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Old 01-29-2014, 12:52 PM   #1
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Tom95YJ's "The Smurf" Build

Ok guys I am starting a build thread for my 89 islander edition Dubbed The Smurf the name stems from an obvious resemblance to a smurf ! This is my 6th Jeep and 2nd YJ , I have been around the block a few times so I am not new to this Obsession as my wife would say.

Heres the back story with a little of idea of how it will be morphing over the next little bit of time :


Last May, I had traded my Auto-X Project/DD Miata for a Pretty clean '89 Wrangler Islander . After looking for someone to trade for almost 2 years I found someone was willing to trade.

Specs on the YJ :

1989 Islander Edition (Pacfic Blue A.K.A. Smurf Blue )
4.2Lw/ Ba10 (works for now)
Hardtop with Full steel doors
208,000 miles
RUST FREE minus the P/S front fender

The Bad : Jeep would not idle on its own, and front axle would not engage in 4 wheel drive. Minor repairs that would scare away most who are not too knowledge able with Jeeps .

My Plan for this Jeep is to keep it simple, and a Budget friendly since it will be DD/ Medium Duty trail rig I had several thousand in my 95 YJ and I was given a Ramen Noodle/ Steel Reserve budget with this one since I am now a Home Owner, Have 2 Kids , and I make about 1/2 as much as I used to 7 years ago. My 95 was build on a Filet Mignon and Topshelf Bourbon Budget.


Mods I intend on doing will be :

4" Lift
TJ Flares
PSC Rear 1/4 gaurds & Sliders
4:10 gears (4banger Axles at first 8.8 rear later on)
F/R Lockers (Spartans)
SYE w/ XJ shaft
TJ Grizzly wheels
Bedlined Interior
Front and rear Bumpers (2x4 boxed steel front stubby with Swing out carrier rear)
8000# winch
Bestop Supertop w 2 piece soft doors

Here are some pics from the first day once I got home with it.




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Old 01-29-2014, 12:58 PM   #2
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A few days after I brought it home I had to take advantage of the Beautiful weather outside .

So the obvious thing to do was Detail the Jeep, Wash, Claybar, Buff the paint , Then to remove the Hardtop and Doors. Once that was done it was time to work on the interior a little. I had replaced the stock shift knobs with the ones I had in my last YJ, Rewired the head unit so it worked, I had also installed my son's car seat so he could enjoy the Jeep with me . After I was finished with that I went back to working on the exterior and Bedlined the T-case skid, Frame, Front bumper, Rear crossmember, and Hitch. Then on to the Underside I Relocated that useless government mandated BS like Trackbars and Swaybars into the Trash can

After I was done doing my projects my buddy came over to check out "The Smurf" We started talking about the running issue so we popped the hood and started to tinker with the carb. We had found a broken Vacuum line under the carb. So we took some extra line off another hose and cut a small piece to install on the bad line. After that it wanted to idle but the Idle set screw was set to like 300 rpm so it died. Tyler had started it up and I had adjusted the screw a little and have it Idling at 750-800 rpm and it runs on its own now. But it has a slight stumble while Idling but when driving its smooth as silk so I am sure the timing is off. I'll address that over the weekend.




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Old 01-29-2014, 12:59 PM   #3
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A few days later I had Ziptied up all the wires under the dash to get rid of the ratsnest of wires . My Neighbors Brother in law sold me his stock TJ Grizzly wheels so I threw them on the YJ today Which makes it look much better !

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Old 01-29-2014, 01:04 PM   #4
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A few weeks later ( Fathers Day Weekend) I took the YJ on its maiden voyage up Forrest lake trail in Unita National Forrest with my buddys CJ5 and our Sons for Daddy/Son Bonding day. In a few pic you'll see I had to tow my buddy a little when a battery cable popped off and his key snapped in his ignition until we decided to hot wire his CJ lol . I also had a stick puncture my sidewall, and had a Hub start clicking and wobbling around















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Old 01-29-2014, 01:04 PM   #5
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Contunued......














