High Mileage 2001 Sahara Build

After staying in Indianapolis last night, I dropped my new frame off at the shop today. They approved the frame and said there wasn't anything clearly wrong with it. They're hopefully going to be stripping it down and getting it to powder coat tonight. I'm also going to be ordering some parts from Savvy and JB conversions tonight. I'll be getting a tummy tuck and all the necessary supporting mods from Savvy and a super short SYE from JB conversions.
What's the frame swap looking to cost you? I'm out of Atlanta and just bought another TJ to fiddle with. The car's in good shape aside from the overly rusted frame and the transfer case skid place hanging by only a few bolts. I'm contemplating whether I should swap the frame and flip the Jeep or part it out. Luckily my '00 TJ has always been here in GA and no rust. Hope your swap goes great!
 
What speed do your vibrations start? My stock driveshaft had a slip that was absolutely gone. You could move it up and down 3/8th of an inch. With that shaft, my vibrations would start at 55 mph. If a buddy has a driveshaft that would fit in your Jeep and he doesn't have any vibrations, I would swap with him and see if they go away. That would help narrow down what your problem could be. There are only a few things that can be wrong with a driveshaft. Your problem sounds like it could stem from the slip being too loose.

My vibes start in at 50mph as an audible harmonic sine wave. Smooths out at 59-61mph, then becomes a physical constant vibe above 62mph felt in the steering wheel, seat, and floor. Just got off the phone with a Tom Woods tech. He confirmed that you should have zero play in that slip. Bad part is I didn't check that when the drive shaft was new, so not sure if there was play or my vibes have contributed to wearing play into the slip. Either way, I might ship this drive line to Tom Woods and have them check it out.
 
What's the frame swap looking to cost you? I'm out of Atlanta and just bought another TJ to fiddle with. The car's in good shape aside from the overly rusted frame and the transfer case skid place hanging by only a few bolts. I'm contemplating whether I should swap the frame and flip the Jeep or part it out. Luckily my '00 TJ has always been here in GA and no rust. Hope your swap goes great!

Depends on whether or not you're having a shop doing it. If you're doing it, you can probably make some money by changing out the frame. But I'll be honest, you'll make way more money by parting it out. If it has green half doors, I'll buy them from you.
 
My vibes start in at 50mph as an audible harmonic sine wave. Smooths out at 59-61mph, then becomes a physical constant vibe above 62mph felt in the steering wheel, seat, and floor. Just got off the phone with a Tom Woods tech. He confirmed that you should have zero play in that slip. Bad part is I didn't check that when the drive shaft was new, so not sure if there was play or my vibes have contributed to wearing play into the slip. Either way, I might ship this drive line to Tom Woods and have them check it out.

Probably a good idea. I had a similar experience when my slip went bad. Vibration just gets worse and worse with speed until it is unbearable.
 
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Depends on whether or not you're having a shop doing it. If you're doing it, you can probably make some money by changing out the frame. But I'll be honest, you'll make way more money by parting it out. If it has green half doors, I'll buy them from you.
I too was starting to think I could make more in parts. Unfortunately, I can't help you on doors since it has it has full Steel Blue color doors Paint Code PQB. I'm out of Atlanta but make runs around here, SC, TN, and NC often for work so will keep a look out. What color interior do you need? I've got a C.Pepper Red TJ for myself I've been hunting for full size doors so I'm always scanning the local markets.
 
I too was starting to think I could make more in parts. Unfortunately, I can't help you on doors since it has it has full Steel Blue color doors Paint Code PQB. I'm out of Atlanta but make runs around here, SC, TN, and NC often for work so will keep a look out. What color interior do you need? I've got a C.Pepper Red TJ for myself I've been hunting for full size doors so I'm always scanning the local markets.

I’m honestly not searching too hard for half doors right now. Already spending a lot on the frame swap. But if any are for sale and I come across them, I’d probably jump at the right price. The people I bought my frame from had green, tan interior half doors for $300. I would’ve bought them on sight but they were already sold.

A new frame can be had for anywhere from $1000 to $3000. If you do it, that’d be nearly your only cost. Having a shop do it adds anywhere from $3000 to $6000 to that. You’d make more parting it out in almost any situation.

Could do weld in segments. That’d be a really hard Jeep to sell in the rust free south though...
 
Be careful with that Savvy tummy tuck. Assuming you're at 4" of suspension lift like I am, you're rear track bar may be dangerously close to your fuel tank skid. Mine is 1/4" away from contacting it, maybe even closer. One more reason I went to the GenRight tank.
 
Be careful with that Savvy tummy tuck. Assuming you're at 4" of suspension lift like I am, you're rear track bar may be dangerously close to your fuel tank skid. Mine is 1/4" away from contacting it, maybe even closer. One more reason I went to the GenRight tank.

