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Discussion Starter #1
Here's an overview of what I'm looking to do over the course of the next few months:

Convert from 2.5L to 6.0L
Convert from Dana 35 to Ford 8.8
Remove tub from frame, blast and paint both
Treat inside of frame
Assess and repair PO's SOA job
Assess and repair CAD (currently front axle locked all time, no cad)
Repair/replace inoperative or broken things (list keeps growing)
Get road legal

Yesterday the preparations began to get the LQ9 6.0 and mated 4L65E ready for install into my 94 YJ which I've now owned for two weeks. I will work to keep this thread photo detailed at every turn.

The PO of this jeep seems like he had some big ideas, but just executed them poorly, so I'll be doing a lot of reverse engineering on this while in process.

Yesterday I got the harness and ecm off and shipped to Novak, got the exhaust manifolds, motor mounts, a/c bracketry, trans cooler lines and starter (which the positive post on the solenoid broke off) off the motor.


I've been calling it swamp thing because the PO opted to paint the exterior in the rough surface paint in this swamp green. That stuff is going to suck to blast off. Backed in, ready for tub removal:


 

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Discussion Starter #2 (Edited)
Well, not much new to report after five hours in the shop today. The four exh manifold bolts that snapped yesterday at the bolt head, snapped flush with the block today when trying to double-nut them out...so it will be exciting trying to drill them straight and get an extractor in there. They still have an inch worth of thread to come out.

I spent the rest of my time disconnecting wire harnesses, brake lines, that blasted steering linkage, rad and shroud. I should only have body mount bolts to go before the tub comes off. It is time to market a 2.5l and auto trans on the local sites.




Check out the engineering on the steering of this SOA job.
 

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was going to do a swamp thing theme on my black Jeep...even had our club sticker guy mock this up for the hood
 

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Nice!
 

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Well, not much new to report after five hours in the shop today. The four exh manifold bolts that snapped yesterday at the bolt head, snapped flush with the block today when trying to double-nut them out...so it will be exciting trying to drill them straight and get an extractor in there. They still have an inch worth of thread to come out.

I spent the rest of my time disconnecting wire harnesses, brake lines, that blasted steering linkage, rad and shroud. I should only have body mount bolts to go before the tub comes off. It is time to market a 2.5l and auto trans on the local sites.

http://s1014.photobucket.com/user/blu542/media/6BFCA498-7039-4BBB-BAD6-A9AC4F9C2244.jpg.html

Check out the engineering on the steering of this SOA job.
http://s1014.photobucket.com/user/blu542/media/524FA8CA-D9FD-4099-8453-06AF43D3FA71.jpg.html
Wow, that steering looks scary. How was it to drive?
Good lock with the build.
 

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Jeeper
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Discussion Starter #7
I was apprehensive to drive it, but it felt fine. All of it is going to be redone, spring perches and all.
 

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Discussion Starter #8
This is going to be a picture heavy thread...bear with me!

A bit of progress over the past couple days...tub off, motor out, transfer case separated.

So things I have received from orders so far:

Novak eng mounts, transfer case adapter, super-short sye, vortec eng cover, cold air kit, corvette fuel regulator

MORE extended shock mounts front and back, Detroit true-trac l/s for the 8.8, oh and the 8.8 is here.

Things on order that haven't shown up:

MORE 8.8 mount kit, stainless brake line kit, stainless bolt kit, energy body mounts, MORE traction bar, Novak 1 5/8" ceramic headers, Novak rad and elec fan, body mount weldments.

Things on the list to order: springs, possibly shackle reversal kit, d/s floor pan parts (got some rot)

Ok pictures!

Motor/trans on the floor


Frame working it's way to bare:


Tub separation:


Sand and coal...seriously coal on top of the fuel tank!


Very jacked up motor mount


And one with swamp thing with Old Glory


The fun continues this weekend!
 

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Discussion Starter #9 (Edited)
This weekend only accomplished general stripping of things.

All electrical out of the eng bay, batt tray, evap, coolant and washer reservoirs, lights, fender flares, back corner guards, (not pictured, but back left was hiding damage) soft top off.







