03 WJ DD / Play Build

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Project Patriot

03 GC 4.0L Laredo

Suspension


Bilstein 5100 (f) and 5125 (r) shocks, KOR Dual SS Setup, Addco 1" Rear Sway Bar, 4.5" Clayton Springs with 2" pucks for a total of 6.5", KOR Sliders, JKS Quicker Disconnects, Iron D44 Rear Swap, Clayton Long Arms Front and Rear, Carolina DS front Double Cardan DS, JKS Tie Rod and Drag Link, JKS Adjustable Front Trackbar with Super Hard Bushings, rotated knuckles, tank tuck.

Tom Woods SYE and Custom Rear Driveshaft. 4.10 gears front and rear, ARB locker in Front and Rear.



Engine

63mm bored throttle body, K&N FIPK with AEM Filter

Summit Transmission Cooler and Remote Filter

Sunpro Transmission Temperature Gauge



Recovery

ARB Bumper, Mile Marker SE9500 Winch with Synthetic Rope

Mopar Factory Hitch Receiver

Custom skid plates

Highlift Jack

Homemade 15lb CO2 setup



Wheels and Brakes

Cragar 15x8 Soft 8s, BFG ATs 35 x 12.5 x 15

PFC Pads, Slotted and X-Drilled Summit Rotors all 4 corners W/ GoodRidge SS Brake Lines



Electrical

Optima Yellow Top to keep it all running

Pioneer AVIC-F900BT Double Din Navigation unit with Sirius Satellite, Alpine 250w Amp, Alpine Type S (doors), Infinity 3.5" Tweeters and Basslink Subwoofer

500watt Power Inverter hardwired in

3rd Generation Projector Headlights with 55watt 4300k HIDs and Digital Ballasts on dedicated relays.

Cobra Model 75 CB radio and Firestick Antenna

Hardwired Cobra Radar/Laser Detector

Viper Security System to keep the bad guys away.



Misc.

Yakima Mega Warrior Roof Rack with extension, spare tire, and tool mounts.

Driving lights on roof rack

Smittybuilt Gear Seats both front seats

Current Pictures

 

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Recent rear bumper build

I like how it turned out and it meets my needs and expectations

Started with some 2x2 and 1x2 and built a frame on the factory hitch

Skinned it with 12 gauge

added a swing arm using a to z fabrication parts

tire carrier attached

Did some grinding, sanding and painting

Finished product, like I said my first welding project and I am happy with the outcome and it meets my needs and functional requirements

 

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Last summers project was to get rid of my busted D44a that I had swapped in for the original D35. The D44a sheared off the three a arm bolts and after a day of trying to get them out and failing badly with a bolt broke below the surface and an easy out broken off in it I gave Chase a call and asked what we could do to get a rear under my WJ that could provide me good DD use, better after market support and not break my bank account.

We came up with a plan to swap in an Iron D44 grafted to my outer D44A tubes. This has morphed into his current D60 offering which he wanted me to do but I decided it was not for me at the time.

Iron 44 spliced to the 44a tubes

truss ready to be welded on

Truss welded on

Rear cover integrated into the truss

Pictures under the WJ

Leftover paperweight

 

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Double Din installed

 

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Going in the shop this week to get Clayton Long Arms front and rear. Going to get it done since I do not have a MIG only a Flux Core and do not want to weld them on without MIG.

 

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claytonized

 

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Look what followed my jeep home today
:drool:

So I got out my sawzall

And now it fits

:2thumbsup:

Got a great deal on a set of BFG ATs 35x12.5x15, like new tread on five and a spare with 50%.

 

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Storage Box

Made a storage box this weekend, needed a place to put all my spares when I wheel and my misc stuff that I always carry. Has room for 4 spare axles, tools, and some fluids. Going to add a latch to keep it closed and some loops on the side to attach straps to hold down stuff on top of it.

Going to do the gas tank tuck in the near future so needed something to organize my stuff that was in the spare area.

 

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Starting my own belly skid for my WJ with Claytons.

Constructed with 2x2 and 1.5 x 1.5 square tubing, planning to skin it with 11 ga sheet, and double that up right under the TC. Also planning in adding a sloped front edge to transition to the clayton crossmember. It does not hang down any lower than the clayton crossmember and provides about 1/2" of space for the TC and Cat. I am getting a new cat and muffler on saturday once that is done I will pull it off, cap the ends, burn all the welds in as it is just tacked together and skin it. Then slap some paint on it.

Oh and 11ga should be just fine, with the cross bracing the sheet metal will not be structural and if it dents a bit who cares but it will keep it "lighter" than using 3/16" or 1/4"

here is one of the cross members supporting the front tire off the ground, just a little deflection as expected.

exhaust is done, everything routed and should allow full flex and the muffler and cat will be completely protected by the skid

will finish the skid up tomorrow hopefully.

painted and installed

 

[NickMaul]

holy smokes man. I saw you at the last URE workday. Never knew how much stuff was piled onto this jeep. how much does that tank weigh?

 

[tsconver]

holy smokes man. I saw you at the last URE workday. Never knew how much stuff was piled onto this jeep. how much does that tank weigh?

too much probably, but probably 1/2 pound lighter after i cut on it last night.

 

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Got the ZJ washer bottle installed and updated my rear tire carrier to hold the bigger tire and my high lift.

Washer pics, bumper pics to come later.

 

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added some lights to the roof, 1" square tubing and four pilot 55w lights

 

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built some tube fender protectors and widened my sliders, big thanks to Kieth for teh bender and welding

bunch of pics of it finished

happy with how they came out hopefully will save soe fender damage in the future

 

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just added a speedo correction to my WJ

Here is a great writeup on it.

http://www.offroadpassport.com/forum/showpost.php?p=11053&postcount=415

works great, my speedo is exact to my gps now, 14.8% off with the 35's

 

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Did a little trail clean up at Uwharrie today for the monthly work day. Picture of the crew and some shots on the poser rock.

 

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So it decided to add a receiver to my ARB front bumper

 

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Well I went and made a big hole in my jeep. God it is empty, any chance of changing my mind?

Left over parts

Followed WJCHRIS' thread on Jeepforum.com so not going to redo the build instructions

Here is the porn, look at that pretty diff

What do you all think, my axle was hitting the tank after I stretched the wheelbase a little so I had to do it.

 

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Had my knuckles rotated and my spring pads flattened out on my front axle. Added 4.5" IRO springs and Bilstein shocks, 5100s on the front and 5125s on the rear.

 

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Update to the rig, broke a front axle at Harlan earlier this year in August. Thought i had blown the CV joint but actually broke the shaft right off at the CV joint on the driver (short) side of the axle. Decided to upgrade and replaced with RCV Performance shafts.

 

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Well time for another update

I decided that EMC at KOH looks like fun. So I am building up for that.

I have trussed, tubed, gusseted, and put RCV axles in the front axle.

Also just got the basic structure of a roll cage completed. 2" DOM

Added Corbeau Seats and Simpson Harnesses.

Built 5 beadlocks using the motobilt kit.

Pictures to follow.

 

[BigGreenMonster]

Do you have a set of the rules for ultra4? That is a good place to start . Some of my buddies ran the EMC a couple of years ago. It has changed a lot

Also, I recognize your avatar... You on CumminsFourm?

 

[tsconver]

Do you have a set of the rules for ultra4? That is a good place to start . Some of my buddies ran the EMC a couple of years ago. It has changed a lot

Also, I recognize your avatar... You on CumminsFourm?

Yeah I am working off the rule book plus working with ken who ran it last year.

Yep same user name on cummins forum.

 

[BRUISER]

You can do it.