New ZJ build- Project: Shady

Jody Treadway

Jody Treadway

Croc wearing fool
Moderator
Joined
Mar 20, 2005
Location
Hendersonville, NC
Guess who's back? Back again...Jody's back, wheeling again.

We are back in Asheville, back in the Rock Corps, TJC and Appalachian 4x4. We are also back in an area where Lisa and I camp, mountain bike and throw muddy hiking boots in the back of a rig.

Enter Project Shady.

I came across this ZJ with some pretty decent parts to begin a build with. 4.5" (ish) of stock control arm lift (eek), IRO track bar (cool), locked D30 with 760 joints (nice), D35 rear (doh!) and nearly new 33x10.50 KM2s (cool). The heat is hot, the AC is cold and all of the electrical items work.

My goals for this build is a rig that we can drive to trails for mild weekend wheeling trips, haul to more extreme parks and it hold up relatively well and take us on outdoorsy getaways. Basically a unibody version of my Welfare YJ. This will be my newest entry into expedition travels.

Build plans:
Swap D35 for an 8.8 w/ 4.10s- got them in the shop
Lock the 8.8
Regear front to match
Build rockrails, skids and rear bumper
Correct the suspension geometry with correct length arms (possible long arm front)
Build roof rack

I'll document the build and also pen a few more Tech articles as I go. On to the pics...
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"
Nice to meet you today man, hope you enjoy the 8.8. If we make it up this weekend I'll give you a shout or if i get confused with the 9" gearing. haha
 
Did you move the rear back with adj. control arms....the wheel looks centered.....and if so....what did you do about the rear sway bar links?
Reason I ask is Im lifting a 98 ZJ to about 3.5...and the sway bar end links appear to be too short.
 
thexjfiles said:
Did you move the rear back with adj. control arms....the wheel looks centered.....and if so....what did you do about the rear sway bar links?
Reason I ask is Im lifting a 98 ZJ to about 3.5...and the sway bar end links appear to be too short.
Click to expand...

That was the day I bought it. It had factory control arms at about 5-6" of lift. The rear axle was pulled forward and the front axle was pulled rearward.
It is now floating on jackstands awaiting me to install the axles. Gonna push the front forward and the rear backward some.
I'm gonna long arm it to re-center the axles. Will have to fab some end links like you said.
I'll update the thread soon...
 
I have some endlinks laying around in the shop Jody. Next time you're in town swing by and I'll dig them out for ya

Sent from my garage
 
Axles are built and ready to install. Luckily, there are other folks who need their axles regeared too. Gonna knock out some paying jobs first and await an order of steel to arrive. :huggy:
 
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Well it has been a while since my last update. My shop has been covered up work work as has my day job. The ZJ is now driving under its own power. Still have some work left like armor and bumpers. Here are the current pics and specs.

*Rough Country long arm upgrade with a mix of coils and spacers- approx 5.5" lift
*IRO front and Ironman 4x4 rear trackbars
*Jody built :D D30 front and Ford 8.8 rear. 4.56's and locked at both ends
*Jody's 4x4 heavy duty tie rod
*Lots of final tweaks, adjustments, etc before I'm close to done with it.

Tomorrow the grille gets hacked so the winch can sit as far inward as possible. Then I'll cut the rockers and insert some 2x4 steel for sliders.
 
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Lots of progress today. I got the bumper about 75% finished and the winch installed. On Monday I'll bend some tube to protect the lights and winch as well as build a fairlead mount.
The winch is as close to the AC condenser as possible (AC works great so I'm keeping it). The furthest forward portion of the fairlead will be 4 3/4" from the grille. That's tucked in pretty darn well.
 
No pics today, but I built a set of rock rails. Gonna bend some tube tomorrow night and get the front winch bumper done.
Getting closer.
 
Been working on the ZJ as time allows. My shop has been super busy with gear jobs, transfer case rebuilds and other projects. This weekend I'm gonna break it in/ test it out at The Flats during our club work day. I still have some areas to button up and finish, but it is trail ready for now.
The front bumper is tucked in about as close as possible to the AC condenser. I wanted it flush with the frame, but that would be impossible while keeping AC. My approach angle is pretty sweet and the bumper also serves as a radiator skid too.
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I like the bumper, makes me want to redo mine now!
 
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