Mini build thread - 94 YJ [Archive] - JeepsUnlimited.com Forums

chuckp

03-14-2007, 04:22 PM

Started with a 94 YJ that I got in Sept:
http://www.oldjeep.com/images/YJ/dsc01777.jpg

Moved the motor forward 7" for better balance and a longer shaft
http://oldjeep.com/images/YJ/motorforward.jpg

The mythical 2.5L AW4
http://www.oldjeep.com/images/YJ/25AW4.JPG
TJ flares on
http://www.oldjeep.com/images/YJ/09302006%20006.jpg
Rats nest of AW4Shifter
http://www.oldjeep.com/images/YJ/Aw4Shifter%20001.jpg
http://www.oldjeep.com/images/YJ/Aw4Shifter%20002.jpg
AW4 and 231 in - Nutter clocked the adaptor for me so it's up nice and high
http://www.oldjeep.com/images/YJ/tcaseClock%20002.jpg
Modified Lokar for the aw4
http://www.oldjeep.com/images/YJ/LokarInYJ.JPG
Link to some pictures of the modified TF999 flexplate that I used with the aw4
http://www.jnutter.com/page4.html

Needs bigger tires
http://www.oldjeep.com/images/YJ/P1230003.JPG

Nothing real exciting, but got the TJ intake tube modified and installed. Evap canister is hooked up too so all the emissions is un-modified. Still need to move the MAP sensor, the wires and vac line are stretched a little too tight since the engine move.

http://www.oldjeep.com/images/YJ/P2270001.JPG

chuckp

03-14-2007, 04:22 PM

Somewhere along the line swapped an 8.8 in

Little filler work on the plate/bumper. Didn't like how it looked before.
http://www.oldjeep.com/images/YJ/P2270002.JPG

Rock Rings from Copperhead fab
http://www.oldjeep.com/images/YJ/P3010004.JPG

H1 tail lights
http://www.oldjeep.com/images/YJ/P3050006.JPG
http://www.oldjeep.com/images/YJ/P3050007.JPG

Starting to look like a jeep. 35" MTZ's
http://www.oldjeep.com/images/YJ/P3070002.JPG

bling floor plate to cover the tranny hole (will be painted black before too long)
http://oldjeep.com/images/YJ/P3090003.JPG

And hacked a piece of the rear corner out, still need to remove it all the way to the seam so that I can put in the patch panel
http://oldjeep.com/images/YJ/P3090002.JPG

The JC Whitney patch panel fit the profile better than I expected. Little bondo and it'll be good as new.
http://www.oldjeep.com/images/YJ/P3090006.JPG
http://www.oldjeep.com/images/YJ/P3090008.JPG

chuckp

03-14-2007, 04:47 PM

Left to do are:
Finishing up the AW4 wiring
Building a couple driveshafts
make a Skidplate
Build rear bumper and tire carrier
Swap in the 4.88 gears sitting on the bench
Some corner and rocker armor

RatherBeJeeping

03-14-2007, 05:17 PM

Very not bad

butch6924

03-14-2007, 05:18 PM

Which locker did you put in the rear axle? Looks like ECTED loom in the dash.

The build looks sweet and I love the idea of moving the motor further forward. Did that shorten the front shaft much?

chuckp

03-14-2007, 05:34 PM

No lockers yet, probabally use aussie lockers when I swap in the gears. The dash switches are for an www.awshifting.com shift controller

gunsworth

03-14-2007, 07:19 PM

what springs are you running?

Goin w an SYE?

chuckp

03-14-2007, 07:55 PM

what springs are you running?

Goin w an SYE?

Set of used BDS 3.5" lift springs with boomerang type shackles on all 4 corners. Allready installed a full SYE when I had the tcase out.

Jeepcrz

03-14-2007, 08:04 PM

Nice setup. Tires seem to fit just right.

