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Old 03-11-2014, 08:15 PM   #1
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THE Hunting Rig

I am going to attempt to put together a fairly detailed thread here for anyone interested. I just recently got out of the Marine Corps after 13 years as a Tank Mechanic. (NO I didn't get kicked out. The downsizing SUCKS and I was ready for more family time.)

I've had this 94 YJ sitting behind my buddies shop for literally 10 years and now that i'm home the build is on. I will update with as many pictures as I can remember to take. I will also let everyone know where I ordered each part from as well as how much it cost.

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Old 03-11-2014, 08:25 PM   #2
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looking forward to seeing what you do, remember we like lots of pictures

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Old 03-11-2014, 08:34 PM   #3
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Operation "Get it Home"

First order of business was to get it home. The poor thing literally looked like it had grown roots. There were weeds and grass growing around the axles and frame. The poor 32x11.50 BFG MTs were dry rotted and buried in the dirt along with the wheels up to the hub. My brother had to pull it out with his truck and then up onto the trailer. This was all after putting on two doughnut spares that my buddy had lying around, his moms spare out of her trunk and a random boat trailer rim. We jackknifed my Duramax and the trailer, then my brother used his truck to pull it up onto the trailer.
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Old 03-11-2014, 08:46 PM   #4
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Good luck
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Old 03-11-2014, 09:07 PM   #5
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Inspection time......

Now that it was home I gave her a good bath and looked it over. This is when I decided on my list of upgrades/places to spend money. This is the list....

1. Sand of the primer (this was sprayed on by the douchebag that stole it from me in the summer of 2004. I got it back after a short 5 months of him driving it with Jetta plates on it.)
2. Replace the aluminium "Pretty" bumpers with a winch bumper and rear bumper /tire carrier.
3. Add a Winch
4. Spray in bedliner for the inside.
5. Paint the outside.
6. Total tune up.
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Old 03-11-2014, 09:31 PM   #6
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Cleaning her up

Not even 3 years old yet and already HAS to have tools when daddy is working. I ordered 5 cans of the spray in bedliner from DeeZee @ 17 dollars a can and although its OK I found a cheaper path. I picked up a few cans of the Rust-oleum spray in bed liner for 7.47 a can and it sprays on thicker and has a rougher texture to it.
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Old 03-12-2014, 12:28 AM   #7
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Old nasty tires...

Next order of business was to get some rubber on the wheels so the thing could be rolled in and out of the garage. None of the tire shops would touch them to remove the old rotted tires off the wheels so my brother and I went to work with the saws-all and a pry bar. 6 blades later the wheels were ready to be cleaned.

I live in southwestern Arizona and little corner tire shops are abundant but not a single one had a used set of 31-33" tires. I had all but given up when I took the old tires to the dump. Lo and behold there was a set of 31X10.50s sitting there and I was lucky enough for the guy working there to "not see where they went."
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Old 03-12-2014, 05:10 AM   #8
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Looks like a great project...I'm doing a frame off resto on my 88 YJ...so far I've had a blast tinking on it...good luck and Semper Fi!!...Gunny Out!!
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Old 03-12-2014, 07:03 AM   #9
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first off,,,welcome home..
cant wait to see where ya go with ur build,,wish we were closer i have a set of 35swampers i would give u for it..

and it always does my heart good to see the kids take part in a build...awsome..
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Old 03-12-2014, 11:22 AM   #10
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Internet shopping!

I had my buddy swap in a Dana 60 out of a 2005 Superduty into my Duramax while I was in Afghanistan this past summer. I had the Fabtech lift kit off the truck laying around and ended up selling so I had a decent chunk of change in my PayPal account to spend on the jeep.

Here is the list of purchases along with price and where I ordered from.

1. Spyder winch bumper for 216.95 shipped.......Ebay
2. Smittybilt XRC8 winch for 299.00 shipped.......Ebay
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Old 03-13-2014, 10:48 AM   #11
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Stinky garage....WTF?!

I had the front end jacked up and left it sitting on the jack stands over night and came back to a smelly garage the next morning. There ended up being a small crack in the bottom of the gas tank so out she came. After 10 years of sitting in out in the Arizona sun with that old smelly fuel I figured the sending unit needed replaced anyway.

Here is the tank after using the plastic welding kit.
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Old 03-13-2014, 10:53 AM   #12
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I picked up a new sending unit on Ebay for $110 with free shipping. Went ahead and replaced the lines for the two little breathers on top of the tank.

