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Old 01-01-2017, 08:50 AM
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1995 slow build

I just got my first Jeep. It is a 95 4.0 5sp with 141k. It runs and drives great but has a good bit of rust to fix. So far I have ordered a new smittybilt top, cut out the driver floor pan, tacked in some sheet metal I had lying around (temporary fix), and replaced the clutch master cylinder. I have autorust.com safe-t-caps for the driver tranny skid and driver forward rear leaf mount. The passenger skid mount will get some light repair and the rear frame sections have a little life left in them. The body will get some new sheet metal and diamond plate rocker covers to hide my poor welding. I will have a friend do the welding on the frame. Here is my starting point.









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Old 01-01-2017, 08:56 AM
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I also already replaced the rear brakes and wheel cylinders. I had to temp in a too long brake line on the right side. I will be remaking the rear lines when I order my lift kit. Here are some rust pics for your viewing pleasure.















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Old 01-01-2017, 08:58 AM
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I also removed the carpet, added my little kicker 8 sub behind the rear seat, and eliminated the Wrangler hood stickers.





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Old 01-04-2017, 07:14 AM
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I built a couple ammo can boxes and used magnets to stick them to the fender wells. I want to easily be able to remove the sub/amp/speakers when I know I will be getting wet.



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Old 01-05-2017, 06:53 AM   #5
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Location: Coastal North Carolina back to my old stomping grounds near Camp Lejeune!!
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Nice work on the ammo/speaker cans. But being removable, how are they wired up?
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Old 01-05-2017, 11:37 AM
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Thanks. I am going to clean up and loom the wiring. I should be able to disconnect at the fuse and ground, pull the wires form the 6x9s, and remove sub/amp with all wires still connected.







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Old 01-05-2017, 12:11 PM
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Pics didn't work.









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Old 01-05-2017, 01:56 PM
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I got my new Smittybilt replacement top on last night. The old one had a couple torn zippers and a zip tied passenger window. I had a bad experience with 4wd.com. They sent a TJ top in place of my ordered top. They also would not help me out with expedited shipping and opted to give me a refund rather than pay for 2 day shipping. I went to morris4x4 and couldn't be happier. They are 2 day ground from me and their customer service was great. I also cut the metal zippers and put on some Paracord pulls. They are much easier on the fingers and look sweet, too.






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Old 01-13-2017, 07:11 PM
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Homemade bumper. All materials were free leftovers from around my work. It was a c channel that I welded together. I have a couple d rings that I may weld on, still on the fence. I still need to cut and weld in the end caps. This was also my first time doing stick welding. I did a good bit of practice first.











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Old 01-14-2017, 07:40 PM
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Started the first of 4 frame sections to repair. Also doing 1 in body mounts to replace the trashed OEM mounts. Lots of stuck bolts.

Frame before demo.


Previous owner did some self repairs.


I assume this brace was trying to keep the shackle from twisting. The weld was busted loose on the body.



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Old 01-14-2017, 07:46 PM
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The rear body mount bolt was completely rusted out and pulled straight out. The next one was seized in the nut. This one had a flat piece of metal as the nut. It was thrashing back and forth on the impact. You can see it trying to bust out.


I had to cut out the body and cut this piece of metal.


The forward shackle bolt was seized in the bushing. I had to cut the shackle and press it out.


Finally ready to start cutting.


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Old 01-14-2017, 08:12 PM
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Cutting wasn't too bad except the PO's repair kept me from slipping the safe t cap over the frame there. We had to put a plate there at least till I get time to do the transmission section. Hopefully between tonight and TMRW afternoon I can get the body mounts done and the rest put back together. That or ride the motorcycle on Monday.











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Old 01-17-2017, 07:21 PM
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Finally got it done (enough). The body mounts made the frame repair a walk in the park. The two rear mounts will be moved inward when I do the rear frame repair. I also had to cut a small piece from the inner shifter boot. It has hard to get in second after the body lift. Smooth as butter now.





This mount was also gone. I had to weld in a plate and cut out the hole.


I had to trim this trim piece that holds the wire loom.


