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Old 01-16-2018, 12:48 PM
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So I had a build thread on another forum but all the pics were lost with photobucket so I thought I would do one here. My wife and I had wanted a Jeep for a while and last August my dad found one and bought it because it was a good deal. The only problem was my wife wanted one that was not red and he didn't know that so we got a Red 95 YJ with the 2.5L and manual with spice interior and top. Plan was for this to be my daily driver back and forth to work instead of the F350 and for her to drive it when the weather is "just right". The first priority was to get everything mechanically sound. Water pump and radiator had leaks so they were replaced quickly. Next the starter was replaced, it went from working fine to completely gone over a couple of days. It would grind going into 5th gear but a change of the transmission fluid seemed to fix that and I changed the rear differential fluid at the same time. My dad has a 95 auto with the 4.0L. I put a 4" lift on it and 33" Dick Cepek Fun Country's on it. While it's fun and looks awesome my plan was/is to stay stock height and add modifications that keep it reliable and useful for our more urban and weekend needs.

Here is how it looked after we first got it although I had already plastidipped the front fenders to get rid of some of the red and try to cover up a dent on the driver's side.
IMG_1083 by [email protected], on Flickr





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Old 01-16-2018, 01:21 PM
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So I can't edit the first post but we've had the Jeep since August of 2016, almost a 1 1/2 years so I'm playing catch up with this thread.

The first thing I did was make some footrest. I had already made some for my dad's so these were pretty quick.
IMG_0975 by [email protected], on Flickr



Next I wanted to change the front bumper and staying with the theme of doing everything I could by myself and on a small budget I decided to modify the stock one. I notched the front bumper a few degrees about 10" from both ends and started adding some 3/16 plate I had laying around.
IMG_0486 by [email protected], on Flickr

Added some cheap LED's because we live on a dark curvy/hilly road out in the county where deer and dogs are fairly common on the drive home when it's dark and the stock headlights are worthless.
IMG_0488 by [email protected], on Flickr

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Old 01-16-2018, 02:55 PM   #3
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Did you plasti-dip the fender flares? If so, how'd that work out. Mine looked like crap when I got it, so I used rubberized undercoating. It's OK, but if I could find something better I'd do it.
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Old 01-16-2018, 03:32 PM
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Did you plasti-dip the fender flares? If so, how'd that work out. Mine looked like crap when I got it, so I used rubberized undercoating. It's OK, but if I could find something better I'd do it.
Thanks
Actually I ended up using Krylon Fusion on the flares. It's been over a year and they still look good but I do suspect they'll need to be re-painted but a $5 can of paint is a lot more practical than new flares at this point in time.

After the front bumper, I pulled the bumperettes off and modified the U-haul receiver hitch that came off my dad's jeep. I removed the 1 1/4" receiver and added a 2". Also added a bit of 2" square tube to stick out a bit farther and serve as a step for the planned roof rack. I have never planned on pulling anything with the jeep besides a super small trailer but I liked a 2" receiver for a cargo rack, bike carrier, and etc...

IMG_0493 by [email protected], on Flickr

The next project was to find out where the rain was coming in and flooding the passenger floor board. With the water hose I figured out it was running between body panels and entering just above the lower door hinge on passengers side. After some time searching on the net and a couple of trips to auto stores I found some body panel sealer. It was mainly leaking in one particular spot but I did across the hood and down both sides. This was a fairly straight forward project that took maybe and hour or two and it all but stopped the invasion of rain. I still have a small leak but it's on the door trim and so far hasn't bothered me enough to address it.

IMG_1063 by [email protected], on Flickr
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Old 01-16-2018, 05:47 PM
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Previous work was done in the first four months of owning the jeep. After Christmas of that year we started thinking about how we would get rid of the red that my wife disliked so much (lots of red jeeps around here). We were up for just buying some rattle can and getting started and could change it anytime we wanted. I started reading about bed liners and quickly decided that was a better option for long term durability and looks. We decided on using Monstaliner but couldn't decide on a color. In the mean time I dis-assembled the interior only to find the factory paint in almost pristine condition besides wear in the front floor boards and two gaping holes that someone had cut on the hump. Looked like they used a hammer a screwdriver. I welded them up best I could and only caught it on fire 3 times in the process. Whatever that glue is between panels is extremely flammable.

