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95YamJam 05-12-2011 06:39 PM

My 95' THE YAM!
I had a 2k TJ that I loved but got rid of. I have also had tons of cars mostly centering around subarus and chevys. I have huge custom project of a 90 subaru wagon that is ateempting to get 35" tires and a full independant supension with a supercharged subaru h6 motor, chevy trans and xfer case, for IRs/ifs 8.8 diffs, 4 wheel steering and basically custom everything.

With a 2 year old the project sits mostly right now. Anyway, i was driving my 2500gmc and It is a great truck but boreing and lumpy to drive everyday and also bad on gas. So i decided to pull the trigger on this 95' YJ on CL.

I wanted a fun DD with part time off road stuff with little projects. So anyway here it is...

Day, I got it two weeks ago.

Yes, I know the shkles are wrong. They get fixed.

So today... Yeah, :)
Front bumper off. I am gonna cut out the bottom captured nuts as one broke out already. Leave the holes for drains. Weld angle brakets on the sides of the rails to mount my new bumper to. Also still use the factory top bolt as well. This way I should be able to put the factory bumper back if I ever choose to. I doubt I will but...
I also got some of the frame tub under coated on the passenger side. The before pic is the driver side but the passenger looked the same.
Wire brush, cleaned a lot, more wire brush, rust inhibiting primer, and truck bed line spray.
Alot more to do but...

95YamJam 05-12-2011 06:42 PM

Got the shackles fixed, turned around and a center support welded in. Also a fender flare trim.

Also gathered parts to fix a leaky pinion and axels seals in the rear. I decided to get a spartan locker for the rear and a new diff cover as well. I hope to have that done by the weeked.

I can't wait to get my bumpers done and take this thing off road!

billytheyj 05-12-2011 11:33 PM

looking good! tires in the near future?

95YamJam 05-13-2011 07:08 AM

I want tires but really will only go 32's at the most. There are 30's on it now. Yeah they will suck but... Honestly looking thru CL for a deal first.

I want the bumpers first that way when I get stuck I will have good hook points to be pulled ot. LOL!

billytheyj 05-13-2011 07:12 AM

Lol yeah I was wondering cuz u have a spartan locker ready to be put in yet with all streat treads!

95YamJam 05-18-2011 11:15 AM

Pinion seal replaced( a lot harder than I thought), both DS u joints replaced, both rear axels seals replaced, spider gears out.

I am ready to put in the spartan and then do all the hardware and shoes on the rear.

Getting the pinion seal replaced was a job in itself. I had to get the correct in lb torque wrench, take a pinion bearing preload measurement, reinstall everything and then reset the pinion bealring preload measurement +5 in lbs.
Not an easy task I should say. I did make my own holder for the axel yoke so thats cool. I double checked myself by using the mark the nut method. It would not have been right so I am glad I did it the way the manual stated. If i would have just marked the nut and replaced it to the same spot the bearing preload would have been to little.

So all in all I learned something for sure and feel confident. I can't wait to do a whole axle setup. I have my 8.8 for my other project that will be a full rebuild/regear.

I can get pics but it's all pretty mundane stuff. The idea of doing the locker now is becuase I needed to have most of the diff dissasembled to change the axel and pinion seals so why not. ;)

95YamJam 05-21-2011 09:04 AM

I got the rear end all buttoned up. All new axels seals, pinion seal, all new drums, shoes, and hardware for the rear brakes. Insatlled the spartan too.
Did some more cleaning on the frame and axel and more undercoating. New diff cover too. Thanks to Tony at Baseline 4x4. Also painted the rear drums with high temp ceramic caliper paint.
First impressions on driving with the locker. I can tell its there but it's not annoying. It locks very easilly, and unlocks right away on turns. I cannot here it ratcheting but I have heard some say that you cannot. So far so good.
Now to get my bumpers done and try this thing out in the dirt.

Driller 05-21-2011 12:35 PM

my 95 YJ looks a lot like yours. one of the front bumper bolts(lower drivers side) had the welded nut weld break loose. how did you manage to get it free as the bumper just swings out some but not enough to reach the bolt.......Driller

95YamJam 05-21-2011 12:40 PM

I just ended up cutting the heads off the bolts. I found the drivers one was broken and it just fell out. I am gonna get the passenger one out too and leave the holes fro drains. I am gonna use the top bolt and weld on new brackets on each side to mount my custom bumpers.

