My second TJ build

[CCompton]

I just got a great deal on my “new” TJ this past fall. I picked it up with a bad Dana 35 (which I wouldn’t have left in anyway). It is super straight and almost rust free, though it does have a large dent in the front rocker and tub areas in front of the driver door. It came with some janky aluminum corner and rocker “guards”, Warn bumpers, a Warn XD9000i winch, and an over the top audio system. So far I’ve put the 4” lift from my old TJ on, Rancho 5000 shocks, swapped in a 4.10 Explorer 8.8 rear (used Barnes4wd brackets), swapped in a 4.10 front from a 2.5 TJ, swapped out my old TJ seats, put a new Sierra Offroad soft top on, ripped out the audio stuff, installed my old Poison Spyder Trail Stinger, and put on on adapters and 17” MT bullet holes on 33s.

My plans are:

-Ford D44HP swap (picking up tomorrow, will be getting chromolys with 760x joints and regearing to 5.13)

-swapping to a ‘97+ F150 8.8 and redrill to 5x5.5” lug pattern

-4” rear stretch, 1-2” front stretch

-DIY midarm suspension (triangulated rear)

-actual armor

-Barnes boatside body lift body mounts

-boatside rockers

-37” tires on the current wheels

-olive drab repaint

-5.3/4L80 swap


The day I hauled it home.

As it sits now (minus the new top).

 

[tnjeepguy]

Nice wheels. And I like the faded red paint.

"patina" - a term describing the natural, weathered look developed over time from exposure to elements like sun and rain, including faded paint and slight rusting.

 

[JEEPSTEVENANAIMO]

I dont think barnes sells the boat side rockers anymore for the tj all i can find are the rocker guards.

 

[CCompton]

I dont think barnes sells the boat side rockers anymore for the tj all i can find are the rocker guards.

They don’t, that I’m aware of. I will probably make those. I was referring to their boatside body mounts.

https://barnes4wd.com/products/jeep-tj-boat-side-body-mount-1-25-body-lift

 

[CCompton]

Nice wheels. And I like the faded red paint.

"patina" - a term describing the natural, weathered look developed over time from exposure to elements like sun and rain, including faded paint and slight rusting.

Thanks. I do like the red in a way, but I love green TJs and really want to do a build with a retro military feel. This was my old Jeep.

 

[CCompton]

Well my plans have been revised. The 44HP deal fell through and finding what I need is like looking for hens teeth. I have decided to go a bit more mild on the build. I have picked up a D30HP already and will be going with 35s instead. I think this is plenty for my use though (not many big rocks in central KY). I also grabbed a spare fuel tank and skid plate to modify for my stretch. I plan to start the tank mods and hopefully burn in my frame link brackets in the next few hours.

 

[CCompton]

No pics as my garage area I’m working in is barely big enough to work in. I have moved the axle back bolted in the lower control arms, welded in the axle truss, welded in the upper coil spring perches, mocked up the driver side Motobilt stretch corner, and began building a skid plate for an RCI 2161A fuel cell that I’ve had laying around (decided not to use the modified stock tank).

 

[CCompton]

Got my shock mounts welded on the frame and axle. I also got it all painted up but didn’t snap a pic the spring perches moved down around 1”. I had 4” springs which are going to be too tall with that change and the body lift, so I have some 3.5” Rock Jock springs coming Wednesday.

 

[CCompton]

Some pics of the start of my fuel cell and skid plate. One is the stock height below the mounting flange to show comparison. Also that depth is with the axle stretch so I have plenty of room to add more length or swap to tons in the future.

 

[Wildman]

I sometimes wish I'd done a fuel cell instead of the GR stretch tank but it's installed and works.

 

[CCompton]

I sometimes wish I'd done a fuel cell instead of the GR stretch tank but it's installed and works.

I’m not really sure why no one goes this route. I’ve never seen anyone run it in the stock location. I’ve seen several that were sunk up into the trunk area, but none completely below the floor. Hopefully it works well for me. I had it laying around unused from another project years ago, so figured why not.

 

[CCompton]

This came in yesterday to help clear room for my upper links.