IMG_1058 by [email protected], on Flickr
IMG_1061 by [email protected], on Flickr

Ended up cleaning it, a bit of scuffing, and then prime and paint with Rustoleum performance enamel.

IMG_1071 by [email protected], on Flickr
IMG_1072 by [email protected], on Flickr

Then re-assemble with a little help from my son. We also changed the window cowl seal while we had it apart.

IMG_1075 by [email protected], on Flickr
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Old 01-16-2018, 06:03 PM
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I was going to replace the factory carpet but after a thorough hosing down and run through the washing machine I decided that it looked pretty good and re-installed it since most of the reviews I had read on replacement carpets weren't that good. I really wanted carpet to deaden some of the road noise. Also got around to installing the Besttop seat covers and under seat security box that I got for Christmas. The security box is made for a TJ but a spacer made from a 1/2" nipple, a heavy duty washer, and a 3 1/2" bolt made it fit perfect. Around this time, I also ordered and installed some fitted floor liners in the front and one in the rear cargo area (Absolutely love these things) I get pretty dirty at work and dump the dirt out of the front liners pretty often. The one in the rear also comes in pretty handy. I don't worry about gas spilling out of cans or other 2cycle equipment I carry back there.

IMG_1077 by [email protected], on Flickr
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Old 01-16-2018, 06:32 PM
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Next up was a set of new tires. I settled on Cooper AT3's in 235/75/15 on the stock wheels. The stock wheels were in pretty good shape but I scuffed them all up and painted black with the same Rustoleum used on the interior. In February of 2017 we started getting serious about the exterior color and ordered samples from Monstaliner. I liked Sans Panties, she liked OD Green, so we settled on Pyroclastic and looking back I'm glad that's the color we settled on. I started pulling off things we could get by without while still driving it. Starting the prep early really helped when it came time to actually start the serious prep. Pulling stickers isn't hard but can be time consuming, same with fender flares, and all the other little things I hadn't really thought about. While waiting on a warm weekend for paint I started working on the roof rack. My intent was to have a place for bag chairs, baseball bags, kayaks, coolers, and etc.... Like most of the time, I went a little overboard and built one big enough to carry everything we might carry occasionally all at once. This was a fun project that took me way to long because I started with a rough idea in my head but no real plan. Frame was made of 1 1/2" square tubing and interior of basket used 1" and 1/2" tubing. Pictures are pretty self explanatory here.

IMG_1100 by [email protected], on Flickr
IMG_1102 by [email protected], on Flickr
IMG_1105 by [email protected], on Flickr
IMG_1107 by [email protected], on Flickr
IMG_1112 by [email protected], on Flickr
IMG_1136 by [email protected], on Flickr
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Old 01-16-2018, 07:14 PM
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.The roof rack turned out quite a bit bigger than I would have liked but I used it for a year in that configuration with only physical issues being it hung over a few inches to far in the back and when standing on the rear bumper you have to lean back a bit which is a bit of a balancing act. Same thing on the sides, I stand in the open door to access things from the side and you have the same leaning problem. Besides that, I never quite cared for the overall look of it. Recently, I narrowed it 6" and moved it forward a bit which is much more comfortable for practical uses. It has also improved the looks a bit (at least I think so). I'll get some new pics of that soon.

The week after completing the rack we got a rare 70 degree February weekend and took full advantage of it. That Friday I started taking things apart. Got my son from school at 3:00 and he started sanding the wide open areas. My wife got there around 4:00 and we started sanding the smaller details. Saturday morning we finishing taping and started mixing the Monstaliner at 9:21 and by 1:46 that afternoon we were done. After having the Monstaliner for almost a year, I don't think we could have made a better choice. It was priced very reasonably, went on well, and still looks like it did the day we finished. I just washed it for the first time because every time it rains everything seems to slide off of it. Granted we haven't had mud caked on it but the everyday road grime dust from gravel driveway and parking lot at work seems to be gone after a good rain.


