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OverkillZJ
10-14-2005, 07:47 PM
Project Phoenix Buggy: The Beast from the East

Some of you might remember a couple of years ago when I decided to revive my rusty Jeep into a nice and capable vehicle, with the goal of making it to Grand Slam West 2004.
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There was a massive thread on NAGCA: http://www.nagca.com/forum/viewtopic.php?t=12581

It’s contents have been copied to MallCrawlin as well (hella faster server), more or less as an archive: http://www.mallcrawlin.com/forum/showthread.php?t=3992
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I also put together a video of that years crazy trip, which can be downloaded (or $5 for the DVD.)

RIGHT CLICK, SAVE AS!

High Resolution – (320 MB) http://www.bigassjeep.com/video/phoenix2004webhigh.wmv
Low Resolution – (96 MB) http://www.bigassjeep.com/video/phoenix2004weblow.wmv

And the last video is the most recent video of us beginning the buggy build. It’ll probably be the last video for awhile until the project is done, and tested. Then will come the best video yet!

Anyway, RIGHT CLICK, SAVE AS! (35 MB) http://www.bigassjeep.com/video/phoenixteaserweb.wmv
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So That should bring you up to speed. The Jeep really did better than I imagined and I abused it as it was meant to be abused. I took it to Moab for GSW in 2004 and 2005, as well as a few weeks of other wheeling out west both years. Of course it was amused back east too. I kept breaking it and fixing it.

After abusing it that much, and flexing it (not to mention jumping it) so many times without a cage, it took its toll on the unibody. When it got to the point where I could no longer really open or close the doors without effort, as well as blowing up 2 more ball joints and yet another locker in the front HP30, I decided that enough is enough. I’ve grown accustomed to the type of wheeling which a full bodied ZJ can only survive so many times. My Jeep was well past that “so many times” mark. I felt like I had 3 options: sell it for next to nothing, part it out and get the already destroyed frame hauled off and crushed, or build it into a BUGGY. Being obsessed with offroading, and being rather attached to my ZJ, I chose to buggy it, and build it big to the point where I shouldn’t really have to worry about breaking things so much.

So here’s the plan:

-gut it
-cut it up almost down to the frame rails
-Build a full roll cage (you’ll see details on plans for that later)
-ditch the weak driveline to go with
-14 bolt rear w/ Detroit locker and disc brakes (4.56)
-HP60 front from a 79F350 with 35 inners, outers, lockouts, detroit (4.56)
-Hydro assist steering
-e350 master cylinder
-Atlas II transfer case to make up with the relatively high gearing in the axles
-PRP suspension seats
-Waterproof sound system
-41.5” Iroks or TSL’s (still up for debate.)
-Either driveline brake, or line lock (more likely skid steer) on the rear brake line
-Radiator and tranny cooler moved to rear / upper cage



I’m sure some of the plan will change throughout the project, but that’s the starting point anyway. I have some talented help, mainly Steve (blackbox renegade) who’s a certified welder and all round likes working on crap as much as I do; and Dave (DMG) who’s a REAL mechanic and good with gears and driveline while I just like to pretend.



First, a few pictures or how it looked in Moab just a few months earlier.

http://www.mallcrawlin.com/wheelinpics/gsw05/GSW2005%20Golden%20Spike%20(13).jpg
http://www.mallcrawlin.com/wheelinpics/gsw05/GSW2005%20Golden%20Spike%20(57).jpg

http://www.mallcrawlin.com/wheelinpics/gsw05/GSW2005%20Golden%20Spike%20(5).jpg

And the darn thing even got a few shots in an issue of 4 Wheel Drive and Sport Utility Magazine. Here’s a link to one of the pics: http://4wdandsportutility.com/freestuff/05104wd_moab_02_1280.jpg