The aftermath.




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Old 01-23-2017, 12:24 AM
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I replaced the radiator. It was a huge hassle because the first one I got leaked. It was from Advance Auto. They were great on the exchange but it still sucked. All the bolts use a clip nut and they were all siezed and broken. I managed to get them all out without the angle grinder. You can get to all of them by taking out the headlights and turn signals. I really need to invest in stock for PB Blaster and anti seize.

The radiator was not leaking but was rotten. I have never seen one this bad.




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Old 01-23-2017, 12:31 AM
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I forgot to put these up.

I got end caps cut and welded on my homemade shop scraps bumper.





I also mounted an old versa-carry on my console for the trusty PX4 to have a front row seat.



Seat all the way back.


Where I like it.


Covered the screw heads to make sure I don't get scratches. It doesn't hit them but you might be able to get into them if you aren't paying attention.


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Old 01-23-2017, 12:34 AM
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Tonight I replaced the belt and valve cover gasket. The belt was no problem. The valve cover was not too bad. The only headache was the coolant hose had to be removed to clear the valve cover.





Just out of the bath.


The new gasket was surprisingly well made. Especially compared to the old one.


This is the stupid hose.


Almost done.




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Old 01-25-2017, 03:30 PM   #17
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Nice rust, err I mean Jeep... You've definitely got your work cut out for you. My Jeep is the same teal color, I've been told that it is a rare one.

Those ammo can speakers are awesome, I may make some too. Those front only speakers just don't cut it when cruising at highway speeds...
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1992 YJ with 5.0 Ford, M5OD R2 Trans, BW 1356 TC, Ford 8.8 rear axle, sitting on 33 x 12.50 BFG MTs. Aluminum 3-core rad, Electric fan, 8k winch
LSD 8.8, custom dash, front and rear bumpers, extended rear axle, fender mods, etc, etc, etc
1996 Ford F-250HD 7.3 Powerstoke CrewCab Shortbed, lifted with 35x12.50R16s, some mods done by PO
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Old 01-28-2017, 09:40 PM
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Yeah. I have named it Rusty. I rewired the headlights with new relays and 12ga wiring. A little brighter and ready for a future headlamp upgrade. I also ordered a 5 channel amp and some Polk audio 4x6 plates for up front. I am going to mount the amp under the driver seat and build a shroud to keep it dry. Coming soon is RT greaseable shackles, rear frame repair and gas tank skid plate.

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Old 01-28-2017, 09:41 PM
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Old 02-02-2017, 05:54 AM
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I managed to get the speakers in the dash without dropping the windshield and pulling the whole dash. I did cheat and cut the top outer stud on both speakers. This made it possible and much easier to put the new ones back in. They are nice and tight even with only 3 bolts. I have just mocked up a wood "shelf" under the driver seat and will be making a steel rack for it once I do my seat swap.





A couple shots of the headlight relay and new wiring. I need a couple spade connectors to eliminate those pesky wire nuts.








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Old 09-04-2017, 08:51 PM
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Been a good while since an update. I will try to find pics to add but I tried a Ranger bench seat but it was too tall for my taste. I also mounted a 5 channel amp under the driver seat and put 2 12s behind the rear seat. A slant back box with rear facing subs fit perfectly. This weekend I replaced the driver side frame section for the crossmember skid. It got a new skid plate and transmission mount. I braced the tub above the 4 driver side body mounts. The rear mount are gone so I moved them in and will cover the back with diamond plate.
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Old 09-04-2017, 08:56 PM
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More pics. Also replaced the cowl seal. That stopped my feet from getting soaked by water coming through the dash. New water pump that luckily let go in my driveway when I got home from work. I found a set of front fenders to prep and replace my rust buckets.
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Old 09-04-2017, 09:02 PM
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More pics and updates. Got a carport and made a place for my doors to hang out. I also got a carrier and mounted my bike rack to it. That is all for now. I have all the pieces to complete the rear frame sections and gas tank skid. There is a lot of work ahead back there on the tub and crossmember. I will try to remember to update my build thread this time.
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