I have also decided that I am looking for 31x10.5x15 tires. 32's are gonna be too big with no lift. Looking for a good used set of mt's.

RLaFitte 05-22-2011 07:36 AM

Great pics and interesting project. Love the color of your Wrangler too. I guess I need to lift mine too, it's too low as is.......

95YamJam 05-25-2011 06:54 AM


I got a good start on the front bumper. I still need to do some tweaking with the brackets. Get the top plate made and welded on, and get the d ring shackle mounts made and burned on. It's really simple but suit my needs.
I may do a small stinger later after I decide on winch stuff or lights. all of that can be added anytime so...
Just for info. All 1/4 wall steel, bolt holes are sleeved, bolts are grade 8. It should not go anywhere. :)

95YamJam 05-28-2011 10:36 PM

Got a set of 5 32/11.5/15 BFG MT KM2s. Almost brand new on a set of black rock rims.
Couldn't pass up a cl deal.
I am gonna put them on tomorrow so i'll have some pics. I guess I better get my lift kit coming. LOL!

95YamJam 05-29-2011 05:03 PM

So I got the tires on. They fit way better than I thought. I still need a lift but they are more than driveable the way they are. I jacked the front tire til the other one lifted off. No rubbing at all in the front and only slight rubbing in the rear. Honestly a small lift shackle would fix it.
I am debating a 2.5" susp lift and 1" body lift. I would like a 4" susp lift but don't really think I need it. I will never run bigger tires than this with these axels or gears so...
Anyway.. I had to test them out. Didn't play long becuse I was by myself in a bad area and it was really soupy with no recovery vehicle.
I still need to get the spare mounted but ran out of time for today and my tire carrier is borked. so...

pwdkawi11 05-31-2011 03:02 AM

how did they hook up? im wanting to get the km/2's

mbaseel 05-31-2011 04:02 AM

1 Attachment(s)
I have a set of the KM2's and they are awesome in my opinion. The only time I have gotten stuck a guy with 37's got stuck and dug holes with his then I attempted to go through with no luck. They REALLY fling the mud if u keep them spinnin and clean and they bite really hard.

95YamJam 05-31-2011 06:11 AM


Originally Posted by pwdkawi11 (Post 1271159)
how did they hook up? im wanting to get the km/2's

I had no problems. Nothing hardcore at all but honesly i don't even think they spun unless i wanted them too for roostertails. :) They are pretty quiet on the road too.


Originally Posted by mbaseel (Post 1271184)
I have a set of the KM2's and they are awesome in my opinion. The only time I have gotten stuck a guy with 37's got stuck and dug holes with his then I attempted to go through with no luck. They REALLY fling the mud if u keep them spinnin and clean and they bite really hard.

Sweet! I am looking forward to trying to get stuck. IMHO it's you don't get stuck your not trying hard enough or your lucky!:)

Great looking yj too!

pwdkawi11 05-31-2011 11:23 PM

ok cool.

RLaFitte 06-01-2011 07:22 AM

95YamJam, in regards to the rust that you have removed... do you have a sand blaster? That would be a wonderful piece of equipment for a project of this type. Great job, man!

95YamJam 06-01-2011 07:49 AM

I do but it was not that bad. I used wire brushes, scrapers and such. Blew everything off /out with an air gun. Used some marine clean from por15, Then rust preventing primer covered with spray on truck bed liner. I still have a little bit to do but it's going well. I also removed all the rusted bumps stop mounts on the rear. removed the rear track bar bracket. Basically got rid of everything that is not nessescary that can hold mud and water.

I need to remove my fuel pump plate and rebuild it cause it is rusted. Also i am gonna need a new gas tank skid someday as well. More than anything i am getting intimate with the underside of it so I really know what kind of shape it's in and then can identify problems and take care of them. All in all the under side is in super shape. The sides of the tub are rusted more than underneath. Nothing detrimental but I will tak care of it.

Not making a show rig at all. Just want it to hold up for a while and have some fun in the process. :)

95YamJam 06-03-2011 04:00 PM

I got some new goodies ordered. 1" body lift/new mount kit, rear 1" lift boom shackles, and some new shocks for 0-2" lift.
My shocks are all completely shot. LOL!
Almost done with the front bumper. I got the 3/4 plate d ring mounts made and burned in. I decided to weld them in from the back too. So it took a little longer. I just have a bit more welding and some grinding and i can paint it and be done with it.
I'll get pics ASAP.