Another good thing I did was remove the plastic tube that was stuck down in the vent hole. Smart asses that designed these things had a sneaky trick to keep you from filling up a 20 gallon tank all the way. But most of you guys already knew that.
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Old 03-13-2014, 10:56 AM   #13
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I got the filler and vent hoses on Ebay too. 40 bucks but 10 for shipping. I tried to get them locally but.....

Autozone-nope
O'rielys-nope
Napa-nope
Dealership- Filler NO, Vent YES but it was $27
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Old 03-16-2014, 11:51 PM   #14
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I will be driving up to Phoenix on Saturday morning to pick up my Ford 8.8 for the upgrade!!!
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Old 03-17-2014, 07:35 AM   #15
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You're off to a good start!!
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1995, 4.0, 5 speed YJ, SOA, TC drop, 8.8 swap with 4.10 and LSD, e-grills bumper, 33" BF all terrains on 15" wheels.
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Old 03-18-2014, 12:39 AM   #16
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looks like you like ebay as much as I do that's how I got most of my parts
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Old 03-18-2014, 08:44 AM   #17
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Looks like you are coming along nicely. Keep it up.
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Old 03-18-2014, 10:53 AM   #18
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Cutting, Sanding and free tires!

Next order of business was to get it ready for some new paint. Since it is going to be primarily a hunting rig we decided to go with the rust-oleum camo green. I sanded it down with the help of my brother and used the pressure washer to get it nice and clean. Went ahead and cut off the old exhaust too. The welds had cracked around the catalytic converter and the stock header had a large crack in the collector.

Big thanks to the cool guy at the dump that let me take the used tires sitting there. It helped out big time being able to push it in and out of the garage.
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Old 03-18-2014, 11:03 AM   #19
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E-Autogrills

I found some copycat tube fenders on Ebay that are almost identical to the Smittybilt XRC's. I got them for $280 from E-Autogrills with free shipping. No surprise that they showed up with ZERO instructions. Didnt really matter because I figured it out on my own. I got the passenger side installed fairly easy and it is actually pretty strong. I can put my full 195lbs on it and bounce and the only thing that moves is the suspension.
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Old 03-18-2014, 04:28 PM   #20
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Lookin good so far, nice build.
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Old 03-19-2014, 02:09 PM   #21
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Getting Crazy

I pulled out the stock Dana 35 yesterday in preparation for the Ford 8.8

Any input from you guys that have done this swap is appreciated. Specifically places to purchase all the little stuff.
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Old 03-19-2014, 02:41 PM   #22
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Nice job so far....having the skills, the tools and a brother to help are priceless...Welcome home, thank you for your service.....

And of course, Semper Fi
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Old 03-19-2014, 03:07 PM   #23
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E bay is your friend.. There are a lot of venders on here that sell kits but I did the e bay thing also. you will need spring perches, u bolts, and shock mounts. you could attempt to cut the old mounts off your axle but it was easier for me to buy new. I bought a brake hose to adapt the original line from the axle to my jeep frame. My next purchase will be the e brake kit to hook up my rear parking shoes inside my disk drum.

Looking good.
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Old 03-19-2014, 03:15 PM   #24
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New Tail Lights

I have never liked the big plastic boxes bolted to the body that we call taillights. While they were off during the painting process I decided to ditch them in favor of some 4" lights from GloLite. Bought them on ebay for $35 with free shipping. A 3 5/8" hole saw did the trick and a little bit of round file work to get them to fit nice and tight.
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Old 03-19-2014, 03:16 PM   #25
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Nice build you've got going here. Can't wait to see how it looks finished!
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Old 03-19-2014, 04:38 PM   #26
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Looks like you moving along at a good pace looking good !!
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Old 03-20-2014, 11:49 AM   #27
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Bit O Help

Hopefully one of you guys following this thread can help me a bit. I am picking up my Ford 8.8 on Saturday. It is out of a 1999 V8 Explorer. The guy at the junkyard said the V6's have a different rear end. Is this correct?

Also, what size springs will I need? I am going with Old Man Emu and want spring under.
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Old 03-20-2014, 12:55 PM   #28
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I don't think that it's different. But I hope someone chimes in. Mine came out of a V8 explorer and it has rear discs. Did you get the same gearing as your front? As far as springs go... unless yours are busted just reuse them, buy spring perches and shock mounts.
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Old 03-20-2014, 12:57 PM   #29
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The OEM perches on the 8.8 are not in the correct location for the YJ.
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Old 03-20-2014, 05:41 PM   #30
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I got one with the LS 3.73 gears. I know im going to have to get new perches. I have been reading the detailed threads that others have put together. Now I just need to figure out my pinion angle.

My jeep doesn't have the stock suspension on it. As far as I can tell it had the Pro Comp 2.5" lift.

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