine I work at and it's the toughest stuff I ever saw. Great for floorboards or bedliners. Great thread and great pics, guys! I will be reading it anxiously to see the progress!
Yea sounds like it is the same idea they sell it at auto zone for about 80 a gallon
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Old 05-28-2011, 06:07 PM   #29
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Herculiner looks great I can't wait to get to work onthe list of things I want to do to mine!!!
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Old 05-28-2011, 06:32 PM   #30
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Lookin' good man!
Keep the pics coming!

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