YORR Stock-Mod ZJ

[Weasel]

YORR - Yellowstone Off Road Racing, local racing circuit that a group of us have been running in that last 4 years. I've been mostly doing pits and co-driving. But been looking for a rig to start building, etc. Was wanting a XJ but, I picked up a ZJ that had been started but the guy had to sell it.

Not sure when I'll be done but I'd like to have it running for the first local race June 13th.

So the rules are pretty open. No internal engine mods, wheelbase 2" from stock, engine stock location, and shocks limited to 2.0" and under.

So what I started with:

Working on getting the heater section and core removed:

And the pile of wire and parts removed so far

Upper bar re-rolled and lower dash bar in:

A is in

All of the damaged sheet metal removed from the front (which was most all of it).

front end boxed in and reinforced

 

[Weasel]

Driver Seat mounted:

Passenger seat tacked up:

Upper cage bars:

Door bars:

Front bumper:

 

[95silverstallion]

Lookin good to me. I wanna cage mine also but Id prefer to do it myself then pay somebody. And I don't have a bender...yet

 

[Weasel]

Oh it definitely helps to have someone that's built a few help you out. It's not as simple as one would think.

 

[Weasel]

Fans and radiator mounted up

Got the rear bumper and tire carrier tacked up today:

tire fits:

 

[KRAKER]

I like it.

 

[Weasel]

well things slowed done and got a bit sidetracked. Pulled the engine and found a crap load of leak sealer in the head. So tore it down and found the bores need to cleaned up and the whole thing cleaned. So talking with Russ about a rebuild setup.

In the meantime found a rear axle, 97 LX450 which is the same as a FZ80. Bummer was that is was from Wisconsin and really rusted. That that it matter a ton as all the bracket were coming off.

loaded up and heading off to have it steel shot blasted. Knocked nearly all the rust off.

Drew up a rear truss and had it cut, needed some quick notching to fit the rear axle.

Tacked up and ready to burn in:

 

[Weasel]

Did some upgrades to the hubs. There are some issues if the studs loosen up and the 2 pins shear and they are only 7mm diameter.

So I upgraded the studs to ARP studs. Then had a local shop drill and tap for another 6 5/16-24 bolts. These are countersunk so the shank extends into the hub 3/8". So added 6 more shear pins with an increase in diameter.

up next is the upper link mount, switching the rear over to a 4 link and ditching the panhard.

boxed in the rear

jigged and burned in

 

[Weasel]

Twisted Customs welds:

and then today got the upper link and coil/lower link mounts in the mail and mounted. Coil mounts are just tacked on until it the jeep can get into the shop and swapped in.

 

[PacificEd]

I'm curious about the wiring and how you will set up the computer to run the engine and transmission. I'd love to get rid of the wiring in my 1998 Grand and upgrade it to something more reliable and simple.

Great job on the build so far. What front axle do you plan to run?

 

[Weasel]

yeah not sure on the front axle, still working that one out.

Plan on using the stock computer for the engine but having it reworked.

Trans will be shifted with the RaDesign's setup.

 

[tm8chris]

The roll cage looks very solid. Any more updates?

 

[Weasel]

Just getting started working on this again:

Got a engine from a buddy for free and found a few AW4's around, bolted to the NP242.

Engine will need to be gone through but I'm not trying to stroke it and get it just reliable if possible. But right now I need to get the drive train mounts done so in it all is going.

Pulled in out of the snow bank and getting ready to remove the stock rear end:

Some grinder and plasma work and old junk is gone:

Frame cleaned up:

buddy helped out with some engine mods, lol

This weekend I'm planning on getting a few things done and will grab some more pictures.
- 5.29 gears ready to install along with a spool.
- Lower rear link mounts are roughed into place and the new subframe is tacked on
- Engine mounts frame side will be strated and tacked this weekend
- Trans cross-member will be done this weekend.
- Rear axle will get the brake caliper mounts welded on hopefully

Rear axle would be ready to other then the shock mounts but those will be added later and can get assembled and painted. I have some tabs being cut for the lowers and I don't think they will arrive till next week.


Still don't have any idea on the front axle yet, possibly a FJ80- flipped. Not sure if the diff will be offset enough. And would rather have unit bearings on the outer but the stupid things are very strong.

I made the decision to gut all the stock wiring and will be running a standalone EMC but haven't decide what yet. Few options out there but unfortunately nothing cheap.

 

[Weasel]

well finally got some good progress done.

Motor mounts on the frame side are done. Used the standard bushing, raised the motor about 1". With the bushing shells tacked in place made a couple round pieces to fill in the hole left by the stock bushing. Pardon the welds as I'm learning over again and was rushing a bit.

Motor mounts were from StinkyFab but something odd happened on the drivers side and the tab was up about 2" too high. So they got cut and rotated down. No big deal. I did find out the the stock mounts on the drivers side were all busted out so glad to have the extra mounting holes. Odd though that the TJ block doesn't have all the boses drilled so will need to do that at a later time.

 

[Weasel]

Next up is the frame, transmission mount, and suspension mounts. Wanted improve the link angles so we decided to build a subframe and mount off of it. So using some 2x3 tubing I started getting it tacked up. Shown with mocked up link locations.

axle at full bump, links nice and flat.

Added in a front cross member:

And made the transmission mount:

 

[Weasel]

Drew up the rear link mounts and had a buddy zip them out on his laser:

They fit perfectly and got the subframe all welded up. Boxed in the front of the subframe.

 

[Weasel]

Last to get done was to install this spool and 5.29 gears into the rear axle:


and mocked up the brakes, have a caliper bracket that I need to have made before I can fully bolt them on. They are a tight fit even with 16's, but it should work.

Diff back in and hubs and axles installed.

Extra flange bolts for the axle:

 

[Weasel]

Spool:

Next up is sling it back under the jeep. I got Hiems on order and am planning on changing the wheels studs over to 5/8". But upper link mounts are the next big item on the to-do list. Will be some notching through the floor, but looking to run a rear crossmember and have the link mounts off of it or maybe right off the stick frame.

 

[PacificEd]

This ZJ is looking good. What year are you starting with?

 

[XJ_ranger]

Any updates Craig?