Ever since the LJ came on the scene, I was fascinated by it. Work and life kept me busy, and most of my spare time was spent building and riding motorcycles and snowmobiles. However, I always wanted to build a Jeep. Now, later in life - and facing my mortality - about three years ago, I decided I'd better find that LJ and build the Jeep I always wanted. I started looking for a low-mileage LJ after Covid was in full-swing.
Finally, in June, 2021, I found a one-owner 2005 Wrangler Unlimited Rubicon halfway across the country with less than 50,000 miles on it. The owner and I hit it off, and I ended up hopping on a plane, checking it out, writing a check, and driving it home. On the way home with it, I stopped at an old friend's house (we'd worked together at one time, but moved on to different states, and I hadn't seen him in many years) to compare his 2006 LJ to mine (he's @06LJR on here), so the joyous occasion was even more joyous!
In the almost three years since I bought the LJ, I've been slowly making mods to it while amassing a pile of parts for it. I still have a very busy life, so it's been tough to dedicate a bunch of time to the LJ. I've rebuilt two other vehicles in the interim, and I think I'm finally getting to the point where I can start the build! Actually, continue the build would be more accurate, since I have been very slowly making progress on it over these past years.
I've always been a backcountry-minded feller, spending a lot of time in places most people never go, so the idea with this build is to put together a vehicle that will get me anywhere I want to go in relative comfort. In addition, I plan to do some occasional rock-crawling with it, since my body can no longer take the abuse of riding things with handlebars.
I'll start this build thread with a picture of the rig from somewhere in Georgia on the way home - on the day of purchase (June 19, 2021):
Ain't she a beaut! Since that day, the following has been done to the rig, roughly in this chronological order (hyperlinks direct to pre-build-thread posts on here related to the activity.) How the change affected the weight of the rig is noted at the end of each change in bold text (when measured.) Note that I tried to measure the affect on rig weight for each change (which I thought would be most valuable to the reader), but you can't cumulatively add them to get my rig weight because some of the changes were removed or modified later, and those changes are not noted here.
Finally, in June, 2021, I found a one-owner 2005 Wrangler Unlimited Rubicon halfway across the country with less than 50,000 miles on it. The owner and I hit it off, and I ended up hopping on a plane, checking it out, writing a check, and driving it home. On the way home with it, I stopped at an old friend's house (we'd worked together at one time, but moved on to different states, and I hadn't seen him in many years) to compare his 2006 LJ to mine (he's @06LJR on here), so the joyous occasion was even more joyous!
In the almost three years since I bought the LJ, I've been slowly making mods to it while amassing a pile of parts for it. I still have a very busy life, so it's been tough to dedicate a bunch of time to the LJ. I've rebuilt two other vehicles in the interim, and I think I'm finally getting to the point where I can start the build! Actually, continue the build would be more accurate, since I have been very slowly making progress on it over these past years.
I've always been a backcountry-minded feller, spending a lot of time in places most people never go, so the idea with this build is to put together a vehicle that will get me anywhere I want to go in relative comfort. In addition, I plan to do some occasional rock-crawling with it, since my body can no longer take the abuse of riding things with handlebars.
I'll start this build thread with a picture of the rig from somewhere in Georgia on the way home - on the day of purchase (June 19, 2021):
Ain't she a beaut! Since that day, the following has been done to the rig, roughly in this chronological order (hyperlinks direct to pre-build-thread posts on here related to the activity.) How the change affected the weight of the rig is noted at the end of each change in bold text (when measured.) Note that I tried to measure the affect on rig weight for each change (which I thought would be most valuable to the reader), but you can't cumulatively add them to get my rig weight because some of the changes were removed or modified later, and those changes are not noted here.
