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Discussion Starter · #1 ·
Hi. Long time reader, first time poster. I thought I would start to document the rebuild of my 1991 YJ.

As my second son was turning 16, I thought "How cool would it be to have a Wrangler as a first car?". So, I started the hunt for a "small" project YJ that he and I could work on together. I found a local jeep that wasn't overpriced and drove it about 30 miles home. It was rough but had many of the things I was hoping for; a hard top, full steel doors, newer tires, 4.0L, automatic, with A/C.

I'll be honest, it's not the first time I had the thought. We had a 1992 YJ 5-speed, 4.0L when my oldest son was 16 and we loved it. Unfortunately, things didn't turn out the way I had hoped for that Jeep and we ended up selling it to buy an RV.

Skip forward about 8 years and, fortunately, I'm now in a position to take on a project that I've been wanting to do for a long time. I work in IT by trade so hard core auto repair isn't one of my strengths but cars have been in my blood since a very young age. I started with a simple goal: ensure the jeep would be safe, fun, reliable, and mildly capable off-road.

So...Here we go...
 

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Discussion Starter · #4 ·
Monstaliner under the replacement '94 tub.

Monstaliner under the replacement '94 tub.
 

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Discussion Starter · #5 ·
Frame Repair

Wow, was this frame much worse than I had hoped for. The front tube was completely rotten through and the rear spring shackle section was really bad. I found some replacement sections on ebay in order to complete the frame repair. I also coated the frame with Chassis Saver Black.
 

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Discussion Starter · #9 ·
Chassis Paint

Looks like a nice project. Nice looking tube your using. I have a 92 and the frame was way gone. So am currently prepping a donor frame. Waiting to see more on yours. Nice job so far. Do you like the chassis saver. Not sure what I am using yet.
IMO there are two choices on chassis paint; Chassis Saver or POR-15. I've only used Chassis Saver but I understand POR-15 is about the same. It's expensive either way but I think it's worth it. I don't plan on getting rid of this jeep any time soon.
 

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Yes. The smaller guages were pretty easy. The two larger ones require you to break the seal on the front glass. It was tricky and didn't look the best when I was done but it's all hidden by the bezel.
Ok thanks for info, I ordered same ones then. Looks great!
 

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IMO there are two choices on chassis paint; Chassis Saver or POR-15. I've only used Chassis Saver but I understand POR-15 is about the same. It's expensive either way but I think it's worth it. I don't plan on getting rid of this jeep any time soon.
Nice build, I like the color choice. I used Frame Coater Kit from KBS Coatings and I'd recommend that you check it out. I haven't had it long... I don't even have the Jeep back together yet, but it's certainly worth looking in to.
 

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Discussion Starter · #17 ·
Major milestone tonight. Tub is on the chassis! Also have many new parts installed: fuel pump, filter, SS braided fuel lines, SS hard brake lines, SS cat and cat-back exhaust, oxygen sensor, coolant hoses, thermostat, temp sensor,
 

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Major milestone tonight. Tub is on the chassis! Also have many new parts installed: fuel pump, filter, SS braided fuel lines, SS hard brake lines, SS cat and cat-back exhaust, oxygen sensor, coolant hoses, thermostat, temp sensor,
Looks great ! Getting closer !
 
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