Jeep Wrangler Forum - Reply to Topic
Jeep Wrangler Forum

Go Back   Jeep Wrangler Forum > YJ Jeep Wrangler Forum > YJ Build Forum > My Longer YJ

Join Wrangler Forum Today

Thread: My Longer YJ Reply to Thread
Post Icons
You may choose an icon for your message from the following list:

Register Now

In order to be able to post messages on the Jeep Wrangler Forum forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.
User Name:
If you do not want to register, fill this field only and the name will be used as user name for your post.
Please enter a password for your user account. Note that passwords are case-sensitive.
Confirm Password:
Email Address
Please enter a valid email address for yourself.
Email Address:


Human Verification

In order to verify that you are a human and not a spam bot, please enter the answer into the following box below based on the instructions contained in the graphic.

Additional Options
Miscellaneous Options

Topic Review (Newest First)
07-30-2014 08:22 AM
Tx 91 YJ Just to give an update. The roll cage didn't fit so it had to go back to the fabricators shop. It had to be cut and reworked because it didn't allow the windshield to lay at the proper angle for the hard top and doors to align properly. Huge disappointment and set back. He has had it for a long while and now closed his shop and doesn't answer his phone. So it's looking like more delays for that part of the project. I was waiting to take it to get the paint done so I could align the doors and get everything straight before it got a new paint job. I could not wait any longer for that and have taken it in for body and paint work as is. I have asked them to remove the hinges for final alignment after I get the cage figured out. It would be nice if people would actually do the work you hire them to do and take pride in their craft. This guy took measurements off his wife's yj that had a soft top. So somewhere along the way stuff got jacked up.
06-02-2014 02:06 PM
Tx 91 YJ I was thinking about a bright silver to contrast the powder coating on the cage and side armor. No final decision yet though.
06-02-2014 01:51 PM
wickedyj Its looking great have you decided on a color for it yet?? Fords new color Dark Side would be cool looking an a different color for a custom built jeep. Frame issues are the only thing holding up from finishing mine.
06-02-2014 12:41 PM
schwag27 hahaha - and I am freaking out about trying to fix my rusty frame spots. keep grinding brother!
06-02-2014 12:36 PM
Tx 91 YJ
Originally Posted by Lil Red JK View Post
Awesome build! Read through it all tonight. Can't wait for the end product!
Originally Posted by Mogimbu View Post
What an amazing project! I love the stretch concept and your execution is great as well!
I may have missed it in the build, but brand thermal and sound deadening material did you use?
Originally Posted by ArcsnSparks View Post
Awesome build! I really admire your vision. Can't wait to see the finished product.

Thanks for the words of encouragement it's defiantly nice to hear some positive feedback when all seems to be running at a snails pace. Also some of my interactions with local shops look at me like I'm crazy for doing this project. I generally avoid describing my project unless it's absolutely necessary. There is a good decal that should describe this project.

06-02-2014 12:25 PM
Tx 91 YJ
More Delays :(

So I thought the month of May would be the home stretch. It clearly wasn't. Not a single post here to update. So I'll update now. I have discovered the major setback is the cage I had built doesn't fit correctly. It pushes the windshield frame forward too much and doesn't allow for proper door alignment or hard top installation. This has pretty much put the project to a grinding halt. No body work or anything can be done until the cage fits properly. Ive grown numb to the disappointment of the constant problems. Ho hum.

The wire harness is in and the Jeep runs. This is helpful since moving it as well as getting it on the trailer and off has been a challenge before this step. I sorted out the grounding issue that was causing me problems. The support bars that go between the firewall and the grill provide ground for the lights and when not installed were causing all sorts of weird things to happen. Those are installed again and now I am just waiting for some shop space to open up so I can get my cage modified for the proper angle of the windshield. Ive got my fingers crossed that this won't take too long. It will also need to be repower coated So add some more time to that. There were also some issues with some other parts that were coated and not properly adhering. So back they go as well. Finely because a update posting isn't nearly as exciting without pictures here you go!

Where the cage mounts to the windshield frame an the gap that doesn't allow for proper fitment.

04-30-2014 03:59 PM
ArcsnSparks Awesome build! I really admire your vision. Can't wait to see the finished product.
04-20-2014 08:23 PM
Mogimbu What an amazing project! I love the stretch concept and your execution is great as well!
I may have missed it in the build, but brand thermal and sound deadening material did you use?
03-30-2014 11:02 PM
Lil Red JK Awesome build! Read through it all tonight. Can't wait for the end product!
03-30-2014 09:19 PM
Tx 91 YJ
Originally Posted by new2jeepin View Post
What did you end up doing on the blower
The blower on the heater box is the factory one. I was considering changing out the blower on the A/C unit but I haven't gotten to that part yet. The A/C blower is still pretty stinking loud. I was thinking of going with a different set up to quiet things down.
03-30-2014 09:16 PM
new2jeepin What did you end up doing on the blower
03-30-2014 09:03 PM
Tx 91 YJ
More Progress

So I am getting a bit of momentum with the Jeep lately. I put the rest of the heater box and ventilation back in. The dash frame, wiring harness dash pad and some of the other dash back into place. I also wired up the new radio and some new speakers.