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Old 01-29-2014, 01:05 PM   #6
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Old 01-29-2014, 01:14 PM   #7
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The following weekend I had to go through inspection and emissions so I had to work on the Jeep I stumbled upon the reason I have a misfire at idle and why my Co2 levels are so high to the point where I barley passed emissions testing I found out why I had a slight stumble at idle and I bypassed my CAD System also .

Who puts this Garbage in the 4.2l ?
Autolite Platinums Yuck. I bought some champion coopers to put in there and I will also possibly be performing the nutter bypass in the future with a TFI Ignition upgrade . to remove majority of the Vacuum lines. I noticed that my Under hood light actually works I also bought a new hub , 36mm socket , and a new torque wrench. Since my socket and torque wrench are in a buddy's toolbox just outside of tellico










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Old 01-29-2014, 01:17 PM   #8
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The Following weekend I did a little more minor work to the YJ, I wet sanded the fenders and grille, Painted them again, Did more sanding and painting. Then I was looking at the front of the YJ releasing it needed something else done. So I bobbed the bumper 13-1/4 " Once the paint cures I will be wetsanding and buffing the grille and fenders to get rid of the orange peel
(I will be replacing the parking lights and radiator so don't worry about the overspray )



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Old 01-29-2014, 01:19 PM   #9
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Later that week I I picked up a set of Rubicon Tj flares off a buddy. So this is a preview of things to come I am currently waiting to hear what's going on with a semi local YJ being parted out. I should know by Thursday if I will get a new rust free p/s fender. If I do I will be painting and installing it. Then installing the Tj flares and removing the steps on the Yj.

I am unsure if I will keep the flares black or if I will color match them. If I keep them black the hardtop will be getting painted semi gloss black

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Old 01-29-2014, 01:20 PM   #10
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I ordered some new lights for the YJ

Some TJ Markers for the TJ flares and some 4" LED Taillights






This is the part # for the LED Tails AutoSmart KL-25108RK
I paid $23.00 for the pair Shipped off Amazon


Saturday I will be picking up a rust free Fender off a 95 YJ , I will also be picking up a few cans of paint so I can paint it before installing the fender and flares.

I will also be picking up some cans of Semi gloss black paint for the hardtop I hope to take it off and get it painted next week some time . I am unsure if I want to keep the TJ flares black or paint them blue to match the factory yj flare color. When I do the TJ flare install I will be removing the steps . I may goto a metal supplier and get some 6x6 by 3/16 angle and make some sliders
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Old 01-29-2014, 01:22 PM   #11
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I got bored sitting around the house tonight so I started to paint the top flat black. I am gonna hit it with some semi gloss clear when it cures. I think the Black top looks much better
Tomorrow I install the TJ Flares





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Old 01-29-2014, 01:28 PM   #12
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Now to start the YJ flare install ! I have to say Southern California vehicles are awesome. 24 year old bolt came out easy no rust and I didn't have to use kroil or pb blaster,





Here is the finished product after the TJ flare install , and painting the black top.


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Old 01-29-2014, 01:32 PM   #13
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I just picked up my newish fender to replace this mess !

I'll prep and paint it tonight.




I painted the fender with the help of my son, Well he decided to take a wrench and try to remove the frame cover . Little man was grunting and surprisingly loosened 2 of the bolts while I was spraying the fender.






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Old 01-29-2014, 01:35 PM   #14
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Started to tear it down today. I was disappointed that it took 20 minutes since the bolts were not seized or stripped







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Old 01-29-2014, 01:38 PM   #15
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Now on to the Flush Mount Led Tail lights !






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Old 01-29-2014, 01:39 PM   #16
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My L.E.D. interior bulbs came in today, So the obvious thing to do was to wait until it was dark to swap them out !


Before:


After:



Comparison shots:




I also replaced my sidemarker bulbs, Man they went from orange to yellow, the back side of the housing also lights up the wheel well !