I’m only at 3” of lift so I’m hoping that isn’t an issue. If it is an issue, I’ll just have to solve it I guess. I’d probably end up with the GenRight tank or some other alternative that my shop recommends. That’s the nice part about the shop I go to. The owner has had too many TJ’s to remember and has worked through almost every issue imaginable. I’m in good hands over there. :)
 
I’m only at 3” of lift so I’m hoping that isn’t an issue. If it is an issue, I’ll just have to solve it I guess. I’d probably end up with the GenRight tank or some other alternative that my shop recommends. That’s the nice part about the shop I go to. The owner has had too many TJ’s to remember and has worked through almost every issue imaginable. I’m in good hands over there. :)

Sounds like you've got it covered then. Truthfully, I'm fine as it sits, I just wanted to add the GenRight tank because it will move it from 1/4" of clearance to about 2.5" of clearance, which just makes me feel a bit better!
 
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I think I'm becoming @Chris over here. Just ordered Savvy rock sliders, Savvy LED tail lights, and a set of Grabars. Just to make sure, do the Savvy tail lights work with the OR Fab tire carrier? Also, do I need the Savvy LED light covers for the Savvy lights to work?
 
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I think I'm becoming @Chris over here. Just ordered Savvy rock sliders, Savvy LED tail lights, and a set of Grabars. Just to make sure, do the Savvy tail lights work with the OR Fab tire carrier? Also, do I need the Savvy LED light covers for the Savvy lights to work?

I believe they work just fine with the OR-Fab tire carrier. It's the Exogate where you have to do some cutting (like I did).

What are Savvy LED light covers? If you ordered the Savvy LED taillights, they come with everything you need.
 
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I believe they work just fine with the OR-Fab tire carrier. It's the Exogate where you have to do some cutting (like I did).

What are Savvy LED light covers? If you ordered the Savvy LED taillights, they come with everything you need.

I now see that the LED light kit comes with covers. I wasn't sure if I needed to order these or not.
 
I now see that the LED light kit comes with covers. I wasn't sure if I needed to order these or not.

Oh no, those are just replacement lenses. If you ordered the kit, it comes with the CNC mounting plates and the lenses as well.

Those replacements are just incase you happen to break one of them.
 
Oh no, those are just replacement lenses. If you ordered the kit, it comes with the CNC mounting plates and the lenses as well.

Those replacements are just incase you happen to break one of them.

Speaking of the Savvy tail lights, I also ordered this relay. Will this work considering I'm running stock turn signals in the front and LED's in the rear?
 
What gear ratio did you go with the 33s
Hi all,
With all the modifications and maintenance I'm doing to my TJ lately, I thought it might be smart to start a build thread. I also want to use this thread to keep track of my Jeep over the years. I'd like to be able to look back on this thread in 10 years and have a pretty detailed look at my TJ's history.

June 2nd, 2001:
My Dad buys my Jeep brand new.

Fall 2009:
This is the first time I went off-roading in my Jeep. The Jeep had about 40,000 miles on it at this point. These are the earliest photos I have of my TJ. Here is my TJ at an off-roading 101 course in Rausch Creek:

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My TJ parked next to some cooler Jeeps:

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October 2013:
This is the first time my TJ entered the state of Wyoming. The Jeep had become a daily driver in 2009, so the Jeep now had 172,000 miles on it.

Driving through Yellowstone in a snow storm:

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Spring 2015:
I finally got my drivers license! The first thing I did was tear the roof and doors off. This was the first time the doors had ever come off the TJ.

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February 2016:
The Jeep now had 191,000 miles on it and was pretty tired. So we decided to freshen the Jeep up quite a bit. We took it to Salt Lake City and had Currie suspension, air lockers, 33's, gears, and a ton of other stuff put on.

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I spent the remaining year and a half of high school exploring forest service roads in western Wyoming.

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September 2017:

I left Wyoming for Chicago and so did the Jeep. Nothing much to talk about here.

July 2018:
I crawled under the Jeep and realized that my frame was much more rusted than I had initially thought. The frame was going to need immediate attention. I decided the best course of action was to do an entire frame swap.

View attachment 55109

September 2018:
I found a frame in southern Tennessee and headed down to look at it. The frame looked straight and besides a little internal surface rust, was 100% rust free. Bought the frame, rented a uhaul trailer, and left for Chicago.

View attachment 55110

And that is where we are today. The Jeep currently has over 225,000 miles on it. I have a lot of plans for my TJ in the next few months.

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What gear ratio did you go with the 33s

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I went with 4.56's. It has some pep around town and isn't horrible on the highway. If you plan to go to 35's and don't do a ton of highway driving, 4.88's wouldn't be an awful choice either.
 
Na, I'm on 32s now. 33 would be the biggest I think I will ever go

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Awesome Thread...Now I get it. You started wheeling with your dad when you were what, 10? That's awesome that you've come to a point in your life to get the Jeep fixed up again. I'd give almost ANYTHING to find the old VW dunebuggy that my dad had during my formative years. It was a real Meyers Manx, Bright orange with aluminum Slot mags and Goodyear Wide ovals in back. It had LOTS of issues with wiring and what not but we had so much fun in that car. He sold it to come up with cash for buying the business he worked at, which worked out really well for him, but we lost track of that car. I've asked him if he remembers who bought it, or if he has any records...he doesn't.

Good Luck! I'm subscribing
 
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