03 WJ DD / Play Build

tsconver

Well-Known Member
Joined
Nov 3, 2007
Location
Durham, NC
Project Patriot

03 GC 4.0L Laredo

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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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tsconver

Well-Known Member
Joined
Nov 3, 2007
Location
Durham, NC
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

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Skinned it with 12 gauge

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added a swing arm using a to z fabrication parts

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tire carrier attached

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Did some grinding, sanding and painting

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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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tsconver

Well-Known Member
Joined
Nov 3, 2007
Location
Durham, NC
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

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truss ready to be welded on

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Truss welded on

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Rear cover integrated into the truss

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Pictures under the WJ

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Leftover paperweight

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tsconver

Well-Known Member
Joined
Nov 3, 2007
Location
Durham, NC
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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tsconver

Well-Known Member
Joined
Nov 3, 2007
Location
Durham, NC
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"

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

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

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will finish the skid up tomorrow hopefully.

painted and installed


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tsconver

Well-Known Member
Joined
Nov 3, 2007
Location
Durham, NC
Well I went and made a big hole in my jeep. God it is empty, any chance of changing my mind?

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Left over parts

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

Here is the porn, look at that pretty diff

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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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tsconver

Well-Known Member
Joined
Nov 3, 2007
Location
Durham, NC
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.
 

tsconver

Well-Known Member
Joined
Nov 3, 2007
Location
Durham, NC
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.
 
Last edited:

BigGreenMonster

Well-Known Member
Joined
Sep 10, 2006
Location
SC
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

Well-Known Member
Joined
Nov 3, 2007
Location
Durham, NC
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.
 
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