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Old 06-20-2018, 12:32 AM
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Round Two

Well I got the itch for a project again that I can't shake. I have been flirting with getting another Jeep for a while. Thought I may get a used JK but prices are stupid for them with crazy high mileage. I completely rebuilt a TJ last year. Plan is to do it again, should be much easier this time as I know what I'm doing and didn't get hosed on a Jeep like I did with the first one.


This was my last jeep. Did a complete frame off down to bare metal, fresh paint, new frame and torque boxes, new pretty much everything underneath actually.





I'm picking this up on Thursday. 1998 Sahara, 4.0 5 speed, 124k miles. The frame is toast but the tub is in good shape and the price was a great deal. Already have a line on a replacement frame. Planning to pull the tub and seal and undercoat underneath, throw the new frame under. I'll bedline the interior also. Not sure If I'll blast and paint the frame or powdercoat it this time. I'll replace whatever needs it underneath once I dig into it but probably won't go to the extent that I did last time, all at once anyway. Planning to spray it mojave sand and get a black top for it.



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Old 06-21-2018, 01:26 PM
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Brought it home this morning. Had a couple of hours before work and got the interior gutted. Found some rot near one of the bases of the roll bar that I wasn't aware of so I'm going to have to figure out what to do with that. Picking up a new from tomorrow at from Davey's.




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Old 06-24-2018, 01:17 PM
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Picked up a frame in amazing shape from Davey's. Also got a tailgate as my jeep had been rear ended and the tailgate was beyond straightening and saving. Haven't had much time to work on it due to work but got the liners pulled and the gas tank dropped. Next step is to cut access holes from the top of the tub to soak the body mount bolts. The old frame is in horrible shape. I don't want to take any chances on snapping bolts as I've been down that road before and it's a PITA to fix.









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Old 06-30-2018, 09:09 PM
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Things are coming along pretty smoothly. Got the body off of the frame and managed to not break any bolts. The middle parts of the torque boxes were pretty nasty on both sides so I decided to go ahead and fix those while i was at it. Also got the corner of the cab patched up. My welding skills aren't that great but the patches are solid. I have the passenger side torque box to finish up and then I'll start getting the bottom of the tub cleaned up and ready to spray. I'm hoping finish welding the other side tomorrow morning and then start getting the dashed pulled. I have all of next week off from work so I'm hoping to get the driveline swapped over to the new frame and get everything primed, blocked and ready for color.

*********************

Not sure why my pictures aren't showing up, going to try a different site for hosting.

This is my first jeep.



Stated out as this and the previous owner did a fantastic job of covering up a lot of problems that later lead me to swapping the frame and that rabit holed into pretty much redoing the whole thing.



Here's the latest progress.

















Here's a link to my previous restoration that's much more in depth than this one will be if anyone is interested:

https://www.wranglerforum.com/f322/2...t-1336737.html
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Old 07-06-2018, 04:29 PM
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Well new frame has been prepped and painted. Also got it raptorlined but not pictures of that at the moment. I'll let it dry over night and start swapping everything over to it tomorrow. In the mean time I'll continue working on the tub. Got the dash pulled and all of the welding done. Had to fix some rust that was near the tunnel, weird spot for it to rot. I'm currently working on getting the rest of the interior of the tub ready to paint as well as underneath it. Picked up some Mojave Sand color and clear today as well.

One of my doors had some funky bondo on it. After taking the panel off it looks like at some point a bullet went through the door. Plan is to cut and weld a patch panel in to fix that.





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Old 07-06-2018, 10:21 PM   #6
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I just picked up a 98 that i am thinking about redoing. the tub is savable but it need's some mount's on the torque boxes replaced. Did you make those mounts or buy them ?
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Old 07-06-2018, 11:15 PM
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I just picked up a 98 that i am thinking about redoing. the tub is savable but it need's some mount's on the torque boxes replaced. Did you make those mounts or buy them ?
I got them from here:

https://www.rustrepairpatch.com/stor..._Products.html

The fit was less than stellar but they're pretty cheap. WAY easier then replacing the actual boxes also.
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Old 07-15-2018, 11:27 PM
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Well things are moving a little slower than I would like. I'm only able to work on this on my off days. I got the driveline swapped over to the new frame and got the underside of the tub coated and bedlined. I'm working on getting the rest of the body panels ready for paint now.





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Old 07-17-2018, 11:40 PM   #9
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Very nice! I sure could use a lift at my place while working on my project...and a nice cleaned out, tall garage.