So let’s get to it. Day 1: begin parting it out and cutting it. There was a whole lot of shock factor. There’s a video of this day here: (right click save as) http://www.bigassjeep.com/video/phoenixteaserweb.wmv



http://www.bigassjeep.com/pics/phoenix/9.24.05.a.jpg


http://www.bigassjeep.com/pics/phoenix/9.24.05.b.jpg


http://www.bigassjeep.com/pics/phoenix/9.24.05.c.jpg


http://www.bigassjeep.com/pics/phoenix/9.24.05.d.jpg


http://www.bigassjeep.com/pics/phoenix/9.24.05.e.jpg


http://www.bigassjeep.com/pics/phoenix/9.24.05.f.jpg


http://www.bigassjeep.com/pics/phoenix/9.24.05.g.jpg


http://www.bigassjeep.com/pics/phoenix/9.24.05.h.jpg

http://www.bigassjeep.com/pics/phoenix/9.24.05.i.jpg


http://www.bigassjeep.com/pics/phoenix/9.24.05.j.jpg


http://www.bigassjeep.com/pics/phoenix/9.24.05.k.jpg


http://www.bigassjeep.com/pics/phoenix/9.24.05.l.jpg


http://www.bigassjeep.com/pics/phoenix/9.24.05.m.jpg

http://www.bigassjeep.com/pics/phoenix/9.24.05.n.jpg


http://www.bigassjeep.com/pics/phoenix/9.24.05.o.jpg


http://www.bigassjeep.com/pics/phoenix/9.24.05.p.jpg


http://www.bigassjeep.com/pics/phoenix/9.24.05.q.jpg


http://www.bigassjeep.com/pics/phoenix/9.24.05.r.jpg


http://www.bigassjeep.com/pics/phoenix/9.24.05.s.jpg


http://www.bigassjeep.com/pics/phoenix/9.24.05.t.jpg


http://www.bigassjeep.com/pics/phoenix/9.24.05.u.jpg


http://www.bigassjeep.com/pics/phoenix/9.24.05.v.jpg

I consider this thread “chapter 2” of Project Phoenix. It’s the same vehicle (well, kind of) – just the next phase!

I’ll keep updating as things happen.

OverkillZJ
10-14-2005, 09:18 PM
Here’s the second day of cutting it up. We were hoping to get the front end and back cut down to the frame rails, but Steve felt like crap, I wasn’t motivated, Heidi didn’t know what to do, and Dave was just amused watching us be stupid for a lot of it.

We still got some done, and got to brain storm a little bit.

http://www.bigassjeep.com/pics/phoenix/10.08.05.a.jpg


http://www.bigassjeep.com/pics/phoenix/10.08.05.b.jpg


http://www.bigassjeep.com/pics/phoenix/10.08.05.c.jpg


http://www.bigassjeep.com/pics/phoenix/10.08.05.d.jpg


http://www.bigassjeep.com/pics/phoenix/10.08.05.e.jpg


http://www.bigassjeep.com/pics/phoenix/10.08.05.f.jpg


http://www.bigassjeep.com/pics/phoenix/10.08.05.g.jpg


http://www.bigassjeep.com/pics/phoenix/10.08.05.h.jpg

http://www.bigassjeep.com/pics/phoenix/10.08.05.i.jpg


http://www.bigassjeep.com/pics/phoenix/10.08.05.j.jpg

Ya, I’m cheap enough to save the 50 cents of washer fluid from the reservoir we removed from the ZJ…

http://www.bigassjeep.com/pics/phoenix/10.08.05.k.jpg


http://www.bigassjeep.com/pics/phoenix/10.08.05.l.jpg

SO MANY FREAKING WIRES TO DEAL WITH! In one wiring harness, there’s speaker wires, light wires, tail light wires, FUEL PUMP WIRES, etc. It’s going to be a huge project just figuring out what I need.
http://www.bigassjeep.com/pics/phoenix/10.08.05.m.jpg
I always thought the radiator and fan shroud could be removed while the fan was still installed, I just didn’t think it involved cutting the front crossmember off! That’s the only cutting we did all day, the rest was taking apart the engine compartment and the rest of the interior, except the dash.
http://www.bigassjeep.com/pics/phoenix/10.08.05.n.jpg

This is where we just sat there saying… Now what?
http://www.bigassjeep.com/pics/phoenix/10.08.05.o.jpg

OverkillZJ
10-14-2005, 09:39 PM
I picked up my new rear axle today. This was a score! Military surplus... It’s a 67.5” wide 14 bolt, STOCK from GM with 4.56 gears, a Detroit locker, Disc brakes, etc. As is, stock from GM. Definitely a rare find.