IMG_1161 by [email protected], on Flickr
IMG_1162 by [email protected], on Flickr

IMG_1171 by [email protected], on Flickr
IMG_1170 by [email protected], on Flickr
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Old 01-17-2018, 02:36 PM   #9
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Love monstaliner! Doing my second YJ soon.
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Old 01-17-2018, 02:38 PM   #10
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Love that stock bumper mod! looks awesome, can you come to SO IL and do mine? lol
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Old 01-17-2018, 08:52 PM
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Love that stock bumper mod! looks awesome, can you come to SO IL and do mine? lol
Would love to make the trip but that's a little to far.

The great thing about the bumper is that it makes a pretty comfortable seat. Two people can sit side by side. I had bought a small LED light to hang from the front of the rack but it whistled to much. I tried putting tape on the cooling fins and flipping it upside down and neither helped so it came off. I ended up mounting it on the frame behind the bumper. The width was right so I made a couple of mounting tabs and heavily tacked them in place. It's far enough back that it doesn't affect the seating. It has a couple of floods on either end and the rest in the middle is a spot and it helps on those back country roads and is switched separately from the other two small floods.
IMG_1178 by [email protected], on Flickr
IMG_1179 by [email protected], on Flickr

A couple of other little things that we've found helpful. First was hanging a small piece of cargo netting, that I found in the shop, from the roll bar behind the sound bar(which I found on craigslist). I think the cargo net was originally to hold a helmet on the back of a motorcycle but it holds sweatshirts and jackets for those colder nights and mornings. Next was hooking up the bungee loops that come in bungee cord assortment packs. First time I've actually found a use for these. Two of them together around the base of the roll bar has just the right amount of tension to hold the rear seat up in the folded position. I leave the backseat folded up anytime someone isn't seated back there.


IMG_1213 by [email protected], on Flickr
IMG_1211 by [email protected], on Flickr
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Old 01-18-2018, 08:28 AM   #12
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I subscribed! Enjoying this thread a lot.
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Old 01-18-2018, 06:17 PM   #13
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Nice job!


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Old 01-19-2018, 09:18 PM   #14
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Nice work.

-

I did a rear storage rack made from refrigerator shelving. It sits level, but is hinged and drops down for easy access.



And it doubles as my trail gun rack.

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Old 01-21-2018, 06:35 PM
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Tophog, Great idea with the rack. I've been on again/off again toying with the idea of a gun rack above the interior cargo net.

I finally got the touch up paint completed on the roof rack and got some pictures of it completed. The original rack was just to wide for ease of use and looked at little out of proportion. I cut 6" out of the center and re-welded. On all four of the corner uprights I measured down approximately 3" and angled them in 45*. I started on one of the fronts and completed it before moving to the other side. The fronts were a little nerve wrecking because of the compound angles. I did all the cutting and welding while they were still mounted and took measurements off the body to keep everything symmetric. The rears were a simple 45*.

IMG_1536 by [email protected], on Flickr

This week I was also able to install the new wiring harness for the H4 headlights that I bought myself for Christmas. The headlights by themselves were a HUGE improvement and the wiring harness was insurance for not overworking the switch, or so I've read. It took longer to zip tie the wires to the bottom of the grill than it did to hook everything up. My hands don't fit very well through the front grill. I gained a little over 1 volt to the lights with the harness to bring the total to just above 14v measured by my cheapo Harbor Freight multi meter. I really like the clear glass on the new headlights.

IMG_1535 by [email protected], on Flickr

Last project for the week was fixing my defrost vent flap. When my son and I replaced the heater core this summer we didn't align the pivot rod that directs the heat to the defroster. Just realized this recently because the heat worked fine and I rarely use the defroster. Thought I was going to have to take the housing back out but thanks to a small hammer, a block of wood, and a large flathead for prying I was able to get it re-aligned and working properly again all while laying upside down with the center console digging into my ribs. While I had everything apart I installed a working bulb into the heater/vent control and duct taped in place because the plastic clips had broken.
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Old 01-21-2018, 10:09 PM   #16
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Much better on the roof rack now. I like the angled supports.

The wiring harnesses are great. Minimal voltage drop, and little chance of overloading the switch. Specially with 20+ year old wiring.

-

My interior rack stores heavy stuff easily. Hiking boots, shovel, recovery strap, etc. without stretching or the stuff bouncing around.

I also did my underseat box basically identical to yours, for my OTHER trail gun!


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