The bulbs I used are 5 diode T10 wedge L.E.D.'s I picked up 20 off of Ebay for $10 shipped
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Old 01-29-2014, 01:40 PM   #17
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Took the YJ out and did a little wheeling, and got stuck. So I had to swallow my pride and call my wife so she could rescue me in the XJ lol















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Old 01-29-2014, 01:41 PM   #18
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Old 01-29-2014, 01:42 PM   #19
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A few days later I did a little Crawling on a rock pile for my RC Crawler


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Old 01-29-2014, 01:43 PM   #20
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I stopped by 4wp today to get my son a few toys for Christmas and picked up a some bling for the smurf to go along with the chrome factory accents that came on the islander package.


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Old 01-29-2014, 01:47 PM   #21
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Took the Yj out to play today. My Gastank skid and hitch got their asses kicked








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Old 01-29-2014, 05:03 PM   #22
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I went out in the desert with a few friends for a bon fire I can attest that it was cold as hell on the way home ( 50* out and driving topless and doorless at 65-70mph with shorts, flip flops, and a short sleeve shirt everyone else had tops and doors or enclosed jeeps lol )







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Old 01-29-2014, 06:41 PM   #23
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Today I talked to the guy whom I bought my spare fender from to see if he had any Axles from a 2.5L Jeep and told him I was thinking about selling my Hardtop for a Soft top He offered a proposal of taking my hard top and giving me a set of axles for $100 so I may go that route considering I will be buying a super top Or I could trade him my top for a 4" lift he already has ........... decisions decisions
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Old 01-29-2014, 09:45 PM   #24
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Nice work! Sub'd to follow build.
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Old 01-29-2014, 09:57 PM   #25
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some great pictures and a great color for a jeep!!
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Old 01-30-2014, 12:43 PM   #26
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Great pics. Looks like everyone had a great time.

Friend of mine had the same Jeep back in the day. What did we call it you ask? Papa Smurf!
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Old 01-30-2014, 12:49 PM   #27
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Quote:
Originally Posted by W5KVV View Post
Great pics. Looks like everyone had a great time. Friend of mine had the same Jeep back in the day. What did we call it you ask? Papa Smurf!
The name is fitting for this color.

I'm just anxious to get my lift ordered ( 4.5" rc with their new military wrap springs ). And the super-top but Im not looking forward to its install since the po stripped a few torx bolts I'll need to remove to install some brackets which I'll replace with hex head bolts . Once the top comes in I'm going to trade the local guy my hardtop and a little cash for his 4:10 axles
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Old 01-30-2014, 01:40 PM   #28
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I rounded a few out on my Jeep when I changed the windshield gasket. Easiest thing for me to do was use a die grinder, knock a little paint off the head of the bolt & tack weld a 1/2" bolt on it. Then just use a 1/2 socket & back it out. Replace with a hex bolt.

I'm slowly replacing all of my torx heads for good grade 5 hardware.

Getting the old suspension off might pose a bit of a problem for you as well, as the leaf spring bolts love to rust to the bushing sleeve. I had to cut all of my spring hanger bolts out. Total PITA, but worth it.
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Old 01-30-2014, 01:45 PM   #29
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Quote:
Originally Posted by W5KVV View Post
I rounded a few out on my Jeep when I changed the windshield gasket. Easiest thing for me to do was use a die grinder, knock a little paint off the head of the bolt & tack weld a 1/2" bolt on it. Then just use a 1/2 socket & back it out. Replace with a hex bolt.

I'm slowly replacing all of my torx heads for good grade 5 hardware.

Getting the old suspension off might pose a bit of a problem for you as well, as the leaf spring bolts love to rust to the bushing sleeve. I had to cut all of my spring hanger bolts out. Total PITA, but worth it.
The leaf spring bolts wont be an issue at all this is originally a Southern California vehicle I've already had the bolts out when I replaced frame shackle bushings a few months back !

As for the torx I do not have access to a welder so I'll just use my bolt extractor set
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Old 01-30-2014, 09:52 PM   #30
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Took the Yj out to play today. My Gastank skid and hitch got their asses kicked








I was checking out that hitch and how low it was. I am chewing on what to do with mine. I wanted to center my hitch in the channel that I am going to weld in to replace the flimsy crossmember, but I think that is going to be way to high. Hmm...

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