Richharr

03-15-2007, 10:44 AM

looks like mine, only better

LeadFoot

03-15-2007, 03:48 PM

Very cool, very useful mods you are doing! Not a typical jeep build up. Coming alone nicely!

chuckp

04-07-2007, 06:06 PM

Finished tire carrier. Just need to weld up the panel supports that tie the upper mounts into the cage.
http://oldjeep.com/images/YJ/P4070003.JPG

chuckp

04-14-2007, 08:36 PM

1st drive today! The AW4 is working pretty well, shift points are too early, but once the 4.88's go in it should be better. Still have some work to do, but it drives pretty well and stops great.
http://www.oldjeep.com/images/YJ/P4140001.JPG

chef

04-17-2007, 01:16 AM

Looks great too, I like the panel for the aw4 shifter. Is that something he's offering or did you custom build something?

Shadly1

04-17-2007, 01:59 AM

First of all... :jawdrop:DAAAAAAAAAAYUM!
Secondly, where did you find H1 taillights???

Thirdly, that dash panel is neat, but why are the lights labeled 1 2 3 4? Shouldn't they be labeled P R N D 3 1-2 if you're using the Lokar auto stick setup?

chuckp

04-17-2007, 09:19 AM

Looks great too, I like the panel for the aw4 shifter. Is that something he's offering or did you custom build something?

The panel was custom built by www.12voltguy.com

chuckp

04-17-2007, 09:20 AM

First of all... DAAAAAAAAAAYUM!
Secondly, where did you find H1 taillights???

Thirdly, that dash panel is neat, but why are the lights labeled 1 2 3 4? Shouldn't they be labeled P R N D 3 1-2 if you're using the Lokar auto stick setup?

I got the H1 lights and buckets off ebay. The panel shows the forward gear that the tranny is in when in manual shifting mode. The lights are controlled by the AWShifting box.

jeepsohigh

04-17-2007, 09:48 AM

Cool build :hoos:

H1 tail light's..............now that is a cool idea I am going to have to use:devbug:

Shadly1

04-18-2007, 05:13 AM

The lights are controlled by the AWShifting box.SWEET!!! I didn't know there was such a thing! I want one! (stupid sore clutch foot)

But still, you need to be in one of the forward gears to make that sucker work. How are you going to know what gear you are in? Do you have an indicator somewhere or are you going to shift by feel?

chuckp

04-18-2007, 08:31 AM

SWEET!!! I didn't know there was such a thing! I want one! (stupid sore clutch foot)

But still, you need to be in one of the forward gears to make that sucker work. How are you going to know what gear you are in? Do you have an indicator somewhere or are you going to shift by feel?

You just shift by feel. You could run indicators off the NSS on the AW4, but I never had any indicators on my TH400 with Lokar in the last jeep. It's pretty obvious when you go from position to position on the shifter.

Richharr

04-18-2007, 12:05 PM

can you shift full throttle?

chuckp

04-18-2007, 12:09 PM

can you shift full throttle?

With the manual shift mode? Sure, it shifts when you tell it to - the awshifting box bypasses the TCU and all of it's inputs. It directly controls the solonoids in the tranny.

chuckp

05-12-2007, 11:01 AM

Budget finally allowed the most important part of a spare tire carrier - the spare tire ;) Doesn't fit as close to the body as I was thinking it would but close enough I guess.
http://www.oldjeep.com/images/YJ/P5120001.JPG
http://www.oldjeep.com/images/YJ/P5120002.JPG

Rock WoRM

05-12-2007, 11:35 AM

nice little build... perhaps U could give a report on how those MTZ's perform, when possible... snow, mud, ice, rocks, boulders, ect. I'm also currious about the road manners, mileage, noise, ect. Great looking tire... almost got those instead of the MTR's. :wavin2:

WoRM :bsod:

chuckp

05-12-2007, 11:50 AM

All I can say about them for now is that they are great on the road. Pretty quiet, handle good on dry and wet pavement.

blakjeep95

05-14-2007, 01:04 AM

lookin good!