This upcoming week will be frame blasting, motor mount and body perch weld-in. Also going to try and get the tub stripped.

More to come!
 

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Well isn't the top of your gas tank where you are supposed to store your coal?? Great progress, look forward to seeing more!
 

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Discussion Starter #12
Thanks for the kind words gents!

So...progress after work the past couple nights leaves us here:

Hoping to send this out for blasting tomorrow


Anyone want some 3.73 stockers with a bad SOA job?


Damage found behind guards so far... at least it's not rust


Hoping to have complete dash out tomorrow night, we'll see. G/f just informed me that there's 300 pounds of Novak, MORE and Qtech boxes at the door. The build side is gunna be fun!
 

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Discussion Starter #14
So... picture-free Thursday updates.

Frame, two 8.8 axles and one Dana 30 are being blasted by my Amish friends.
Frame will then get the Eastwood internal frame coat stuff, then be powder coated...yep found someone with a booth big enough!
While relaxing with a beer and cigar last evening, it dawned on me that the 6.0 might as well be freshened up while I have it out. I have three shops I work closely with putting some numbers together for that. Just want new bearings, bushings, rings, valve seats, gaskets...etc. Certainly not going to need more power.
Gearing up to put one 8.8 in jeep #3 (see garage) this weekend, so probably won't get to too much other than stripping the dash on swamp thing.
Neighbor thought I was moving out today with all the crap that has been delivered here for the thing, but did get it moved to the shop.

In so far:

Detroit trutrac for the 8.8
Two 8.8 mount kits
Lubelocker gaskets for two jeeps
Driveshaft adapters
Steering correction kit
Stainless preformed brake lines
E-brake cables
Rear shock mounts, body mount brackets, energy body bushings
Full stainless bolt kit
Trucklite led headlights and led tail lights
Headers
Eng mounts
OME springs and greaseable bushings
Trans adapter and SYE
Transfer case shifter
MORE extended shock mounts
D/s floor pans

Things backordered:
MORE traction bar

Things considered:
MORE shackle reversal kit (through frame for no height change)
Steering column change (gonna shift on the floor)
Detroit trutrac for Dana 30
New tires/rims
Need some kind of bumpers
Need some kind of fender flares

If anyone has thoughts on any of this let me know. I'd like experienced input before realizing I've made a mistake once it's all together...

More updates (with pics) to follow.
 

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I really liked my RockHard bumper,


but it was too heavy for my little 4cyl, so went with an Aluminum based MetalCloak
 

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Discussion Starter #16 (Edited)
^ much appreciated input neighbor, and fine looking yj! Are those your state inspection tires? Looks like you could fit 35's under there! I may be leaning toward fabbing my own front bumper, not sure yet.

So Saturday plans for the build were interrupted by jeep #1 losing clutch yesterday. Bro-in-law got stranded with the dreaded floppy clutch pedal on his way to work. I told him to have it towed to my shop, I'd pick up the bill. He's the one wanting to buy this thing at the end of the month, so gotta turn it around quick!

Saturday morning "serious business" mode:


One corroded clutch bleeder valve replacement later, the '91 Sahara is back in business. Missed a day of working on two 8.8's, but gained a brother-in-law helper for Sunday if he wants a jeep to drive next week, someone has to get me back to my car tomorrow!
 

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Discussion Starter #18
Progress should pick back up this weekend after being bombarded with snow and Sahara problems this past week. Tomorrow is get 8.8 in #3 day and Sunday is strip dash and hvac out of swap thing. Oh and Sunday is coffee meetup day at the first church of Quadratec
 

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Discussion Starter #19
Alright, so another slow going weekend!

Got one 8.8 stripped, this week it will get primered and we'll get the perches set.


Then I focused a little on The dash, which is going down to the metal.


Then I got hungry and wrapped up, here's what we look like today.


Hopefully better progress next week. Did have a good time at Quadratec's Jeep's & Java today. Really impressive turnout.
 

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Discussion Starter #20
Alright, now on the eve of jeep-work-weekend, I'm excited to report that my frame is back from blasting. So...it's time to cut off the old body perches, those really bad motor mounts, and fix a couple little holes.



Should make some good progress the next couple days...
 
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