I made some spacers for the new speakers because the YJ just has an odd set up and the last ones I had in there the speaker hit the metal dash/grill and eventually destroyed them. I used some hard fuel line that I had left over from re-pluming the fuel lines.

Lastly I have some electrical issues that I'd love some help with. If you have had similar issues and the fix please let me know. Here is the link
03-27-2014 11:31 PM
bobbowtie will be badass when it is done
03-27-2014 07:42 PM
Monster93 I have to say.. Very cool!!! and very clean welds, Great work on it, I really admire good craftsmanship and imagination, Really great job brother!
03-25-2014 11:37 PM
Tx 91 YJ So I got the heater box back in it's spot.

I have been salvaging some of the hardware. Here are the body bolts I might have to replace one but the majority of them did pretty well soaked in vinegar and repainted.

Now this is where I called it a night. Where does this all go again?!?!

03-21-2014 10:06 PM
Tx 91 YJ Now that it's been mentioned I do remember someone using a s10/blazer blower. I'll have to dig for that.
03-21-2014 09:22 PM
Zombiekiller wow sub'd
03-21-2014 07:55 AM
YJ Nate Yea, it was the blazer iirc. I dont know the specifics though.
03-21-2014 06:30 AM
kywaterman I was wanting to think a blower motor out of an s10, not sure what year though, was the stronger one people swap in. But anyways, looking good. Very neat project you have going on here.
03-20-2014 11:24 PM
new2jeepin I forget exactly what model it is but I wanna say Durango blowers bolt in and offer much improved air flow.
03-20-2014 08:39 PM
Tx 91 YJ
Heater box rebuild

So in pulling everything apart I decided I wanted to rebuild the heater box. A new box was 179 so I thought I could do better. I purchased a new heater core and then some adheasive foam to replace the 20+ year old dirty foam. So it was about 20 bucks for the foam and 38 for the new heater core.

I cleaned up the exterior of the box and repainted everything removing rust as needed and scraped off the old foam and cut new replacements. It wasn't that difficult to get done and turned out pretty nicely. I am finding that the YJ is old enough for some parts to be difficult to find but not old enough for lots of restoration support from the companies like LMC. The stuff I can find like baffles and new foam it was much more expensive than doing it myself and by the time I added up all the different parts it would be more expensive than the new box.

Here are a few pictures. I haven't put the blower motor back in yet. That is the next step and then off to the A/C unit. I bought new hardware for the A/C and I am toying with removing the blower and replacing it with a brush less 12v fan that I am thinking will push more CFM than the factory set up. I haven't quite figured out how to get that particular fan to regulate between low/med/hi. So that is the next project in putting the dash and everything back together.

Here are some pics of the heater box. I won't be using it for this season but I am pretty sure next season it will come in handy if next winter is anything like this winter.

Trace and cut:

Pretty nasty old foam. No telling what has been absorbed over the years

Cleaned up repainted and refoamed. Should be much more effective!

03-12-2014 02:39 PM
Tx 91 YJ So I figured I'd replace the filler neck and vent hose since they were reasonably accessible at this point. A trip to the auto parts store and no one has them in stock around here. Who knew they would be such a specialty item. It's the small things that nickel and dime you to death. I also cannot seem to find washer nozzles to replace mine. I broke one and the other is old and brittle.
03-12-2014 11:29 AM
daddyjeep Cool, we like progress...and pics. Glad you are getting things done again.
03-12-2014 12:09 AM
Tx 91 YJ
More progress

Hey so I have good news on the Jeep build. More progress. I got the top coat on the thermal/sound deadening spray done Monday. I had a friend and a neighbor help me put the body back on the frame tonight. I am very happy that I don't have a pile of Jeep parts any more and it is now looking like a Jeep again.

And because progress and pictures go so well together here is a visual aid to my happiness.

03-06-2014 08:07 AM
shotzy Wow a truly amazing build. Keep up the good work.
03-05-2014 10:57 PM
daddyjeep If that happens a good mud bath should get rid of that smell for you.
03-05-2014 10:34 PM
YJwrangler92 Gone through the Entire thread and I am blown away by the amount of work and energy you have put into this. Lots of respect and keep pushing, It will be a beast when its done.

03-05-2014 08:22 PM
Tx 91 YJ
Originally Posted by charleybrwn13 View Post
What type/brand of undercoating did you use?
Lizard skins thermal and sound control.
03-05-2014 08:22 PM
charleybrwn13 What type/brand of undercoating did you use?
03-05-2014 08:21 PM
Tx 91 YJ Thanks for the words of encouragement. I have felt a little down about this process lately. I think I'll be able to get some work done next week. I have a few days off and hopefully I can get the body back on the frame.

Currently purchasing parts for the heater box rebuild. That has been looking a little dated with the foam rubber seals going bad. Who know I may even have a new car smell when this is all done lol.
This thread has more than 30 replies. Click here to review the whole thread.

Posting Rules
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off

All times are GMT -5. The time now is 04:52 PM.

Jeep®, Wrangler, Liberty, Wagoneer, Cherokee, and Grand Cherokee are copyrighted and trademarked to Chrysler Motors LLC. is not in any way associated with the Chrysler Motors LLC