Bratt007

05-14-2007, 02:03 AM

WOW!! :thup2:

Very nice. Everything with a purpose. No fluff.

The build gods are happy:jump:

chuckp

05-14-2007, 03:31 PM

WOW!! :thup2:
Very nice. Everything with a purpose. No fluff.
The build gods are happy:jump:

The herculiner is also done. Need to start fixing the messed up clearcoat on the front clip now.

Working on some fluff - I've got some spiffy seat covers coming to cover up the old vinyl and the mismatched back seat :)

http://www.oldjeep.com/images/YJ/P5090010.JPG

chuckp

05-17-2007, 07:11 PM

Some cosmetic stuff. Sanded the messed up clearcoat and paint off the front clip and did a quick rattle can job. Good enough for me.
http://www.oldjeep.com/images/YJ/P5170001.JPG
http://www.oldjeep.com/images/YJ/P5170004.JPG

And picked up some cheap seat covers to make the inside look better.
http://www.oldjeep.com/images/YJ/P5170002.JPG

chuckp

11-28-2007, 10:28 AM

Back to work. This winter I need to do some armoring.
Got the hoop done last night, it sits up higher than some that you see, but I wanted it to be functional and actually save the radiator when I roll. Still need to cut and cope the support for the passenger side.
http://www.oldjeep.com/images/YJ/PB280007.JPG
http://www.oldjeep.com/images/YJ/PB280009.JPG

Richharr

11-28-2007, 11:56 AM

specs on the hoop? tubing, welder, bender, etc.

chuckp

11-28-2007, 11:58 AM

specs on the hoop? tubing, welder, bender, etc.

1.75" x .120 tubing Hobart 180 and a homebuilt bender with pro-tools die.

Richharr

11-28-2007, 12:05 PM

1.75" x .120 tubing Hobart 180 and a homebuilt bender with pro-tools die.

thanks, it came out nice, I'll keep it in mind when the time comes for mine.

wj_2002_4.0

11-30-2007, 05:57 PM

People like you that are so freaking handy make me mad....I'm jealous!!!!
BTW...I'm using your H1 light setup also...

robertcrav

02-04-2008, 04:06 PM

Or are you clearing the 35's with the 3.5" BDS springs and TJ Flares?? or is there a bl somewhere?

Thanks,
Rob

btw...love the H1 tail lights.:thup2:

chuckp

02-04-2008, 04:10 PM

Or are you clearing the 35's with the 3.5" BDS springs and TJ Flares?? or is there a bl somewhere?

Thanks,
Rob

btw...love the H1 tail lights.:thup2:

No body lift. The shackles give another 5/8" lift. Some rubbing at full stuff but works well.

http://www.oldjeep.com/images/Norstads152008/100_3738.MOV

http://www.oldjeep.com/images/Norstads152008/photos/photo54.jpg

robertcrav

02-04-2008, 04:12 PM

so I should be good if I go with the 3.5" springs, 1" bl, and TJ Flares then...sweeeet :pablo:

chuckp

02-04-2008, 04:14 PM

so I should be good if I go with the 3.5" springs, 1" bl, and TJ Flares then...sweeeet :pablo:

If you don't use a longer shackle, the military wrap is going to hit the frame in the back. Boom shackles are a must for the rear. You can get some cheap ones from www.copperheadfab.com

Gasturbine

02-04-2008, 04:24 PM

Nice build Chuck.

Any reason you didnt go SOA, since you were doing the springs anyway?

chuckp

02-04-2008, 04:27 PM

Nice build Chuck.

Any reason you didnt go SOA, since you were doing the springs anyway?

SOA is a whole other bag of worms. It isn't as simple as flipping the axle to the bottom of the springs. Cheaper and easier to stay SUA

Gasturbine

02-04-2008, 06:58 PM

It isn't as simple as flipping the axle to the bottom of the springs.