So, tipping the tub over on its side (in your last image)...no issues with that - damage, scuffed paint, dented panels? I was considering doing that when I'm ready to undercoat the bottom, but am concerned about how to get it tipped over and when I do, causing damage.
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Old 07-17-2018, 11:44 PM   #10
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Right now my tub is off the chassis and the chassis is bare (awaiting the engine). I would love to be able to chop up the tub and make a "truck" out of it - like this guy. I wouldn't even know how to start...
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Old 07-20-2018, 07:08 PM
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Very nice! I sure could use a lift at my place while working on my project...and a nice cleaned out, tall garage.

So, tipping the tub over on its side (in your last image)...no issues with that - damage, scuffed paint, dented panels? I was considering doing that when I'm ready to undercoat the bottom, but am concerned about how to get it tipped over and when I do, causing damage.
I’m definitely spoiled to have access to my dads garage and tools. I have a lot of respect for the guys to do this in the driveway. As far as looking this up on its side, you won’t do any structural damage but you can scratch up the paint if you don’t put anything down on the floor. Every time I’ve done is I’ve been repainting anyway so I’m not worried about it. You may have to get creative to find a way to flip it over on its side without having a lift.
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Old 07-20-2018, 07:13 PM
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Right now my tub is off the chassis and the chassis is bare (awaiting the engine). I would love to be able to chop up the tub and make a "truck" out of it - like this guy. I wouldn't even know how to start...
That would definitely be cool. A lot of body and metal work involved.
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Old 07-28-2018, 10:42 PM
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Finally ready to get some primer on it. Hopefully this time next week I’ll have color on it.



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Old 07-29-2018, 05:31 PM
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Epoxy primer is on. I’ll get 2k sprayed on this weekend and hopefully get everything blocked as well.

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Old 08-01-2018, 01:13 PM   #15
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Iím definitely spoiled to have access to my dads garage and tools. I have a lot of respect for the guys to do this in the driveway. As far as looking this up on its side, you wonít do any structural damage but you can scratch up the paint if you donít put anything down on the floor. Every time Iíve done is Iíve been repainting anyway so Iím not worried about it. You may have to get creative to find a way to flip it over on its side without having a lift.
Well, I tipped it over on its side yesterday. Getting it off the stands was the hardest part - by myself - with an engine hoist. It kept wanting to list to one side or the other. I finally just lowered it real fast - LOL. No damage though.
Once flat on the ground, I flipped it like a tire - grabbed the bottom and heaved.
It made it real easy to pressure wash. Next up: undercoating and bedlining.
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Old 08-05-2018, 10:33 PM
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Well, I tipped it over on its side yesterday. Getting it off the stands was the hardest part - by myself - with an engine hoist. It kept wanting to list to one side or the other. I finally just lowered it real fast - LOL. No damage though.
Once flat on the ground, I flipped it like a tire - grabbed the bottom and heaved.
It made it real easy to pressure wash. Next up: undercoating and bedlining.
Good deal. What are you doing for undercoating?
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Old 08-05-2018, 10:35 PM
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Paint Day!!

Finally got color sprayed. Turned out great, panels are probably straighter than they were from the factory. I like the color, should look really nice with some black accents. Still have to do the doors, hood, tailgate, cowl and windshield frame but I feel like I'm starting to make some progress.



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Old 08-19-2018, 10:37 PM
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Got the body back on the frame and the rollbar reinstalled. Everything lined up nice and perfect from where I fixed the body mounts. Planning to get the windshield frame installed and new glass put in next as well as raptorline the intereior so I can put the dash back in and get all the wiring reconnected.
Some jackass before me hacked the wiring harness all to pieces splicing in places where he shouldn't have and used house wire for accessories. Rather than trying to fix everything and figure out what was what I just got new harnesses. Those are installed and should be good to go. Doors, tailgate hood and everything else has been painted so things should start going back together fairly quickly.







