YJ Build Thread

jsipe007

Member
This has been an ongoing project for a long while but figured it may be worth posting here for anyone curious.

94 YJ, manual, 4.0, np231 with SYE

Here is how it started a few years back:

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jsipe007

Member
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Started with Dana 44s, selectable lockers front and rear, sua.

Decided to follow in Shinobis steps and go 40s with Wontons. Super duty 60 front, 99-04. GM14 bolt 1980s era.

Original plan was rear coils but that changed and now going coilovers.


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jsipe007

Member
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Went with a Dave’z Off-road Ford full width outboard kit up front. This kit is meant for a kingpin not the super duty so I do have some frenching on the leaves. Not too worried about it, gonna be cutting all that off in a year out two for a three link with panhard soon anyways haha. This was 4, almost 5 years ago now!

Front 60 has 5.38s with a Yukon zip locker. Rear 14 bolt is 5.38s welded.

I had the unit bearings drilled to 8 on 6.5 to match the rear 14 bolt.

Found a number of places where the frame was cracked so repaired accordingly. Also replaced all body mounts due to years of abuse.


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jsipe007

Member
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Original plan was to do coilovers before the axle using MotoBilts kit for the YJ.

Did some number crunching and found that that just wouldn’t work with the coilovers I plan to run. Ended up going genright style.

The disc brakes are not going to be easy to bleed in the rear with the caliper on top but I can figure it out (hopefully) a mighty vac and mtb style bleeding should help


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jsipe007

Member
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I love posting these pics all in a day, the build is flying by! Haha total elapsed time at this point though is almost 5 years. I lost steam mid build and finally picking it back up. Got some momentum!

A and B pillar tie ins are done. I will be mounting the seats directly to the cage and going with 5 point harnesses and corbeau seats. The factory tub mounts are caved in and the seats need a solid mount. I will keep the factory sliders, they bolt right up to the corbeau Baja JP seats.

Roll cage cut, notched, welded in. Other than seat mounts looking good. I have a removable 5 point harness strap bar that bolts to the cage as well. I have read that this is critical to the harness function and safety so I want the shoulders to be adjustable if I need to lower/raise them.

My new seat mounts will be about an inch lower than stock and pushed back 2in as well for additional led room. I retained the factory angle and built the seat tubes around the factory mount so I have a reference for angles and mounting.


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jsipe007

Member
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Jeep is on four wheels. first time in years haha.

40x13.5r17 pro comps. Black steelies with 4.5in backspacing. Might have some clearance issues up front but the rear is looking good.

Right now I have it mocked up with Bilstein 14in coilovers but they have the extended/compressed length of 16in coilovers. I plan to get some 14in kings on order so I can drop the rear a bit but retain up travel


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Last edited:

CashMoney

I piss excellence.
Vacuum bleeder will help, I ended up unbolting my calipers though and moving them just to bleed them when I had mine. With another pair of hands it goes pretty easy.
 

jsipe007

Member
Awesome info, thanks!

The bleeders still are at the highest point so I may have gotten lucky but we will have to see.

Goal for this weekend is to get the Genright tank installed and hopefully make some progress on the seats!


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DirtyChemist

Well-known member
Premium Member
There are a couple pairs of coil overs on the face book market place currently. I thought about picking them up for my Cherokee and just decided the money could go elsewhere.
how hard was that vertical weld on the drover side link bracket? Looks tight.
 

jsipe007

Member
I was originally thinking 14in ORIs, saw a set of orange STXs for a decent price but I lucked out and a friend had some new 14in Fox coilovers I’ll run instead.

These Bilsteins are 25.5 approx collapsed and 39.5in extended while the Fox coilovers are 21.5in collapsed and 36.5 extended, that should give me much better travel now that the brackets are welded on. We did the mock and measured but the brackets are pushed about as far as they can go.

Good news, the Bilsteins will end up in the front, I can do custom coilover hoops and make them fit (hopefully? Lol). I went off the deep end this week and ordered everything minus the custom items for the front. Barnes Heims, panhard mount. Everything else is artec, going to use their TJ front superduty swap and do a 3 link with panhard. I figure this will keep it relatively known and the hardest part will be positioning the frame side brackets.

There were a ton of pita welds that’s for sure. I had the Jeep high enough up on Jack stands that I was able to crawl around under it pretty well and the body lift made it so I could get in between the frame and brackets.

I’ve got a 220v wire feed Lincoln and definitely hit the duty cycle a few times. I’m not the best welder by any means but I’m sure they will hold, I’ve seen a lot sketchier haha.

Definitely had a lot of welding by feel, lots of areas where I couldn’t really see. Prep though is key, areas that were prepped properly turned out halfway decent!

I’ve been stalking your build thread as well, looks sweet. Not too many one ton XJs out there. Excited to see how it turns out! If you need coil springs, there’s a pirate 4x4 thread and I’ve scored some pairs cheap on eBay as wel


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DirtyChemist

Well-known member
Premium Member
I was originally thinking 14in ORIs, saw a set of orange STXs for a decent price but I lucked out and a friend had some new 14in Fox coilovers I’ll run instead.