Oh, I know how to do it. Keeping every thing square, level (or not), and plumb can be taxing, thats why you do one tack, and re-measure everything again, and then again, and then again, and then again, and then....:loopyeye:

Cheaper and easier to stay SUA

It actually doest cost that much (providing you have all the required tools), but agreed its easier to stay. :thup2:

Again, nice job.

PAjeepinNH

02-05-2008, 04:29 AM

Don't know if you switched them later or not but in those first couple of picts, your front boomerangs are on upside down. Short side goes up in front, down in back....FYI

Joe Dillard

02-05-2008, 04:56 AM

Nice work! :yup: Not sure why I didn't read thru this before. :bangnerd:

Sweet looking rig.

chuckp

02-05-2008, 08:30 AM

Don't know if you switched them later or not but in those first couple of picts, your front boomerangs are on upside down. Short side goes up in front, down in back....FYI

You can mount them either way depending on what you are trying to accomplish. They are mounted like that to clear the front bumper on compression, I'm not using them as anti inversion shackles.

PAjeepinNH

02-06-2008, 04:56 AM

Meh. Invert your shackles then, see if I care :touche: Nice build though regardless. :thup2: What did you get that AW-4 out of?

chuckp

02-06-2008, 08:54 AM

Meh. Invert your shackles then, see if I care :touche: Nice build though regardless. :thup2: What did you get that AW-4 out of?

The AW4 is out of an 89 cherokee. They used the aw4 behind some 2.5L 87-89 or something like that.

chuckp

03-16-2008, 01:24 PM

Finally time for some cage work.

Nothing fancy, sort of a copy of the way that KozWorks does their add-in cage - except that this fits a lot closer to the windsheild.

Got one side cut and bent, need to do the other side and then put in a couple crossbars. Looks like I'll need to remove the lower windshield brackets otherwise I'll never be able to fold the windsheild down. That should also allow me to move the down tube a little closer to the dash.

http://www.oldjeep.com/images/March%202008/P3160001.JPG

Richharr

03-16-2008, 01:28 PM

Finally time for some cage work.
Got one side cut and bent, need to do the other side and then put in a couple crossbars. Looks like I'll need to remove the lower windshield brackets otherwise I'll never be able to fold the windsheild down. That should also allow me to move the down tube a little closer to the dash.

what about window crank and parking brake clearance? any solutions or just living with it like everyone else?

chuckp

03-16-2008, 01:45 PM

what about window crank and parking brake clearance? any solutions or just living with it like everyone else?

Window crank looks like it will clear once I can move the down tube up 1/4", but if it doesn't I'll put on the shorter cranks.

Parking brake, I don't really care about - it's not hooked up anyway. But it would be easy enough to modify the pedal if I cared.

Edit: Window cranks clear just fine once I removed the lower windsheild brackets and moved the tube within a hair of the dash.

chuckp

03-19-2008, 01:49 PM

Slightly more progress, other side fitted. Nice thing is that it is so tight to the dash that the window cranks clear the down tubes. Next I need to figure out the spreaders, I want to do something more interesting than a couple of straight tubes.

http://www.oldjeep.com/images/YJ/March2008/P3190001.JPG

wj_2002_4.0

03-21-2008, 01:33 PM

Hey chuck.....I believe you mentioned you got the lights on ebay....were the off a Humvee? I can't find them anywhere and would like to get a pair and do exactly what you are doing.....You ok w/ me stealing your good idea?

chuckp

03-21-2008, 01:41 PM

Wasn't an original idea, I got the idea from a magazine arcticle. I don't see any on ebay right now. The taillights are used on a lot of military vehicles and trailers. The mounting buckets are Military H1 only - as far as I know.

