LJR long term "rebuild"

More progress today, a full day in the shop with very few pictures. I was busy and forgot.

First I lifted up the Jeep into monster truck mode and built both hydraulic lines with new hose and field serviceable ends. I bought extra hose and kept my old fitting for trail repair for me or my friends. I wrapped the new lines with abrasion protection and installed them.

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Next we starting working on the rear armor. We have both sides fitted and cut out. I still need to figure out the fuel filler and cut the hood. We should be stripping everything for powder next weekend.

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We were going to use bump stops but decided to do rear suspension mounting point revision number 476 and utilize the hydraulic bump stop in the ORI. We cut the upper mounts off again, and redesigned some slightly longer ones. Now we get full flex in the rear with no contact.

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I’ll take more pictures next time. Getting close now.
 
Good progress today.

Cut the hood down and added some molding and latches. Fits decent enough.

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Fit the inner fenders and checked everything for clearance. Had to do some trimming but it works.

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Decided to side mount the fuel filler. My buddy tig welded some bends. Just need a short piece of 1.5” to connect it.

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Pulled all the armor off and will take it in for powder coat next week. We are down to a small check list of things to complete and lots of painting. Couple more weekends and we should have it ready for trials. Still will leave some wiring and clean up for me that I can do at home.
 
Dropped off all the parts for powder coat this morning. Should have them back Friday. This weekend we paint the suspension and skids and start reassembly and brakes.

Still have a few things to finish up:

Paint suspension
Mount seats
Build harness bar
Paint roll cage (I have a new/used OEM cage to install, mine is damaged)
Brake plumbing
Fuel plumbing
Relocate trans cooler to under tub

Few days and it should be running and ready for exhaust work.

Will finish wiring up all the SPOD stuff and seat heaters later. Trail lights are nice to have but not critical.

Getting excited now!
 
Dropped off all the parts for powder coat this morning. Should have them back Friday. This weekend we paint the suspension and skids and start reassembly and brakes.

Still have a few things to finish up:

Paint suspension
Mount seats
Build harness bar
Paint roll cage (I have a new/used OEM cage to install, mine is damaged)
Brake plumbing
Fuel plumbing
Relocate trans cooler to under tub

Few days and it should be running and ready for exhaust work.

Will finish wiring up all the SPOD stuff and seat heaters later. Trail lights are nice to have but not critical.

Getting excited now!

Which trans cooler are you relocating?
 
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Which trans cooler are you relocating?

Derale that the PO installed in front the the condenser. The fan is a puller and it’s mounted backwards so it’s fighting the radiator fan.

I’m going to mount it high behind the t case skid. With the body lift it should be out of harms way and help with my cooling issues.
 
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Derale that the PO installed in front the the condenser. The fan is a puller and it’s mounted backwards so it’s fighting the radiator fan.

I’m going to mount it high behind the t case skid. With the body lift it should be out of harms way and help with my cooling issues.

I have a derale as well that I built a guard for that mounts it to the tub. Here it is:

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It’s sitting on a shelf in my shop. If you think you could use it, and it will help, I can send it over.
 
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I have a derale as well that I built a guard for that mounts it to the tub. Here it is:

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It’s sitting on a shelf in my shop. If you think you could use it, and it will help, I can send it over.

Be glad to buy it off you and pay shipping. Exactly what I was planning to build with out the building it part. I can send you a shipping label. All I have is the core and fan.
 
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Be glad to buy it off you and pay shipping. Exactly what I was planning to build with out the building it part. I can send you a shipping label. All I have is the core and fan.

No need. PM me your address and I’ll send it up. I’d love to see it on your rig. I’ll also send the cooler as well just in case it’s any different than yours Just to make sure it fits. If you don’t use it you can pass it on.
 
No need. PM me your address and I’ll send it up. I’d love to see it on your rig. I’ll also send the cooler as well just in case it’s any different than yours Just to make sure it fits. If you don’t use it you can pass it on.

Wow, I really appreciate it. Let me at least cover the shipping. I’ll send a DM.
 
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Busy week, pick up all my parts from powder coating. They look pretty good for what I paid. Got a couple new tires for the trailer, still need to find a few random bolts for the brake calipers. Lots of work to do tomorrow, but its getting really close now.

Decided to go all red since most of the red jeep I see are red / black. Hope it looks good. At least until the first trail ride.

