03 WJ DD / Play Build

Discussion in 'Build Threads' started by tsconver, Jan 2, 2011.

  1. tsconver

    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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  2. tsconver

    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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  3. tsconver

    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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  4. tsconver

    tsconver Well-Known Member

    Joined:
    Nov 3, 2007
    Location:
    Durham, NC
    Double Din installed

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  5. tsconver

    tsconver Well-Known Member

    Joined:
    Nov 3, 2007
    Location:
    Durham, NC
    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.
     
  6. tsconver

    tsconver Well-Known Member

    Joined:
    Nov 3, 2007
    Location:
    Durham, NC
    claytonized

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  7. tsconver

    tsconver Well-Known Member

    Joined:
    Nov 3, 2007
    Location:
    Durham, NC
    Look what followed my jeep home today
    :drool:

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    So I got out my sawzall

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    And now it fits

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    :2thumbsup:

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

    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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  9. tsconver

    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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  10. NickMaul

    NickMaul Well-Known Member

    Joined:
    Jul 4, 2009
    Location:
    Virginia Beach
    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?
     
  11. tsconver

    tsconver Well-Known Member

    Joined:
    Nov 3, 2007
    Location:
    Durham, NC
    too much probably, but probably 1/2 pound lighter after i cut on it last night. :)
     
  12. tsconver

    tsconver Well-Known Member

    Joined:
    Nov 3, 2007
    Location:
    Durham, NC
    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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  13. tsconver

    tsconver Well-Known Member

    Joined:
    Nov 3, 2007
    Location:
    Durham, NC
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    Kevin Carlisle likes this.
  14. tsconver

    tsconver Well-Known Member

    Joined:
    Nov 3, 2007
    Location:
    Durham, NC
    added some lights to the roof, 1" square tubing and four pilot 55w lights

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  15. tsconver

    tsconver Well-Known Member

    Joined:
    Nov 3, 2007
    Location:
    Durham, NC
    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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  16. tsconver

    tsconver Well-Known Member

    Joined:
    Nov 3, 2007
    Location:
    Durham, NC
  17. tsconver

    tsconver Well-Known Member

    Joined:
    Nov 3, 2007
    Location:
    Durham, NC
    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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  18. tsconver

    tsconver Well-Known Member

    Joined:
    Nov 3, 2007
    Location:
    Durham, NC
    So it decided to add a receiver to my ARB front bumper

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  19. tsconver

    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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  20. tsconver

    tsconver Well-Known Member

    Joined:
    Nov 3, 2007
    Location:
    Durham, NC
    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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  21. tsconver

    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.
     
    CasterTroy likes this.
  22. tsconver

    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: May 29, 2018
  23. BigGreenMonster

    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?
     
  24. tsconver

    tsconver Well-Known Member

    Joined:
    Nov 3, 2007
    Location:
    Durham, NC
    Yeah I am working off the rule book plus working with ken who ran it last year.

    Yep same user name on cummins forum.
     
  25. BRUISER

    BRUISER silent.. but deadly Moderator

    Joined:
    Mar 17, 2005
    Location:
    Raleigh
    You can do it. :)
     
    boatedwagon likes this.

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