 

[Wildman]

I’m not really sure why no one goes this route. I’ve never seen anyone run it in the stock location. I’ve seen several that were sunk up into the trunk area, but none completely below the floor. Hopefully it works well for me. I had it laying around unused from another project years ago, so figured why not.

Did you make that skid plate for the fuel cell yourself? I couldn't find one when I was looking and it's part of what stopped me from going that route. I wanted it sunk in some. Maybe not all the way down but like half the cell under the floor. And then setting up a filler neck so you didn't have to open up the back was also part of it.

I like what you're doing. What did your HP44 come out of? A Bronco or truck? I've got one in my Tj also that I narrowed to Waggy width. Wish I still had it stock width now since I would like the 65" width but live and learn.

 

[CCompton]

Did you make that skid plate for the fuel cell yourself? I couldn't find one when I was looking and it's part of what stopped me from going that route. I wanted it sunk in some. Maybe not all the way down but like half the cell under the floor. And then setting up a filler neck so you didn't have to open up the back was also part of it.

I like what you're doing. What did your HP44 come out of? A Bronco or truck? I've got one in my Tj also that I narrowed to Waggy width. Wish I still had it stock width now since I would like the 65" width but live and learn.

Sadly the D44HP deal fell through, but I may still grab one if I can come across one. I had the main section for the skid bent by a machine shop and will be fabricating the mounting flanges and sides. I plan to be really finishing out that after I get my rear bolted back in.

 

[CCompton]

Did you make that skid plate for the fuel cell yourself? I couldn't find one when I was looking and it's part of what stopped me from going that route. I wanted it sunk in some. Maybe not all the way down but like half the cell under the floor. And then setting up a filler neck so you didn't have to open up the back was also part of it.

I like what you're doing. What did your HP44 come out of? A Bronco or truck? I've got one in my Tj also that I narrowed to Waggy width. Wish I still had it stock width now since I would like the 65" width but live and learn.

Sadly the deal on the D44HP fell through, but I still may pick one up if I can come across another one. For the skid I had a machine shop bend the primary piece. I will be fabricating the mount flanges and sides though. I hopefully will really be plugging away at that soon, after I bolt all the rear axle back in.

Also thanks for the compliment. I have partly made my way through yours as well (it’s a rather large thread) and have used it as a bit of guidance in what I’m wanting to do.

 

[Wildman]

Sadly the deal on the D44HP fell through, but I still may pick one up if I can come across another one. For the skid I had a machine shop bend the primary piece. I will be fabricating the mount flanges and sides though. I hopefully will really be plugging away at that soon, after I bolt all the rear axle back in.

That is what I'd figured. I'd asked around near me when I was building mine and couldn't find anyone close to me who could bend stuff. Damn that is too bad. The HP44's in my area have gone up CRAZY in price over the last 5 years. When I'd gotten mine I only paid $100 for it but it was a bare housing and I had it shipped from PA to WA so that cost me $75.

Also thanks for the compliment. I have partly made my way through yours as well (it’s a rather large thread) and have used it as a bit of guidance in what I’m wanting to do.

Yes it turned into a lot longer & larger project then what I'd first planning. And it only got derailed once or twice.

If you have questions about specific stuff just ask and I'll try to point you to where it's located in the thread or just answer your question. I'm glad to help anytime I can.

 

[CCompton]

Thanks. I will probably end up taking you up on that offer if I can grab up a 44.





I got the new RockJock rear coils put in along with the newly painted and greased control arms. It sits a tad higher than I had hoped in the rear, but I don’t have the rear armor or a spare on it yet. Also got the wheels and tires back on. The 33s have got to go now. It's dying to have something bigger. If work doesn't kill me tomorrow I plan to start on the exhaust and tank skid.

 

[Wildman]

Thanks. I will probably end up taking you up on that offer if I can grab up a 44.

You just have to keep watching... And being willing to travel some to get one. I am shocked at how much they are selling for now. There are ones where people are asking $1K for a pretty stock HP44. Heck that's what people are asking for a Dana 60. I never thought a HP44 could get to the same cost as a Dana60.

 

[CCompton]

I got the fuel cell skid almost complete. I I just need to drill some drainage holes in the bottom and paint it up.

 

[CCompton]

Piddled around with the exhaust a bit. I’ve got to grab a few more bends before I can do anything else to it.