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Old 08-21-2018, 01:16 AM   #19
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TJ frame swap questions: I bought a 2001 Wrangler, 4 cylinder, manual. It had some cracks in the frame. My BF took it home to weld. 7 months and 3900 miles later he tells me the frame is too badly rusted to weld. Tried to sell it but the tire kickers are beating me up on the price. What exactly is involved in replacing a frame on this model Jeep? I can get a frame for 1500 and since the tub is rotted too, I found a tub for 500. My son is a Mopar certified mechanic so he’ll help with it. What else am I going to need and how long will it take to swap out the frame? thanks guys!
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Old 08-21-2018, 05:18 AM
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TJ frame swap questions: I bought a 2001 Wrangler, 4 cylinder, manual. It had some cracks in the frame. My BF took it home to weld. 7 months and 3900 miles later he tells me the frame is too badly rusted to weld. Tried to sell it but the tire kickers are beating me up on the price. What exactly is involved in replacing a frame on this model Jeep? I can get a frame for 1500 and since the tub is rotted too, I found a tub for 500. My son is a Mopar certified mechanic so he’ll help with it. What else am I going to need and how long will it take to swap out the frame? thanks guys!
Depends on your mechanical abilities and access to tools really. It’s a munch more daunting job than it really is. There are 11 bolts that hold the body onto the frame. Depending on the amount of rust we’re talking about they can be a pain to get out without breaking them, if you break any you’re in for some fun. My advice, especially if you’re getting a new tub would be to drill or cut holes where the body mounts are and spray them daily or two or three times a day with some ATF/Acetone mixture for a few days before you try to tackle taking them out. After the body mount bolts are out all that you have to do is disconnect the fuel line, evap return line, brake lines, all the electrical wiring from the tranny, fuel pump and all wiring from the motor to the firewall and then lift her on up. This is my second one but both times I’ve had access to a lift which has been super helpful. Look up the redneck garage on YouTube, he’s done several Jeep restorations in his driveway and has lots of good videos. Assuming everything can’t apart smoothly you may be able to knock it put in a weekend but that’s probably being generous.
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Old 08-22-2018, 01:20 PM   #21
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Good deal. What are you doing for undercoating?
This.

I used it on the chassis after painting it with POR15. It's good stuff.
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Old 08-23-2018, 12:25 AM   #22
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Thanks for the info and the advice!
Your Jeep looks great!
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Old 08-24-2018, 08:37 AM   #23
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TJ frame swap questions: I bought a 2001 Wrangler, 4 cylinder, manual. It had some cracks in the frame. My BF took it home to weld. 7 months and 3900 miles later he tells me the frame is too badly rusted to weld. Tried to sell it but the tire kickers are beating me up on the price. What exactly is involved in replacing a frame on this model Jeep? I can get a frame for 1500 and since the tub is rotted too, I found a tub for 500. My son is a Mopar certified mechanic so heíll help with it. What else am I going to need and how long will it take to swap out the frame? thanks guys!
I'll second what hpclayto said. I'll also add that make sure the frame is for a 4-cylinder engine. The mounts are different for the 6-cylinder.
Not all the wiring has to be removed from the engine to pull the engine, just the wiring attached to the firewall and the wiring for the body controls (lights, radio, ignition, etc.).

The following is a video from a guy that discusses everything needed to be disconnected from the tub to lift it. He doesn't show lifting it, but it's thorough.

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Old 08-24-2018, 07:26 PM
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Got quite a bit done, tub is lined. Dash is back in, new wiring harnesses installed. Gas tank back in, fuel, evap and brake lines ran. Windshield frame is back on, new glass in. Got the side skirts back on. Still need to get my flares on, finish up some wiring in the engine bay, get the hood and tailgate back on but it's starting to come along. Also need to come up with a top, not sure what I'm going to go with yet.





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Old 09-12-2018, 06:04 PM
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Got her all back together for the most part and took it for it's maiden voyage yesterday. Everything is working like it should.







I still have a few things left to finish up but it's about 90% done at this point. Have a few more parts on order to get the doors back together. Still have to get a top, gonna get a trektop NX when the funds allow. May put a new lift on it also, I think it's got a 2" rough country on it. Rides okay but I'll probably swap it out for something else down the road. Also may but bedrug carpet in but I'm still trying to decide on that. And lastly I'm going to get the seats reupholstered in black to match the new black interior. At least it's drivable now and I can enjoy the fall weather though.
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Old 11-02-2018, 12:25 PM
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Got the new top on and the doors put back together and on. Had to take it to the shop to get some electrical problems with the A/C sorted out. Heat wasn’t working so I flushed the core and put a new thermostat on, it will melt your face off now. I’m calling it done at this point. Everything turned out well.
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Old 11-05-2018, 10:51 PM   #27
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That looks great! You did an awesome job.
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Old 12-21-2018, 07:15 PM
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That looks great! You did an awesome job.
Thanks, turned out good. Off to it's new owner tomorrow.

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