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Old 03-10-2016, 11:56 AM
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'93 YJ 2.5L to V-8

Well, I guess I should start at the beginning...

I bought a '93 YJ for my 16 year old son. It only had 120,xxx miles on it and I was told it had just been overhauled. I paid more than I should have for it! It came with a hard top, bikini top, and both half and full doors. No tops for the half doors, the drivers side full door doesn't open from the outside...the passenger full door doesn't open from the inside...it was almost comical...at first.

The tires were bald and had a bad radial pull. So I bought new tires for it...got a good deal on the last of the tires that were in stock, $780 for all 4! Then it started having compression issues! Great!!! Took it to a mechanic since I didn't have the time to pull the head and do all that work myself. I knew it was a burnt valve since there was no anti-freeze in the engine oil.

$800 later, I have the jeep back. Now, not only have I paid too much for the jeep but I dumped another $1600 on the stupid thing...wife not happy!

Jeep runs for one full day and I lose compression again, this time on the interstate on my way to work. The jeep BLOWS UP! I mean a GIANT plume of white smoke pours out from under the hood, the engine SHUTS OFF in the middle of traffic, and I am in the middle of a 4 lane highway! WTF?! I have the jeep towed back to the shop and I call to tell them what happened.

The guy calls me back a week later to tell me that "you overheated the engine"???? Says that my "thermostat" went out??? I am no master mechanic but I have never had that happen to me, even when I blew the thermostat!

So I get the Jeep back and I don't even make it up my driveway before it dies again. Look at the engine oil...yuuup...Anti-freeze! Great!!! Blew the head gasket! Call the guy back and I get "I don't want to see that damn jeep ever again!" and he hangs up on me...WHAT?

Call around and I can't find anyone to look at it for less than a GRAND! I figured, screw it! I am rebuilding the jeep! So he we are...starting, yet another, glorious jeep build!

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Old 03-10-2016, 12:14 PM
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The story continues...

This is what I have, so far, for the jeep build.

I ordered a Phoenix Customs 350 build to approx 330hp, block painted shiny red with Chrome everything else.

I ordered a Monster Transmission to be custom build to match the engine HP and Color.

I ordered, and have since received, a Monster Transmission Transfer Case.

I am putting an 8.8 rear end in that I grabbed from a pick & pull ($90)

I ordered 2.5" X pipes for exhaust

I am not sure about headers yet. I was leaning toward huggers since there isn't much room, but then I thought about all that Chrome that will be sitting in the engine bay and then the ugly non-chrome exhaust pipes that will have to be made to fit. SO I am still undecided.

We are getting a new steering wheel, new soft top, new seats, all new door seals and windows seals, new bumpers, new 4" lift, and probably going to paint it OD Green.

So by the time this is all said and done, I will have paid almost 3 X's what the jeep is worth.

And wife still not happy!

I will post pictures as I move through the build. All I've done thus far is order everything, pull the engine, and drink a lot of beer!

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Old 03-10-2016, 03:08 PM   #3
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Advanced adapters has hugger headers that come in chrome.
Deep down I bet your glad that 2.5 blew

717043-HDR : Inside Frame Rail ,Chevy Generation 3 LS series V8,Conversion headers | Advance Adapters
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Old 03-11-2016, 09:14 AM
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Quote:
Originally Posted by jeeptank91 View Post
Advanced adapters has hugger headers that come in chrome.
Deep down I bet your glad that 2.5 blew

717043-HDR : Inside Frame Rail ,Chevy Generation 3 LS series V8,Conversion headers | Advance Adapters
Thanks for the link jeeptank91. I will check them out.

I actually am glad that all this happened. I have always wanted to build a vehicle with my son(s). I just thought it would be under different circumstances! I truly hated that 2.5! I live in East Tennessee and there are very few roads that aren't hills...and not just little rolling hills...BIG hills. I couldn't climb my driveway or any of the other hills in my neighborhood without being in 1st gear or constantly downshifting! What a gutless engine to put in a Jeep.