Here's one place you can new ones with buckets - I think these are the LED version
http://www.truck-lite.com/webapp/wcs/stores/servlet/ProductDisplay?catalogId=10001&storeId=10001&productId=24204&langId=-1

Otherwise, start tracking down military surplus places

CleanFreak

03-21-2008, 03:44 PM

I have the buckets just to recess the factory Jeep tail lights. Trying to get that done next weekend.

wj_2002_4.0

03-21-2008, 10:03 PM

chuckp

03-21-2008, 10:10 PM

I have another question for you....On your YJ to TJ style gas filler placement, did you just reuse your YJ plastic gas filler hardware and use a TJ's gas "tube" or did you cut your own tube? I am am sure it's the same gas tank just the gas tube and placement of the gas cap is different....that would make it easy to just buy the TJ's gas tube....Hopefully my description makes sense...

Thanks...

TJ tubes are different at the filler end. I just cut the stock hoses in half and used some copper. Got the idea from a kit that BDS sells with some of their really tall body lifts.
http://www.oldjeep.com/images/YJ/P3120002.JPG

wj_2002_4.0

03-21-2008, 10:52 PM

I think I can get ahold of a free TJ filler tube and gas cap setup....Physically I could get the large gas tube to fit on the YJ's tank.....My one question is in the difference in the vent tubes between the YJ and the late 90's TJ(97 I believe)...The vent tube is tiny compared to the YJ's...Any suggestions or issues you would see with this????

chuckp

03-21-2008, 11:05 PM

wj_2002_4.0

03-21-2008, 11:47 PM

I think I might have the answer.....To re-use my YJ's filler and gas cap and only use the TJ's round exterior part that mounts to the body...It's worth a shot to by the TJ stuff on Ebay for 10.00 and it looks like it might just work with the YJ's filler hardware...It if doesn't directyl bolt together I should only have to drill a few holes.....I'll take some pics when I get all the pieces together.....Thanks....

chuckp

03-22-2008, 04:11 PM

Got some more welding done this morning. All the junk attaced at the stock hoop is still just tacked. I need to pick up a big welding blanket so I can get the rest done without burning up the seats.
http://www.oldjeep.com/images/YJ/March2008/P3220008.JPG
Red lines are future spreaders, might leave out the center one in the back once I get a kid to test getting in and out.
http://www.oldjeep.com/images/YJ/March2008/P3220004.JPG

Deej

03-23-2008, 04:05 AM

Nice, and make sure you give the diagonals the extra bend for head clearance as well, looks a lot like my cage, I'm not sure why I didn't just go straight to the windshield, it would've been easier than bending the long piece.

http://gallery.hot4x4.ca/albums/album99/abl.jpg
http://gallery.hot4x4.ca/albums/album99/aax.jpg

chuckp

03-23-2008, 09:20 AM

Nice, and make sure you give the diagonals the extra bend for head clearance as well, looks a lot like my cage, I'm not sure why I didn't just go straight to the windshield, it would've been easier than bending the long piece.

Yup, that's exactly what I'm going for and will definitly be bending for the extra clearance.

RockRidge

03-24-2008, 01:17 PM

Re Your Yj/TJ Fuel Fill Hose swap:

I just replaced the filler and vent line in my YJ on saturday. The Fuel fill line is 1" dia. and the vent line is 11/16".

Hope this helps!
Ed

po156

03-27-2008, 01:10 PM

looks very nice

chuckp

03-27-2008, 01:16 PM

looks very nice

Thanks. And for anyone who cares, the e-brake is still operational with the down tube in that position, not even hard to get at. The only problem is that the release has to be shortened a bit, it hits the tube before it can disenguage the brake pedal.

