1/2 Ton TJ Build

VortecJeep

VortecJeep

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Joined
Aug 24, 2005
Location
Concord, NC
I've been collecting parts for a year now, being patient, doing the research, looking for good deals, not going into debt, and getting the right stuff. Finally we got started. Chuckman has the know-how and the equipment and has been more than willing to tackle this project with me. I would not be doing this without him; I am most appreciative!
The vehicle is a 2000 Wrangler Sport with 4.0 and 5 speed and about 125K miles on it. This vehicle has been my daily driver since 2002.
Goodies include:
HP 44 and Ford 9" with 4.56 gears and spool in the rear. Front locker will come later.
Rubicon Express coils.
Custom radius arms on the front using creeper joints, builder bushings, 2" DOM.
The rear will be custom long arms with triangulated uppers.
JB Conversions SYE.
Here's a pic with the front axle out and the new axles just sitting underneath on a sweet cart Chuckman built. That thing makes it so easy to work on the axles.
ai303.photobucket.com_albums_nn152_VortecJeep_TJ_20Build_TJwithnofrontaxleresiz.jpg

.
The track bar bracket was inspired by Clayton's. The 1st shot is before welding. The second shot is after it was installed. It is BEEFY! Notice the vertical pieces attach to the frame on 3 sides and a horizontal piece bolts to the original track bar bracket.
ai303.photobucket.com_albums_nn152_VortecJeep_TJ_20Build_trackbarbracketbeforeweldingresize.jpg

ai303.photobucket.com_albums_nn152_VortecJeep_TJ_20Build_trackbarbracketresize.jpg

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We finished up today with making and installing the frame brackets for the front lower control arms.
ai303.photobucket.com_albums_nn152_VortecJeep_TJ_20Build_newlowercontrolarmframebracketresiz.jpg
 
new brakes, bearings, hubs, tires, wheels, and the the lower control arms Chuckman built with a Creeper Joint at the frame and bushing at the axle. Next will be the uppers and the track bar.
ai303.photobucket.com_albums_nn152_VortecJeep_TJ_20Build_passengerlower.jpg
 
weld spatter looks :poop: in these pics!! cant seem to get it minimized burning in 1/4" and making good penetration. anybody got any ideas????? (miller 175 0.30" settings 10/75)
the coolest part (I think) is the way we did axle mounts and used the cast on wedge style d44. I think its tits- its a hybrid of what justjeepin86 did on his suspension, but I needed more offset with these wheels. will try to get close ups soon.
anybody that cuts his own brackets will appreciate that Ive been making patterns, plaz cutting them and the owner is ginding them to look like they came off a waterjet. its nice and we save some serious $$. plus it gets me back on task of design. works out great.
gotta say, Matts really not going light on the parts- its good stuff and the d44 is built to last. all new everything except the tubes and shafts. hes learning as we go and I think he could tear it all down himself if he had to. still not a 60... :huggy:
 
Upper links in!
 
92yotaman said:
what tires are you running? they bring the beef
Click to expand...
BFG MT KM2, it is the new style for BFG. 35x12.50 on 15x8 wheels. I can't wait to try them out. I keep forgetting to take pics, but will take lots of pics of all the front axle brackets before we stuff it back under the jeep. Chuckman is really doing a phenomonemal job on the fab work. I think he wishes his CJ was like this!:driver:
 
Looking good man
 
front is complete and ready to bolt in. of course the site wont let me upload pics tonight...
 
VortecJeep said:
BFG MT KM2, it is the new style for BFG. 35x12.50 on 15x8 wheels. I can't wait to try them out. I keep forgetting to take pics, but will take lots of pics of all the front axle brackets before we stuff it back under the jeep. Chuckman is really doing a phenomonemal job on the fab work. I think he wishes his CJ was like this!:driver:
Click to expand...
Yup, Ive outdone myself on this. It wayyy better than my current setup, but Ive gotten alot better in the last 5 years since I did mine and I didnt have a plasma cutter then either.:huggy:
 
front's in, but not 100%

Charles got brackets on the front axle finished up and looking good, so when I got there tonight, we rolled the front axle under it and hooked up the control arms, track bar, and bled the brakes. We still don't have the steering built, so ignore the rusty old tie rod in the picture, we just stuck it in there for reference. Notice the tie rod is on top instead of on bottom though and the new tie rod ends are 1-ton chevys.
Here's some pics before the axle went under the jeep:
Passenger side:
ai303.photobucket.com_albums_nn152_VortecJeep_TJ_20Build_0_27passengerbracketsresize.jpg
diff and driver side, trackbar's got beef!
ai303.photobucket.com_albums_nn152_VortecJeep_TJ_20Build_07_27diffbracketsresize.jpg
Here is the whole thing:
ai303.photobucket.com_albums_nn152_VortecJeep_TJ_20Build_07_27HP44resize.jpg
 
Front's in continued

And here is the jeep as it sits tonight, 35s on the front, 31s in the rear. Ignore the rusty tie rod, it is just there for reference. It will be replaced by 1.5" DOM with chevy 1 ton TREs. Tomorrow, we pull the rear axle.
ai303.photobucket.com_albums_nn152_VortecJeep_TJ_20Build_07_27resize.jpg
 
before and after at the same time

js800_P7290004.jpg
Got the TJ out and turned around today:beer:
 
another

neighbors dont even notice stuff like this in front of my house anymore...
 

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Charles, you forgot to post the picture of the temporary-redneck-steering-setup that only allowed me to turn the wheels to the right when we moved it! It was like NASCAR in the Southern Hemisphere.
 
VortecJeep said:
Charles, you forgot to post the picture of the temporary-redneck-steering-setup that only allowed me to turn the wheels to the right when we moved it! It was like NASCAR in the Southern Hemisphere.
Click to expand...
no, I didnt forget :rolleyes:
 
ok so no pics, but progress.
weve put in a SYE and while the tcase and skid was out I got my big head in there and welded in the front and rear lower mounts. Got some BTF rear mounts from Carolina Truggies and they were DEFINITELY worth the money to not have to make. The self jigging design is pimp. Ive youve put some together, you know what I mean.
Tonight, got the rear upper truss/lower mounts/coil buckets mocked up and tacked in place. Going to take a break and hit the toy run, so will be next week until we put weight on the rear to set pinion and upper link mounts.
 
Been slack about taking pics, but went over to Charles' for a couple minutes today, so I snapped this teaser pic of the rear control arms. The pinion support on the 9" was broken, so we replaced it, but now the pinion depth is way off. I'll be setting pinion depth tonight and checking the gears again. Replacing all brake parts, so had to wait on the emergency brake cables to arrive. ended up ordering 2 left side e-brake cables for a 78 Bronco to get the right lengths. Once I get the gears set again, we can start bolting the rear together. Shocks should be in next week.
ai303.photobucket.com_albums_nn152_VortecJeep_TJ_20Build_teaserofrearcontrolarms.jpg
 
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