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Long day today. Jeep is disassembled, everything off for paint.

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Pulled out the damaged roll bar and cleaned out the Jeep. Fitted the new undamaged roll bar and started working on a harness bar and seats.

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Disassembled both axles and cleaned / painted the housings. Got the rear ready to install. Also painted all the links and steering parts, as well as several small parts. Looks like we have a "build your own Jeep" kit in the shop now.

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Tomorrow we mount the new trans cooler from @NashvilleTJ, install both seats, remove paint and reinstall the roll bar, and start reassembly.

Made a parts run tonight for some last minute bits. Should have it real close to going home tomorrow with a hard deadline of next Saturday. Then its the muffler shop, and lots of wiring for me to sort out.

Really excited now, its almost a Jeep again!
 
Long day today. Jeep is disassembled, everything off for paint.

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Pulled out the damaged roll bar and cleaned out the Jeep. Fitted the new undamaged roll bar and started working on a harness bar and seats.

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Disassembled both axles and cleaned / painted the housings. Got the rear ready to install. Also painted all the links and steering parts, as well as several small parts. Looks like we have a "build your own Jeep" kit in the shop now.

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Tomorrow we mount the new trans cooler from @NashvilleTJ, install both seats, remove paint and reinstall the roll bar, and start reassembly.

Made a parts run tonight for some last minute bits. Should have it real close to going home tomorrow with a hard deadline of next Saturday. Then its the muffler shop, and lots of wiring for me to sort out.

Really excited now, its almost a Jeep again!

Congratulations on almost being done. Looking really good too.
Can't wait to see it out of the shop.
 
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Working over time this weekend. Didn’t take many pictures but we got a lot done. First project was the trans cooler. We pulled the grill off and remove the existing trans cooler that was strapped to the condenser. The fan is a puller so it was fighting against the radiator fan (I did not install it that way). Hope that removing the extra heat load from the cooling package will help with temps.

We started pulling the factory trans hard lines and removed the fitting in the side of the trans. We didn’t have the needed conversion fitting for 6AN on hand so Willie made me some. He turned the factory fitting down in the lathe and tig welded a 6AN stainless bung to it. Pretty sweet huh?

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We installed the rear axle, links, and driveshaft and started planning the cooler location. @NashvilleTJ shipped me an under mount cooler with a sweet guard on it. No matter how we positioned it something was making contact with the cooler at bump. We ended up needing to remove the guard and tuck it up behind the rear footwell. Worked great, I built hoses for it with Fragola push lock hose and 6AN elbows.

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Next we assembled the front axle, steering, brakes etc and installed the axle. Got the ram connected and routed the lines, ran the pump with an electric ratchets to prime and bleed. Set the toe, just need to center the steering wheel and lock down all the jam nuts.

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Got all 4 ORI’s and the fuel tank installed. Ran all the lines and vents. Filled the lower ORI chambes to 100psi and set the ride height to 6’11” at the highest point so it’ll fit in my garage. Should give us 5.5-6” up and about 8” down. She’s a big ole bitch.

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We bleed all the brake and got the pedal nice and firm. Hope this Black Magic big bore master will be enough for the one ton brakes @mrblaine any input here? It’s front your 17” TJ kit.

All we need is fuel and a hot battery and it’ll drive. Stopped and grabbed a new group 34 interstate at Costco on the way home.

All that’s left is to bolt on the armor, paint the cage, install inner fenders, and fill the diff fluid and it’ll be shakedown time.

Next Saturday it comes home. Whatever is left is on me. Willie has several more projects lined up and wheelin season is here.
 
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There is no such thing as a big bore master and no such thing as one ton brakes. They have specs, the only way to know anything is to know what they are.

Master that comes with your 17” big brake kit for 2006 TJ / LJ. 2005+ Ford F250 front brakes, 2002 Chevy 2500 gas truck 14 bolt rear disk brakes.

Will this master be enough, I f not what can you sell me that will be?
 
Master that comes with your 17” big brake kit for 2006 TJ / LJ. 2005+ Ford F250 front brakes, 02 Chevy 2500 gas truck 14 bolt rear disk brakes.

Will this master be enough, I f not what can you sell me that will be?

What diameter are and how many pistons are in the front calipers?
What diameter are and how many pistons are in the rear calipers?