- Removed OEM Lug Nuts and Installed McGard Lug Nuts/Locks
- Installed Buchanan Precision 1.5" Seat Riser Kit - gained 3.24 lb
- Removed Cold-Air Intake and Replaced with Stock Intake - lost 3.53 lb
- Removed OEM OPDA and Installed Crown OPDA - lost .11 lb
- Installed Bartact Seat Covers - gained 6.42 lb
- Installed SpeedoHealer (the LJ came with metric 33" tires on it, but no speedo change) - thanks to the generosity of @mrblaine! - gained .33 lb
- Removed Rubicon Rocker Guards and Installed RockSlide Engineering Electric Steps Kit with Armor (I have a short wife, and my knees and hips ain't what they used to be!) - gained 146.12 lb (includes 1.51 lb for 1/8" thick rubber strips added between sliders and body - removed later)
- Replaced Door Handles on the Full Doors
- Installed MORyde Tailgate Reinforcement Kit and Hinges (modified for tail lights and powder-coated OD green) - gained 24.59 lb (includes 5.98 lb for the modified plate for the hinge side, which was removed when the Genright corners were installed)
- Installed HyLine Offroad Spare Tire Carrier (modified to fit on the MORyde bracket and powder-coated OD green) and installed snubber spacers - gained 8.09 lb
- Removed OEM Head Unit and Installed Alpine iLX-W650 Head Unit and Metra Dash Kit - lost 2.39 lb
- Removed Walmart Battery and Installed NorthStar NSB-AGM24M Battery - gained 21.82 lb
- Removed RanchHand Rear Bumper and Installed Dirtworx Rear Bumper with Hitch and RockHard Frame-Bumper Ties (I use a cargo basket for meat coolers when hunting) - lost 11.35 lb (all of this was re-done when the rear frame was raised)
- Removed SmittyBilt XRC-8 Winch (Steel Cable and Roller Fairlead) and Installed Warn M8274-S with cover and Wireless Remote System (Barnes M8274 Mount) - gained 26.52 lb
- Installed TRE Safety Thimble and Safety Thimble Fairlead - gained 3.25 lb
- Removed Ranch Hand Front Bumper and Installed Savvy Front Bumper (powder-coated OD green) with Hooks, Light Mounts, Winch Guard, and Hardcore Corner Guard Kit - lost 78.8 lb
- Installed Quadratec Plug-n-Play Tow Hitch Wiring Harness - gained .53 lb
- Installed License Plate Frame with LED Light - gained .44 lb
- Removed OEM Tail Lights and Installed Savvy LED Tail Lights and License Plate Relocation Kit - gained 2.91 lb
- Installed Alpine Front Camera (eventually to be replaced with three separate cameras - thanks for the idea, @Apparition!) - gained .48 lb
- Installed Alpine Third Brake Light and Rear Camera - gained 3.60 lb
- Installed TeraFlex Hand Throttle Kit (for both on-board air and winching) - gained .50 lb
- Installed ORO York Compressor Kit - gained 36.44 lb
- Removed OEM Alternator and Installed Singer 270A Alternator - gained 1.34 lb
- Removed OEM Headlights and Installed Heated Truck Lite LED Headlights - gained 2.15 lb
- Removed K-C A-pillar Light Brackets and Installed Rockhard 4x4 A-pillar Light Brackets (powder-coated OD green) - lost .84 lb
- Removed (4) PIAA Driving Lights and Installed (4) Rigid 36204 6" Driving Lights (2 on bumper, 2 at bottom of A-pillars) - gained 2.92 lb
- Installed 50" Black Oak LED light-bar mounted on HyLine Offroad aluminum brackets (powder-coated OD green) - gained 20.98 lb
- Installed Black Magic Big Brake Kit, New Rear Brakes, and Wizard Brackets (thanks for making top-notch products, @mrblaine!) - gained 7.74 lb
- Installed Revolution Gear Rear Chromoly Axles - lost .47 lb
- Installed 00 Power Cables (self-made) - gained 4.81 lb
- Installed Secondary Power Distribution Center (thanks for the guide, @Steel City 06!) Note: This was later removed, to be replaced with a Switch Pros system. - gained 5.12 lb
- Installed Custom Lower Switch Panel from Custom 3D Fab. Note: This was later removed, to be replaced with a Switch Pros system. - gained .98 lb
- Installed Upper sPOD Switch Panel (thanks, @PNW_LJ!) Note: This was later removed, to be replaced with a Switch Pros system. - gained .87 lb
- Installed Black Magic Brakes Raised Front Swaybar Brackets and Reverse-taper Knuckle (more fine products from @mrblaine!) - gained 2.29 lb
- Installed Clayton Offroad Front Spring Retainers (because the Rubicon Express springs that came on it have a short free length) - gained .15 lb
- Installed Savvy Steering Box Skid (powder-coated OD green) - added 2.19 lb
- Installed Wouxun KG-1000G Plus GMRS Radio - gained 5.75 lb
- Removed OEM T-case Shift Linkage and Installed Savvy T-case Cable Kit. Note: This was removed and replaced with the Atlas shift kit. - gained 1.11 lb
- Installed Savvy Body Lift. Note: The two rear aluminum spacers were removed with the rear frame raise and the six side body mount spacers were removed with the Genright raised body mounts - gained 7.74 lb
- Installed Savvy Engine Lift - gained 2.38 lb
- Installed Fumoto USA Quick-drain Oil Valve
- Removed OEM Shift Tower and Stick and Installed B&M Shift Tower and Stick - gained 1.54 lb
- Installed Repainted Hood Shroud and Color-matched Headlight Bezels
- Installed BMB Front License Plate QR Bracket (yet another great product from @mrblaine!) - gained 1.47 lb
