[frozenZJ]

I decided to move my build up thread over to this forum from another one as Cody has done a kickass job of raising this place from the dead. I tink there is a thread on my front bumper build already but I'm going to put it all here for easy reference. I'm also waist deep in a front three link build and input is always nice.

So, anyway....

Picked up this '98 limited for a good deal so I can run trails with the family in bad weather. I already have a truggy built up but I got caught in a bad windstorm in Moab once and thats OK for me, but not for me, two kids and the wife.

Idea is to be able to hit most trails in Moab up to about Pritchet level or so. Any harder, and I can get the truggy.

 

[frozenZJ]

First thing I did (no pics) was put in a rear Aussie into the Dana 44a. It amazes me that people hold off so long on this mod when it makes such a huge difference in ablility.

Next was to build a front bumper so I could hang a winch and get some decent tow points.

 

[frozenZJ]

Next was a four inch lift with adjustable control arms in the rear and the same in the front but with stock upper arms that I reinforced and made about an inch longer. This allowed 33" tires to fit decent. I had to trim the pinch weld and the very bottom of the fender.

Then it got a trip to Moab. Oh, it also got a set of JKS disconnect sway bar ends but I never took them off. The tire liked to hit at full stuff so thats going to be a future project.

 

[frozenZJ]

Then I ended up with a wrecked 5.9. So, I stripped it out and got a bunch of parts! I swapped out the interior seats (nicer leather), leather handles and door panels, and swapped out the 5.9 amp and put in the sound bar. The motor was already gone but I
swapped out the computer and the alternator. Also got and electric fan for it.

Also put in my CB. Still need to run the mic and antenna. So that after the rear bumper build.

 

[frozenZJ]

With that done, I put in a front locker and went on a snow run. Ran about 8 pounds of air and it was working great. Then I drove over a hidden spring in the snow and the driver side dropped hard and I hit the far side of the hole pretty fast. This one smashed the upper control arms at the very ends where I did not reinforce then and also bent the passenger upper link mount on the axle. This caused the pinion angle to go bad enough that it took out the stock yoke and straps. Great.

 

[frozenZJ]

I patched that together and started on a rear bumper. Decided to build it off of a modified stock reciever. I pulled off the stock cover, cut a bunch of the metal away and ten flipped the tube over for the reciever and bolted it back on. Started to build off of that.

 

[frozenZJ]

I have not done much with the bumper since then as I decided to fix that front end. I hate stuff failing like that so I decided to do something about it.

First step was to reinforce the frame with some 1/4" angle. Looking back I with I would have used C channel but its on there now.

 

[frozenZJ]

Then I built a new crossmember to replace the stock one. I patterned off of the Clayton one and made it a three piece one. This also raised up the drivetrain about an inch or so.

 

[besthaticouldo]

dude! could you build me a front bumper like that?!

 

[frozenZJ]

Also picked up a HP30 that had seen better days. I cut off the stock lower control arm mounts and welded in some aftermarket ones. It also saw the sandblaster to clean it up. I was going to go with a radius arm setup with a kind of half truss thing but I changed my mind and cut it all off and built a different kind of truss.

 

[frozenZJ]

I'm cutting out a bunch of steps here. This really took me like months to do.

Also built the mounts for the lower and also the upper link on the frame side.

This gives me 5" of seperation at the frame.

 

[frozenZJ]

Oops I'm out of attachment room. I'll see if Cody will loosen that up for me or If I'll need to find a host somewhere.

Anyway, I have room for one more! Here's a few steps forward.

 

[frozenZJ]

I also stuffed in some 4.56 gears in the HP and I also have some alloy short shafts for it. I'm also going to the chevy 1 ton steering setup. The knuckles are already reamed out but the steering arm is not. Also going to redo the track bar. I've also going to put on a tranny cooler, the electric fan. I also put on the 5.9 hood vents. They do seem to let out a lot of hot air as snow wheeling can sure heat things up!

 

[Lifted5.9]

noticed you had a white 5.9 for parts, wouldnt happen to have the front bumper for it would ya?? btw nice ZJ build!!

 

[frozenZJ]

That parts 5.9 is long gone. The front was trashed anyway. Dont know what happened to it but the front axle was bent and the rear was smashed up pretty bad.

 

[swoop95]

Very nice build thread, remember seeing it on MC

 

[fuzzy59]

Nice looking grand. Got a shot of the steering?

 

[frozenZJ]

Nice looking grand. Got a shot of the steering?

Sorry, have not hit the steering yet. Here's a pic of it all torn down and then how it sits right now.

That upper bar is tight. I took a hammer to the floor a bit and I can raise the axle up enough so that there is about 3.5" of space between the axle spring mount and the bump stop. Calling that good. It hits the floor and the exhaust at about the same time so I'll adjust for that.

 

[frozenZJ]

For fun here is a pic of the lower arms and the aftermarket adjustable arms that I was using. BEEF!

Next is too get the new Ball Joints one and start getting stuff together so I can set up the steering and the trackbar.

 

[fuzzy59]

I really like your front bumper. It appears like it can be tied easily if you wanted to add some more steel.