MulishaMudder

03-27-2008, 03:38 PM

chuckp

03-27-2008, 04:10 PM

I and probably a bunch of people with ax5's would like to know what is invovled in the aw4 installation. Took mine out for its first run after the rebuild and the old ax5 started hanging in reverse for some reason. ( I guess it dosent like the big tires.) Any adapters, problems, likes, dislikes. Since mine is a trailer queen now this swap would be great. Give me any info you can. Your jeep looks sweet and innovative at the same time. Thanks:bowdown:

It's actually a big pain to find the parts. The 4 cyl AW4 was only used in jeep cherokees for a couple years. You can also get the same bellhousing from some isuzu troopers. The 4cyl TC and TCU is also hard to find. The stock YJ Auto flexplate has to be drilled for the AW4 pattern and you need a custom bushing for the TC Snout to ride in. Probabally some other stuff I forgot about.

chuckp

03-29-2008, 10:41 AM

Pretty close to done
http://www.oldjeep.com/images/YJ/March2008/P3290002.JPG
http://www.oldjeep.com/images/YJ/March2008/P3290003.JPG

Done:
http://www.oldjeep.com/images/YJ/April2008/P4130005.JPG

drwall

03-29-2008, 04:54 PM

chuckp

03-29-2008, 04:57 PM

Chuck, the jeep looks great. You have done quite a bit of work on that beauty. I was wondering if you know anyone or have ever taken the roll bars out of the 92-95 YJ's and put them in the 87-91 YJ's. Is this possible, or would I be better off just fabbing up my own roll bar?

Early to late style cage is basically a bolt in, that gets asked a lot.
http://www.jeepsunlimited.com/forums/showthread.php?t=886454

Richharr

03-29-2008, 06:09 PM

you sir, are building one fine rig:thup2:

chuckp

05-10-2008, 10:46 AM

Got the sniperfab rockers on and herculined. Just need to trim up the flares and put them back on. Next job is transmission replacement, my AW4 has filled up it's filter with clutch material.

http://www.oldjeep.com/images/YJ/May2008/P5100001.JPG

chuckp

05-16-2008, 07:32 PM

Got around to pulling the tranny. Don't need an expert to diagnose this one. The first filter was full of what was definitely clutch lining and the 2nd one was full of metal. (Must have run out of clutch)

Getting pretty good at pulling AW4's. Took 45 minutes to get it out and another 30 to dissassemble all the pieces to move to the next one.

http://www.oldjeep.com/images/YJ/May2008/P5160004.JPG

next victim

http://www.oldjeep.com/images/YJ/May2008/P5160009.JPG

chuckp

02-18-2009, 06:07 PM

Fast forward a few months - prep for the winter runs

Couple aussies and a TJ shaft as long as the front end is apart anyway. Back one is in already, front is waiting for a couple days. Air compressor in my shop died and the replacement isn't here yet.
http://www.oldjeep.com/images/YJ/Jan2009/P1130004.JPG
http://www.oldjeep.com/images/YJ/Jan2009/P1130003.JPG

chuckp

02-18-2009, 06:08 PM

Next on the agenda, some 4340 shafts. Stock shafts didn't care much for the locker :)
http://www.oldjeep.com/images/YJ/Feb2009/P2110003.JPG

new toys. Yukon 4340 shafts and superjoints

http://www.oldjeep.com/images/YJ/Feb2009/P2180001.JPG

chuckp

02-18-2009, 06:09 PM

And a longer term project which I just rebuilt, converted to a 2 way motor.

http://www.oldjeep.com/images/YJ/Jan2009/Winch/29d2_1.jpg
Got the end plate modified to fit the new motor casing.
http://www.oldjeep.com/images/YJ/Jan2009/Winch/P2030001.JPG

Wireless control and solonoid pack showed up. Got a cheap one meant for a 12K Gorilla Winch
http://www.oldjeep.com/images/YJ/Jan2009/Winch/P2030002.JPG
Mostly assembled, need to get the 2 new bushings before I can finish.
http://www.oldjeep.com/images/YJ/Jan2009/Winch/P2030003.JPG
Corner was broke off. It's up in an area that won't leak. Looks like it is meant to hold the brake cable. Will have to see if it has to be welded, or if some JB weld and washers over the 2 effected holes will be sufficient
http://www.oldjeep.com/images/YJ/Jan2009/Winch/P2030004.JPG