- Installed Color-matched GenRight Corner Armor (wanted Savvy, got tired of waiting) - gained 41.21 lb
- Removed Factory Full Doors and Restored and Installed Factory Half-doors with New Bull Dawg Uppers - lost 19.97 lb
- Installed Hard-coated Aluminum Front Recovery Eyes (thanks, @sunnysideup_lj!) - gained .61 lb
- Installed Painted Fender Flares (OD green)
- Fix Cracked Fuel Filler Nipple on Tank
- Reinforce Top Tank of Radiator (an idea to prevent the common cracking failure)
- Move Rear Frame Up To Match Body Lift and Make Rear Bumper the Rear Cross Member - gained 2.56 lb
- Install Hutchinson Rock Monster 15x8 Bead Lock Wheels (thanks, @Bigfoot-NM !) And BFG KM3s - gained 29.16 lb
- Install Savvy Gas Tank Skid - gained 4.93 lb
- Install @Fluxor's Aluminum Rock Slider Backers and Modify Rockslide Engineering Step Sliders - gained 25.08 lb
- Remove Axles from Jeep
- Install M.O.R.E. 1" Steering Riser - gained 0.12 lb
- Install Atlas 4-speed Transfer Case - gained 41.45 lb
- Make and Install Transfer Case Skid Plate (thanks for the aluminum, @mrblaine !) - lost 10.62 lb
- Install Savvy Engine And Transmission Skid Plate - gained 15.60 lb
- Make and Install Transmission Mounting Bracket - lost 1.22 lb
- Make and Install Transmission Cross Brace - gained 9.66 lb
- Install Savvy Mid-Arm Kit Frame Brackets and Move Front Frame-side Trackbar Mount 1" Forward - gained 17.72
- Install Genright Body Lift Brackets - gained 3.67 lb (gain is 5.20 lb, if you include the remaining BMB acetal pucks and lift hardware at five locations)
- Install Cutting Brake Levers in Cab - gained 4.60 lb (so far - still need to consider future brake line changes from frame rear calipers)
- Weld on Weld/Nut Washers for Frame Mid-arm Control Arm Brackets - gained 3.54 lb
- Bonus Project - a More Elegant Cable-end Connection for the Thumb Throttle
- Re-install Transmission and Atlas Transfer Case
- Bonus Project - Zip-Tie Tabs for Fastening Hoses and Harnesses to the Upper Control Arms - gained 0.30 lb (9 tabs and hose clamps)
- Re-install Carpet (removed for Atlas/Tummy Tuck)
- Bonus Project - Replacement of OEM Subwoofer with Kenwood KSC-PSW7EQ Subwoofer - gained 1.75 lb
- Install Control Module for Step Sliders - gained 0.30 lb
- Install chili_pepper's Cabin Air Filter Assembly - gained 0.34 lb
- Re-install Rocker Armor and Step Sliders
- Wire Step Sliders
- Install Manifold, Oil-Coalescing Filter, and Associated Components for York - gained 3.47 lb
- Install ARB Mini Compressor (thanks to the discussion started here) - gained 5.13 lb
- Install Switch Pro RCR-Force 12 Switch Panel, Control Box, Fuse, and Power Cable - gained 3.94 lb (no wiring, yet)
- Install ARB Breathers for Front Differential/Transmission/Atlas T-case and for Rear Differential - gained .87 lb (no hoses, yet)
- Bonus Project - Replace MorRyde hinges and plate and HyLine Offroad spare tire carrier with Fluxor hinges, tailgate armor and valance, and lightened spare tire carrier
- Design Center Console Insert and 3D Print It - gained 0.88 lb
- Bonus Project - Design Caps for Front Upper (Frame-side) Spring Bucket Holes and 3D Print It - gained 0.04 lb
- Re-install Center Console (removed for Atlas/Tummy Tuck)
- Re-install Seats (removed for Atlas/Tummy Tuck)
- Re-install Transfer Case Skid and Engine/Trans Skid
- Install Savvy Mid-Arm Axle Brackets Front and Rear
- Install Iron Rock Offroad Lower Control Arm Mounts with Weld and Nut Washers to Front Axle
- Weld on Rockjock4X4 Mini-Skids
- Weld on Axle Weld/Nut Washers
- Install Revolution 4.88 Gears Front And Rear
- Install ARB Lockers Front and Rear
- Install RCV Front Axle Shafts
- Modify and Install Barnes Diff Covers, Modified with Hard-facing
- Design, Make, and Install AR400 Differential Skids
- Install New Spicer Ball Joints
- Install Rockjock4X4 Bump Stops Front and Rear
- Install Axles in Jeep (w/ Savvy mid-arm Control Arms)
- Make and Install Hard Brake Line on Rear Axle
- Install Flexible Brake Lines Between Frame and Rear Axle
- Design Supplemental LJ Body Mount Brackets and Rear Antirock Mounting System
- Install Dorman Extended Front Brake Lines
- Install Rockjock Currectlync System with @mrblaine 's 4340 Tie-rod
- Install Rockjock Front Tracbar
- Install Rockjock4X4 4" Coil Spring Set
- Order and Install New Tom Woods Driveshafts
- Make and Install Cat-back Exhaust System
- Make and Install Exhaust Hanger Bracket for Above T-case Skid Plate
- Make and Install Rear Stiffener for T-case Skid Plate
- Install Hydro-assist System (PSC parts with @mrblaine 's BMB kit)
- Plumb ARB Lockers Front and Rear
- Add Towers for the Front Fox 2.0 Shocks with DSC Reservoirs (11" travel)
- Outboard the Rear Fox 2.0 Shocks with DSC Reservoirs (12" travel)
- Re-install Fender Liners (modify to fit, if necessary and possible)
- Install Element Fire Fire Extinguishers
- Install "The Wiz" for GMRS Radio
- Install Baja Designs S2 Sport Wide Reverse Lights
- Install LUX Rock Lights
- Install Front Cameras
Last edited:
