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Discussion Starter #1
I had a 2k TJ that I loved but got rid of. I have also had tons of cars mostly centering around subarus and chevys. I have huge custom project of a 90 subaru wagon that is ateempting to get 35" tires and a full independant supension with a supercharged subaru h6 motor, chevy trans and xfer case, for IRs/ifs 8.8 diffs, 4 wheel steering and basically custom everything.

With a 2 year old the project sits mostly right now. Anyway, i was driving my 2500gmc and It is a great truck but boreing and lumpy to drive everyday and also bad on gas. So i decided to pull the trigger on this 95' YJ on CL.

I wanted a fun DD with part time off road stuff with little projects. So anyway here it is...

Day, I got it two weeks ago.





Yes, I know the shkles are wrong. They get fixed.

So today... Yeah, :)


Front bumper off. I am gonna cut out the bottom captured nuts as one broke out already. Leave the holes for drains. Weld angle brakets on the sides of the rails to mount my new bumper to. Also still use the factory top bolt as well. This way I should be able to put the factory bumper back if I ever choose to. I doubt I will but...

I also got some of the frame tub under coated on the passenger side. The before pic is the driver side but the passenger looked the same.
Wire brush, cleaned a lot, more wire brush, rust inhibiting primer, and truck bed line spray.
Alot more to do but...
Before:

After:
 

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Discussion Starter #2
Got the shackles fixed, turned around and a center support welded in. Also a fender flare trim.
:)




Also gathered parts to fix a leaky pinion and axels seals in the rear. I decided to get a spartan locker for the rear and a new diff cover as well. I hope to have that done by the weeked.

I can't wait to get my bumpers done and take this thing off road!
 

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Discussion Starter #4
I want tires but really will only go 32's at the most. There are 30's on it now. Yeah they will suck but... Honestly looking thru CL for a deal first.

I want the bumpers first that way when I get stuck I will have good hook points to be pulled ot. LOL!
 

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Lol yeah I was wondering cuz u have a spartan locker ready to be put in yet with all streat treads!
 

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Discussion Starter #6
Pinion seal replaced( a lot harder than I thought), both DS u joints replaced, both rear axels seals replaced, spider gears out.

I am ready to put in the spartan and then do all the hardware and shoes on the rear.

Getting the pinion seal replaced was a job in itself. I had to get the correct in lb torque wrench, take a pinion bearing preload measurement, reinstall everything and then reset the pinion bealring preload measurement +5 in lbs.
Not an easy task I should say. I did make my own holder for the axel yoke so thats cool. I double checked myself by using the mark the nut method. It would not have been right so I am glad I did it the way the manual stated. If i would have just marked the nut and replaced it to the same spot the bearing preload would have been to little.


So all in all I learned something for sure and feel confident. I can't wait to do a whole axle setup. I have my 8.8 for my other project that will be a full rebuild/regear.

I can get pics but it's all pretty mundane stuff. The idea of doing the locker now is becuase I needed to have most of the diff dissasembled to change the axel and pinion seals so why not. ;)
 

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Discussion Starter #7
I got the rear end all buttoned up. All new axels seals, pinion seal, all new drums, shoes, and hardware for the rear brakes. Insatlled the spartan too.
Did some more cleaning on the frame and axel and more undercoating. New diff cover too. Thanks to Tony at Baseline 4x4. Also painted the rear drums with high temp ceramic caliper paint.
First impressions on driving with the locker. I can tell its there but it's not annoying. It locks very easilly, and unlocks right away on turns. I cannot here it ratcheting but I have heard some say that you cannot. So far so good.
Now to get my bumpers done and try this thing out in the dirt.


 

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my 95 YJ looks a lot like yours. one of the front bumper bolts(lower drivers side) had the welded nut weld break loose. how did you manage to get it free as the bumper just swings out some but not enough to reach the bolt.......Driller
 

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Discussion Starter #9
I just ended up cutting the heads off the bolts. I found the drivers one was broken and it just fell out. I am gonna get the passenger one out too and leave the holes fro drains. I am gonna use the top bolt and weld on new brackets on each side to mount my custom bumpers.


I have also decided that I am looking for 31x10.5x15 tires. 32's are gonna be too big with no lift. Looking for a good used set of mt's.
 

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Great pics and interesting project. Love the color of your Wrangler too. I guess I need to lift mine too, it's too low as is.......
 

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Discussion Starter #11
Thanks!

I got a good start on the front bumper. I still need to do some tweaking with the brackets. Get the top plate made and welded on, and get the d ring shackle mounts made and burned on. It's really simple but suit my needs.
I may do a small stinger later after I decide on winch stuff or lights. all of that can be added anytime so...
Just for info. All 1/4 wall steel, bolt holes are sleeved, bolts are grade 8. It should not go anywhere. :)


 

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Discussion Starter #12
Got a set of 5 32/11.5/15 BFG MT KM2s. Almost brand new on a set of black rock rims.
Couldn't pass up a cl deal.
I am gonna put them on tomorrow so i'll have some pics. I guess I better get my lift kit coming. LOL!
 

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Discussion Starter #13
So I got the tires on. They fit way better than I thought. I still need a lift but they are more than driveable the way they are. I jacked the front tire til the other one lifted off. No rubbing at all in the front and only slight rubbing in the rear. Honestly a small lift shackle would fix it.
I am debating a 2.5" susp lift and 1" body lift. I would like a 4" susp lift but don't really think I need it. I will never run bigger tires than this with these axels or gears so...
Anyway.. I had to test them out. Didn't play long becuse I was by myself in a bad area and it was really soupy with no recovery vehicle.
I still need to get the spare mounted but ran out of time for today and my tire carrier is borked. so...




 

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I have a set of the KM2's and they are awesome in my opinion. The only time I have gotten stuck a guy with 37's got stuck and dug holes with his then I attempted to go through with no luck. They REALLY fling the mud if u keep them spinnin and clean and they bite really hard.
 

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Discussion Starter #16
how did they hook up? im wanting to get the km/2's
I had no problems. Nothing hardcore at all but honesly i don't even think they spun unless i wanted them too for roostertails. :) They are pretty quiet on the road too.

I have a set of the KM2's and they are awesome in my opinion. The only time I have gotten stuck a guy with 37's got stuck and dug holes with his then I attempted to go through with no luck. They REALLY fling the mud if u keep them spinnin and clean and they bite really hard.
Sweet! I am looking forward to trying to get stuck. IMHO it's you don't get stuck your not trying hard enough or your lucky!:)

Great looking yj too!
 

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95YamJam, in regards to the rust that you have removed... do you have a sand blaster? That would be a wonderful piece of equipment for a project of this type. Great job, man!
 

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Discussion Starter #19
I do but it was not that bad. I used wire brushes, scrapers and such. Blew everything off /out with an air gun. Used some marine clean from por15, Then rust preventing primer covered with spray on truck bed liner. I still have a little bit to do but it's going well. I also removed all the rusted bumps stop mounts on the rear. removed the rear track bar bracket. Basically got rid of everything that is not nessescary that can hold mud and water.

I need to remove my fuel pump plate and rebuild it cause it is rusted. Also i am gonna need a new gas tank skid someday as well. More than anything i am getting intimate with the underside of it so I really know what kind of shape it's in and then can identify problems and take care of them. All in all the under side is in super shape. The sides of the tub are rusted more than underneath. Nothing detrimental but I will tak care of it.

Not making a show rig at all. Just want it to hold up for a while and have some fun in the process. :)
 

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Discussion Starter #20
I got some new goodies ordered. 1" body lift/new mount kit, rear 1" lift boom shackles, and some new shocks for 0-2" lift.
My shocks are all completely shot. LOL!
Almost done with the front bumper. I got the 3/4 plate d ring mounts made and burned in. I decided to weld them in from the back too. So it took a little longer. I just have a bit more welding and some grinding and i can paint it and be done with it.
I'll get pics ASAP.
 
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