Once this is all said and done, I will be more than happy that I put all the money and effort into this vehicle. I just hope that I will still be able to sleep in my own bed if my wife ever finds out just how much I've spent on this project!
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Old 03-11-2016, 09:34 AM   #5
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Also What are your plans for cooling. That yj radiator wont be able to keep the 350 cool. I got mine from Novak although in was expensive I wanted to make sure I protected my investment. They come with or without electric fan and shroud.
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Old 03-11-2016, 11:02 AM
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Also What are your plans for cooling. That yj radiator wont be able to keep the 350 cool. I got mine from Novak although in was expensive I wanted to make sure I protected my investment. They come with or without electric fan and shroud.
I've looked into a few different options. I've been following a couple different Threads on here and have looked into what they have used. The Novak is a common name in most threads.

I haven't gotten that far in the decision process. I'm actually looking into the wiring harness right now. I'm trying to decide if I need a new harness for the 350 or if I can keep the Jeep one and use what I need out of it.
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Old 03-11-2016, 11:59 AM
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jeeptank91

What did you do for your fuel pump?
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Old 03-11-2016, 03:02 PM   #8
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I have not dropped the tank yet (darn Rain) but I have researched it and plan on installing a pump stock to the 350 in the YJ tank. (With a little modification and ingenuity)
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Old 03-14-2016, 07:18 AM   #9
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So I dropped the tank this weekend. I Removed the yj fuel pump and installed a fuel pump from autozone that is stock to the engine I am putting in. Although the pump was smaller it fit well I had to drill another hole in the bracket that holds the pump a little lower and put in a longer piece of fuel line. I was even able to use the yj's sock filter.
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Old 03-14-2016, 11:11 AM
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Dang rain!

Well, had rain most of the day Saturday which made it impossible to get anything done on the YJ. Top that off with a bad U-Joint in my F150 and there went my weekend.

I did get my X pipes this past Friday. Now I am thinking of going with outside the frame headers. Having to wait on all of these parts to come in is giving me too much time to rethink what I am doing...this could be dangerous!

I am planning on tearing out the rest of the seats and carpet and putting in Herculiner. I've read a few posts about how well others projects have turned out. Guess I will give it a shot and see how it turns out. Hope all goes well! I really don't want to put carpet back in the YJ but if it doesn't turn out well that is what I will be doing.

Anyone interested in purchasing a hard top? Black outside with Tan inside. All the glass is still intact. The back window shocks are not working though. It is in pretty good shape still.
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Old 03-14-2016, 12:32 PM   #11
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I had researched using outside the frame headers too but your pipes will need to go back under the frame (loosing ground clearance )and from what I read people had a tendency of crushing their pipes where it came back under the frame.
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Old 03-14-2016, 12:36 PM   #12
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Here's what my inside the frame headers look like.
(can you spot the clutch alignment tool)

Attachment 2889489
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Old 03-15-2016, 10:05 PM   #13
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I used rams horn manifolds rather than headers. They flow pretty good and I was able to stay inside the frame with my exhaust.

I used the Jeep wiring harness and just modified it to get the limited electrical I needed but I went old school carburetor so it was more removing wires than anything.
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Old 03-17-2016, 03:20 PM
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I used rams horn manifolds rather than headers. They flow pretty good and I was able to stay inside the frame with my exhaust.

I used the Jeep wiring harness and just modified it to get the limited electrical I needed but I went old school carburetor so it was more removing wires than anything.
I am hoping to reuse the wiring as well. I really don't want to buy a new harness...I can find a 1000 other ways to better spend $500! I am wanting to use headers on my engine. I am going with 2.5" exhaust. I am probably not going to put any mufflers on...just use the X-pipes if I stay inside the frame. If I do decide to go outside the frame, I am just going to run straight pipes back. Loud pipes save lives!
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Old 03-17-2016, 03:22 PM
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I used rams horn manifolds rather than headers. They flow pretty good and I was able to stay inside the frame with my exhaust.

I used the Jeep wiring harness and just modified it to get the limited electrical I needed but I went old school carburetor so it was more removing wires than anything.
By the way, what part of WI are you from? I use to live up in the LaCrosse area for a bunch of years. Had to get away from those damn winters! Gotta love life in TN!
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Old 03-17-2016, 10:24 PM   #16
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The rams horn I have are for 2 1/2 pipes. I have 2 1/2 from the manifolds to the Y and 3 from there back. Cross over is under the transmission right behind the bell housing.

