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Old 10-17-2013, 09:49 PM   #1
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2005 tj build

I bought my Jeep bone stock a little over a year ago and now she's sitting on 35s. I do almost all of my own fabrication and will be posting my work here. Projects to look forward to are an 8.8, front bumper w/ stinger, rear tire carrier, full cage, and more!

Right now I'm working on the 8.8 which I put 4.88 gears in, Lincoln locked, and welded the tubes to the housing. I just need to mock everything up and weld the brackets on.

I also have the front bumper w/ stinger in the works. The base right now is a 4"x4" square tube and the stinger will be ~29" from the bottom of the bumper.

Pictures to come later!

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Old 10-17-2013, 09:52 PM   #2
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When I first started prepping the axle.

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Old 10-17-2013, 09:55 PM   #3
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This is currently what I'm working with as far as the front bumper goes. Once I have the bumper how I want it I'll weld the stinger on and tackle the support tubes for it. I'm considering tying it into my cage down the road.
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Old 10-17-2013, 10:26 PM   #4
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Looking good bud!
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Old 10-17-2013, 10:32 PM   #5
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bump
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Old 10-17-2013, 10:34 PM   #6
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bump
Hello good sir.
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Old 10-17-2013, 10:44 PM   #7
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Day 1

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31s shortly after

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3" lift along with 1" body/mml

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My Jeep got me a job lol. Yay 35s!

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I think it's safe to say my axle u joints were DONE

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Old 10-18-2013, 12:48 PM   #8
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Sorry, no internal pictures. I put everything together before I even thought about it!
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Old 10-18-2013, 12:57 PM   #9
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I forgot that I had tube fenders in the works too. I decided to order the DIY ones from Blue Torch Fab. I've always liked their products. I ordered them about a week and a half ago, so hopefully they'll be here soon.
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Old 10-18-2013, 02:24 PM   #10
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Cool gonna follow along on your build. I like the pics so far.
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Old 10-21-2013, 02:18 AM   #11
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I was going to tackle the front bumper today, unfortunately we got hit hard at the shop today so I didn't get off in time to get the rest of the stuff I needed. So tomorrow I'll be picking up the d-rings and paint I need. This is going to be a fairly basic bumper. The plan is to cut my frame as far back as I can (basically to my steering box) and weld the bumper to the frame. I do need to think carefully about this though because I am planning on putting a Durango steering box in at some point and seeing as I have to do a little bit of fab work (surprise!) I really need to make sure it will fit so that I don't have to cut all my welds and redo it. Anyway, I picked up 4 somewhat thick plates with holes drilled through the middle from Lowes and I'm going to weld 2 of them together and cut the edges down for my shackle mounts. I'll weld those onto the bumper, then mock up the stinger before doing the final weld to the frame. I'll be doing most of this work at night tomorrow so I won't really have many pictures, but I'll be sure to get plenty of the finished product!

As far as my axle goes I'm planning on tackling it not this coming Thurs/Fri, but the following week. In the meantime I'm going to start taking measurements for my cage!
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Old 10-21-2013, 09:05 AM   #12
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You planning on cutting the tube crossmember up front? You want to borrow my winch for a mockup? It's a 8000# shittybuilt.
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Old 10-21-2013, 05:55 PM   #13
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You planning on cutting the tube crossmember up front? You want to borrow my winch for a mockup? It's a 8000# shittybuilt.
I don't think I'm going to cut the tube, but my frame sticks out past that about an inch so it will give me about the same approach angle I have now. Thanks, but I'll be using my friends for the mockup, he has a warn sitting in the garage that he might end up giving me.
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Old 10-24-2013, 07:05 PM   #14
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I had the bumper just about finished when all of a sudden my welds turned really sloppy. It turns out that my argon wasn't feeding through. I grinded off the bad welds and went and warrantied my welder out. Sitting at the eye doctor right now for my appointment so hopefully I'll be able to finish things afterwards.
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Old 10-24-2013, 09:27 PM   #15
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Spend a few hours welding then go see the eye doctor. I hope you didn't get any flashes.
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Old 10-24-2013, 09:45 PM   #16
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Ya! Someone else is going to end up wheeling your rig when you're finished
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Old 10-24-2013, 10:00 PM   #17
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If I may make a suggestion regarding your D-rings....
I would order up some D-tabs off the net....then cut slots in your bumper and push them through the backside of the bumper... then weld them from the front & back side.....much stronger then what you have now and a lot safer too.

Just my $.02
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Old 10-24-2013, 10:49 PM   #18
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Spend a few hours welding then go see the eye doctor. I hope you didn't get any flashes.
My eyes have actually gotten better
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Old 10-24-2013, 10:51 PM   #19
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If I may make a suggestion regarding your D-rings....
I would order up some D-tabs off the net....then cut slots in your bumper and push them through the backside of the bumper... then weld them from the front & back side.....much stronger then what you have now and a lot safer too.

Just my $.02
I agree. I actually have some steel that I drilled holes into and just need to shape into tabs. What's on there right now isn't going anywhere though, I burned them straight through.
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Old 10-24-2013, 10:52 PM   #20
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Painted it. Those welds burnt right through. Going to eat some dinner and then work on the stinger.

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Old 10-25-2013, 10:32 PM   #21
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I had my friend do the welds on the stinger, he's a lot better with tubing than I am.
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Old 10-28-2013, 08:33 PM   #22
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Lookin good!!
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Old 10-29-2013, 12:35 AM   #23
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Lookin good!!
Thanks! My fenders are supposed to be coming in sometime this week. The plan is to run support tubes from the stinger to the fenders. I'll also be running a tube across the stinger for mounting my lights.
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Old 10-29-2013, 01:23 AM   #24
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Looking great
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Old 11-07-2013, 11:58 AM   #25
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I haven't been able to touch the Jeep in a while. One of the other techs quit so I've been having to cover. I just dropped the Jeep off with Stan to get my rear end put in so it's not sitting in my driveway forever. My fenders still haven't come in either...hopefully we'll get another tech soon so I can finish everything up myself.
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Old 11-13-2013, 08:25 PM   #26
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Axle is in, thanks to Stan for helping me out. My welder is good to go again as well, but still no sign of my fenders. I plan on doing the front gears this Thursday/Friday if I have the time. (New lady friend is putting a damper on Jeep progress ) An issue did arise from my axle install which I had anticipated: drive line. I ordered my adjustable uppers and will be doing my sye shortly. Hopefully my parts will come in so I can stop talking about what I'm doing and actually show it
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Old 11-13-2013, 10:14 PM   #27
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I'm watching this. Nice build you got going.
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Old 11-14-2013, 04:40 PM   #28
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I'm watching this. Nice build you got going.
Thanks Bob! I got delayed today, but I'm planning on doing the gears tomorrow. It will be my second gear set ever! I'm hoping to get some cool pictures
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Old 11-19-2013, 03:07 PM   #29
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Metalcloak adjustable uppers are in. I was having a lot of trouble getting the passenger side arm in, so I ended up adjusting it about 1/8" shorter than the drivers side. My pinion angle looks a lot better, I haven't had a chance to test drive it though. I ordered my sye a few days ago as well. Aiming for Friday for the front gears, but there's a lot to be done on other things in preparation for Thanksgiving.
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Old 11-28-2013, 01:30 AM   #30
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Front gears are done, got a perfect pattern on the first go! Going to cut my fenders since the new ones still aren't in. My sye is here, but I'm going to calico for the weekend so I won't be doing that until I get back.

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