Gus' '99 TJ build

[gus54]

Time to get this build thread going. Many of you have heard about my plans for this 4.0L 5 speed, but for those who haven't I'll give a brief rundown. The theme is a tribute Jeep to my Dad's WWII service. He was kind of a hero and I've wanted to do this for a while now. It will be painted with OD green Krylon Fusion and have markings indicating his company and division of the engineers along with his serial number across the hood. The Jeep will be low, only lifted with a 1.25" BL/MML and my old LJ low mileage springs with a 3/4" spacer on top of the front springs. I will fit 33x10.50 BFG KM2s by losing the rear flares and inner wells and trim if needed, and in front lose the flares and either do a hack job flat fender out of the OEM fenders or if that doesn't work get some MCEs. Armor will most likely be UCF aluminum deep cover belly up and rockers. Front D30 will get a TruTrac and 4.56 gears and the rear will get a Superior Super 35 kit with Detroit and 4.56 gears. Other stuff will include Novak shifter linkage, Crown Steering, winch and cage. And of course I must include etc etc.

Okay...the day after I brought it home - already hacked the front bumper:


Some of the useless weight I removed. Also removed the hitch and sold it and the rear seat:


It had no tow hooks after I removed the hitch so I put on the old 7k hooks I had in front and the rear hook that was on my LJ. Also ditched the rubber bumper pads to make room for the military stenciling. Also cut the front bumper into a stubby:



Continued:

[nick_n_ii]

Good sounding plan....

[gus54]

Next I addressed some of the surface rust. No fancy body work, just sand it and prime it:




The Jeep was in pretty good shape for a 99 that I got for $4700, but a few things still needed to be fixed. The sway links were rotted off but I had my old LJ links which I will modify to quick discos. Front Pinion seal leaked and the upstream O2 had to be replaced. Front brakes and U-joints should be enough for now..hopefully...although the sway bar bushings are pretty dry rotted and will need to be replaced soon.


Painted the only chrome on the Jeep black...the headlight bezels:


I really like the flat rear end look on a Wrangler so I took off the tire carrier and third brake light. Had a nice warm day so I tried out the Krylon. Nice paint. Goes on great!


As you see there is no rear window...anymore. ripped it to shreds trying to unzip it. The whole top is dry rotted and will go in the trash. Eventually if I decide to get a top it will be a Trek Top.

Continued:

[gus54]

Bought some old school 4" round incandescent tail lights from Auto Zone for $8 each. Lots cheaper than LEDs and no special flasher needed. Plus there was no LEDs in the 1940s haha. Traced the hole with the gasket and cut with a jig saw:


I'm pretty happy with the look of these lights. The nice thing is the housing is metal so it acts as it's own ground once screwed in place.


Picked up my new plates, ditched the plate holder and flush mounted it: BTW...if you are getting new plates for the first time for a vehicle you need the registration, e-check, AND the title. Didn't know about the title so that was another trip back to the BMV.


Here is the 33x10.50 KM I got from Ricky that I will use as a spare mounted in the rear of the tub next to the 30x9.50s on it now. The front tires aren't too bad but the rears are totally bald. The new tires and flat black soft 8s will go on in 2 weeks. Once they are on I will flex it on a mound of dirt here at work and see how much bump stop I need to add to limit up-travel. Probably glue hockey pucks to the spring perches like I did on the LJ as that worked really well.


Here is a general link to the build pics on my PB account. Also albums with pics of my LJ in action at JS: http://s732.photobucket.com/albums/w...%20TJ%20build/

Next up is to remove the flares and inner wells in the rear and see what I'm going to do with the front. I have a sawzall and I know how to use it!

[DEERE G]

Sounds like a nice plan Gus. Looks like a pretty good candidate to start with.

[squarejeep]

Looks good I'm a fan on the OD green. Hell I just like green

[Camokyle]

Gustopher that looks awesome!

[gus54]

Thanks guys! Progress on the major stuff is totally dependent on how much OT I can get. Right now the OT situation is not looking too good. But on the bright side that gives me the time off I need to get the fenders done and prep it for paint and Herculiner once the weather gets warmer...for more than a day!

[Buick Guy]

Looking good Gus!

[gus54]

Got the front brake pads and rotors installed today. Also got the rear flares and inner wells taken off. Didn't have time to get a pic but I will before the 33s go on for a before and after. Might be getting them as soon as day after tomorrow if the wheels come in.