I am in NE WI - near Chilton. One of my daughters went to UW La Crosse.
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Old 03-21-2016, 08:28 PM   #17
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can I see the Jeep please?

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Old 03-21-2016, 08:41 PM   #18
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Here are some of the in-progress pictures. I need to get some as it sits now with new 2 1/2" lift springs and the 8.8 installed (not to mention the hood, etc.).
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Old 03-21-2016, 08:42 PM   #19
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and a few more for good measure.
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Old 03-22-2016, 06:34 AM   #20
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Not you, WICruiser! We've already seen yours! I meant the OP! Lol.
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Old 03-22-2016, 09:09 AM
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can I see the Jeep please?

I don't really have much done with it yet. I've ordered the engine, still waiting on it, ordered the tranny, should be here this week, ordered the transfer case, got that sitting in the garage, ordered the X-pipes, also sitting in the garage.

I am hoping to make it to the pull-a-part in the next couple of weeks and get the 8.8 and clean it up. I have the inside gutted and ready for the Herculiner, hoping to get that done this weekend. Once I get more progress done on the jeep, I will post pictures. Right now it looks like every other torn apart jeep you've seen.

I have a buddy of mine that is going to come down the 1st week of June and help me put this thing back together. We will have 7 days to get the engine in, fuel working, and exhaust figured out. I hope that my plans all work out...otherwise I will be finishing all that we don't get done on my own!

With baseball season for my 2 sons starting this past weekend, I will only have every 3rd weekend to work on the jeep. I will get it painted one of these weekends before June and post pictures; but don't laugh! I am not a professional painter and I will be painting it in my driveway with a plastic wrapped 2x4 framed room. I hope it all turns out good!
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Old 03-22-2016, 09:10 AM
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and a few more for good measure.
That is a nice looking Jeep!
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Old 03-22-2016, 09:44 AM
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Here is what it looked like when we first got it. The one on the right is my son's friends Jeep.
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Old 03-22-2016, 09:48 PM   #24
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Dere she is.

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Old 03-22-2016, 10:08 PM   #25
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Looks pretty nice as received.

I hope you are better at documenting with pictures than I am. Seems like I always have a ton of pictures with none showing what I want to show people.
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Old 03-23-2016, 11:08 AM
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Looks pretty nice as received.

I hope you are better at documenting with pictures than I am. Seems like I always have a ton of pictures with none showing what I want to show people.
The outside wasn't too beat up. It had a bad leak around the windshield that I found after a really hard rain. Turned left while driving and my feet got soaked on my way to work! Not happy...

The hood has a few dings that were "attempted" to be fixed. The inside is what is bad. Not rusted or anything just cobbled together and striped down. I hope to have it back to full glory once I am done.
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Old 03-28-2016, 10:03 AM
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Not much to Update

Well, I didn't get much done this weekend, with it being Easter and all. Saturday was spent at the baseball field from 10 am to 8:40 PM! Practice with my team and them a triple header, one day tournament for my youngest son. Took 2nd place so I guess it wasn't too bad.

I did get the inside sanded down Sunday afternoon. The the floor boards on the drivers and passenger sides were in pretty bad shape. I had to get the belt sander out with 40 grit and take it all the way back down to metal in order to get all of the rust off. It took a lot longer than I would have wanted. The previous owner used after market Velcro patches to hold the carpet in place. That took an awful lot of goo gone and heat gun to get that sticky mess off.

I had to spray primer on the pan once I was done sanding everything. Now that all of that is done, I will be able to put down the bed liner this week, providing the rain doesn't threaten to stop me.
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Old 03-28-2016, 03:44 PM
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This is what she looks like now. Progress, however slow, is still progress!
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Old 03-29-2016, 02:40 PM
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Look what came today!
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Old 03-29-2016, 06:19 PM   #30
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[B]To be continued....:
You Don't Buy a Jeep, You Build One.

2009 Chevrolet 3500HD Duramax - Tow Rig-25 Ft gooseneck ready to haul
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