95YamJam 06-04-2011 04:28 PM

Front Bumper done for now. I may add a "stinger" of some sort later IF I get a winch.

billytheyj 06-04-2011 09:38 PM

Winch or no winch I love the looks of stingers! I built mine and only used it once while dropping into a washed out creek. I say put a stinger on it!

Ageless Stranger 06-04-2011 10:15 PM

Your rig looks great! Nice work so far. :appl:

95YamJam 06-05-2011 06:49 AM

Thanks guys! Stingers aren't really my thing on DD type jeeps like mine. I may do a small upper bar later that would be a winch protetctor if I get one.

I also might get some lights too because night wheeling is freaky with just the headlights. :)
Bored after work. Mostly poser pics but I did do some wheeling. Scary at night but she did great!

95YamJam 06-08-2011 06:14 AM

I got my goodie box the other day. I got all 4 shocks put on. Wow! what a difference. Rides totally different.
Also, next time I decided to BL a 16 year old jeep...someone please reach thru the computer and slap me. LOL!
Not really that bad but bad enough. 3 of the 11 mounts had to be some surgery. The steel mounts on the frame are ok but the body mount bolt locations are borked. I got two of them cut out and repaired. So 1 more and the BL is done.
Also I got a new radiator. I knew there was some "green" on top but when the shroud came off, it's done and there were 2 small wet spots. The jeep never ran hot so... . Luckily the local parts store had one in stock for $120 bones.
I'll get some pics of the BL when I'm done.

95YamJam 06-09-2011 05:28 PM

So with some blood sweat and tears and some new cuss words the jeep is ready to go for it's maiden badlands trip.
What was done in the last week?
1" BL, had to rebuild 3 mounts on the body side
new radiator
1" lift shackles rear
mounted "flag"
fix cig lighter
added a bit of steering stops Just to make sure my tires don't hit the leafs when aired down.
checked/filled all fluids
4 new shocks
So it does not sound like much but I was humpin to get iot all done.
I did some garden flex tests and will get pics up in a bit.

Driller 06-09-2011 05:44 PM

you have been busy, looks good to me! just put the bilstein shocks on mine and was only able to get them stock from quadratec after another outfit I purchased from put them on 4 month backorder. had some difficulty getting it done(rusted bolts and shock top bolt) then discovered rust in fuel filter frame area that needs some repair. all else looks ok when I did the other 3 shocks. cleaned up and rust primered and painted each of wheel wells and springs. getting there slowly but getting there....Driller

95YamJam 06-09-2011 08:20 PM

Thanks , it does take time but its fun.

95YamJam 06-14-2011 05:12 PM

So after a mostly successful wheeling day in the badlands i got the jeep cleaned up. All is pretty good. The wheeling pics are in the event thread.
I did break a part on the soft top where it hit a tree, gonna try to find a used one. Not a super big deal cause it still works but I wanna fix it.
Since I blew the rear brakeline coming off the trailer I also started getting the rear brake stuff hashed out. I got all the stuff I need including a 3" longer rear rubber line made. Just need to bend it, flare it and get it put on then I can have rear brakes again. Big thanks to the guys at Brake Materials for getting me all the corect stuff. Everything and I mean everything was rusted off. LOL!
While I was messing with the brake lines I noticed a gas smell and I had noticed one last week working on the under side of the jeep. Well i found it. Fuel filter was rusted thru and weeping. So I got a new filter and some lines to get that replaced. The bad part is that I need to fab up a new fuel filter gaurd plate as mine is basically rusted gone.
Lastly my front fender rust got the best of me a bit. When I rubbed the flare on the front drivers side the rust basically came apart. I still have wheel clearence but need to do something about it. Need to think on that some but it will be fixed by the next wheeling trip.
So all in all mostly not badlands damage persey, but more maint to get this sucker tip top.

95YamJam 07-29-2011 06:39 PM

So started working on the jeep again. Working on the rear bumper now. In my tinkering around the rear(lol). I found some frame rust. It was not showing until I started digging at it. I need to do some patch work on both sides underneath. Other than that it's pretty solid. I wil get some pics of the new bumper. The main bumper is pretty much done but now I need to fix the frame rust before I mount it.
Also 2.5" lift springs are here and waiting to go on when the frame gets fixed. I had a longer brake line made when I redid the rear brakes. My wifey works at a place that can make me some longer SS front lines. :)

Bumper pics:

Still need to build all the mounts, also I will eventually build the tire carrier but for now I have enough to deal with.

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