These Bilsteins are 25.5 approx collapsed and 39.5in extended while the Fox coilovers are 21.5in collapsed and 36.5 extended, that should give me much better travel now that the brackets are welded on. We did the mock and measured but the brackets are pushed about as far as they can go.

Good news, the Bilsteins will end up in the front, I can do custom coilover hoops and make them fit (hopefully? Lol). I went off the deep end this week and ordered everything minus the custom items for the front. Barnes Heims, panhard mount. Everything else is artec, going to use their TJ front superduty swap and do a 3 link with panhard. I figure this will keep it relatively known and the hardest part will be positioning the frame side brackets.

There were a ton of pita welds that’s for sure. I had the Jeep high enough up on Jack stands that I was able to crawl around under it pretty well and the body lift made it so I could get in between the frame and brackets.

I’ve got a 220v wire feed Lincoln and definitely hit the duty cycle a few times. I’m not the best welder by any means but I’m sure they will hold, I’ve seen a lot sketchier haha.

Definitely had a lot of welding by feel, lots of areas where I couldn’t really see. Prep though is key, areas that were prepped properly turned out halfway decent!

I’ve been stalking your build thread as well, looks sweet. Not too many one ton XJs out there. Excited to see how it turns out! If you need coil springs, there’s a pirate 4x4 thread and I’ve scored some pairs cheap on eBay as wel


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Pirate is pretty dead these days. I should have done this 10 years ago. Almost at a point I trust myself to weld something serious up like rear spring perches and get a drive shaft so it’s a little done. The front should be a ton of work I’m unfamiliar with.
 

jsipe007

Member
Yeah for sure haha. I overthought the rear big time, I don’t think the front will be too bad.

You can plan it all out in your head but at the end of the day you’ve got to put the brackets where they fit and design around what you got.

I ordered up all the brackets for the front, planning Artec 3 link with panhard bar. That will still be a ways down the road. I’d like to get the rig up and wheeling first!


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DirtyChemist

Well-known member
Premium Member
Yeah for sure haha. I overthought the rear big time, I don’t think the front will be too bad.

You can plan it all out in your head but at the end of the day you’ve got to put the brackets where they fit and design around what you got.

I ordered up all the brackets for the front, planning Artec 3 link with panhard bar. That will still be a ways down the road. I’d like to get the rig up and wheeling first!


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I bought an Artec truss never thinking I’d end up with coilovers. Live and learn.

As for the welds they’re probably okay. What were you welding and what did you have the welder set at to hit the duty cycle limit?

Oh yeah the Rusty’s crossmember I bought won’t exactly work since the Artec truss says to put the three link mount passenger side and Rusty’s put their upper link on the driver side. Fun times.
 

jsipe007

Member
I’ve got a Lincoln 220v 180A welder and the only real time I’d hit the duty cycle was after 10 or so minutes of continuous welding. I’m running 75/25 and inefil .035 wire. Most welds have been in the 3/16-1/4 material range although the truss backbone is 3/8.

I’m not worried about the welds, not always the prettiest but did a good job prepping before welding, certainly much stronger than the various frame cracks I had before haha

The artec superduty truss I got allows for the upper on either side, I bet you can make it work.

When artec was having their sale, I got the front truss and all axle brackets plus their frame side brackets. Planning to do hoops for the coilovers and run the Bilsteins up front but may need to notch the hood/fenders.

Currently on the to do list is to finish steering. I just got the machined knuckle back and crossover arm. Also got new ball joints and need to pull shafts and swap everything over. I went with XRF ball joints, we’ll see how they do!

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DirtyChemist

Well-known member
Premium Member
I got mine during one of their sales too. Also a 180 amp welder with 0.035 wire. Should be fun.
 

jsipe007

Member
Very nice! Check out Inefil wire, it’s very affordable and welds much nicer for me than the Lincoln wire that I was previously using

Not much additional to report other than the tank is installed and plumbed. Still haven’t started tearing into the front to do ball joints/steering and need to finish the seat mount brackets


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kcarlmax

Member
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Jeep is on four wheels. first time in years haha.

40x13.5r17 pro comps. Black steelies with 4.5in backspacing. Might have some clearance issues up front but the rear is looking good.

Right now I have it mocked up with Bilstein 14in coilovers but they have the extended/compressed length of 16in coilovers. I plan to get some 14in kings on order so I can drop the rear a bit but retain up travel


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Nice YJ project! I'm currently running Pro Comp MT's also. Got mine from 4wheelonline last January. I love the way they conquer offroad. These tires can take the mud, sand and rocks. On pavement, they are a bit loud and heavy but that's to be expected from a mud tire.
 

jsipe007

Member
Made a bit more progress. Seats and console are ready to install, just need to paint the roll cage.

I went with Corbeau Baja JP seats and kept the factory slider mechanism. The seats are dropped about 1in from factory and pushed back until they touch the cage (about 1in as well)

Hydro assist is complete and new brake master cylinder installed. I went for the e350 mc conversion but originally planned 2500 dodge master cylinder. The e350 is near bolt up on the YJ.

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jsipe007

Member
But most exciting of all… something showed up today!

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I wasn’t expecting these for another few weeks but they are charged and just need springs!


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