This thing is 495 pounds as packaged, and 450 pounds out of the crate. I took it out myself too, I was a little too anxious.

http://www.bigassjeep.com/pics/phoenix/10.14.05.a.jpg


http://www.bigassjeep.com/pics/phoenix/10.14.05.b.jpg

Here you can see what was stamped on the box: GM Rear axle destined for the US Military. I think my buggy is a better use!
http://www.bigassjeep.com/pics/phoenix/10.14.05.c.jpg

Here’s after I got it all unpackaged. Steve and I area going all the way up to Buffalo New York tomorrow morning (bright and freaking early) to pick up a pair of 60’s, but the trailer I’m using is SCARY when unloaded. We’re leaving the 14 bolt on it for dead weight.
http://www.bigassjeep.com/pics/phoenix/10.14.05.d.jpg

Here’s after practicing backing up with a trailer, A LOT, haha. I got it about .5” from the tree.
http://www.bigassjeep.com/pics/phoenix/10.14.05.e.jpg


Now time for bed, need to leave here at 7am tomorrow to ALMOST get there on time.

Bill
10-15-2005, 01:17 PM
I am anxious to see the new axles, I am sure this trip is going to have a whole bunch of intersting stories.

Who wants to take bets on how many times Steve and Matt get pulled over on the way to Buffalo and back? Maybe we an bet on how high the ticket is going to be? Or which state he gets it in?

This could be interesting...

OverkillZJ
10-15-2005, 11:41 PM
Who wants to take bets on how many times Steve and Matt get pulled over on the way to Buffalo and back? Maybe we an bet on how high the ticket is going to be? Or which state he gets it in?


The answers:

Only pulled over once for doing 85 in a 65, ticket is $160ish.
State = PA.

I ran out of gas.
We passed a flaming car. Still smoking.
I dropped a 60 rear off of a dump truck. I almost fell with it. Oops.
Steve and I also lost our IHOP virginity. DAMN THAT PLACE IS YUMMY!

Other than that, it was the usual BS we both do that would offend about 99.99% of the population. Was definately a fun trip!

I'll have pics up later, can't find my camera's cable. Dang I've got some big axles...

xsjado
10-16-2005, 12:43 PM
you mean to tell me, you both made it back here alive?

OverkillZJ
10-23-2005, 12:22 AM
Last Saturday, Steve and I left for a short road trip to Buffalo, New York to pick up a set of front and rear 60’s from a 1979 F350. We’re not planning on using the rear, but it’s being sold as a set, so I figured I’d take it for a boat anchor if nothing else.

We left my house at about 7am, which hurts after a night of drinking! We were making good time, apparently too good considering the ticket I got. I’m not used to how well the WK handles at speed, it’s very quiet and smooth. I ended up breaking 90 a few times, which I’d never do on purpose with a trailer. Oops. That was a $163 lesson.
http://www.bigassjeep.com/pics/phoenix/10.15.05.a.jpg


Here we are getting the axles off of the flatbed onto the trailer. At one point when moving the rear, I was walking forward holding my half, and ran out of truck. Axle went crashing down pretty good, breaking some of the wire mesh on the trailer. Shouldn’t be too bad to fix.
http://www.bigassjeep.com/pics/phoenix/10.15.05.b.jpg


http://www.bigassjeep.com/pics/phoenix/10.15.05.c.jpg

Neither Steve or I had ever been to an IHOP (if you can believe it). We don’t have them anywhere near where we live, and I’ve never found time to stop at one on any of my road trips. While we were there, I parked the WK in a lil’ curb crawling fashion.

Mmmmmmmm IHOP…
http://www.bigassjeep.com/pics/phoenix/10.15.05.d.jpg

Here’s the kicker. After getting a ticket, and breaking the trailer, I did the dumbest thing yet. Since the WK is a company vehicle, and I had the corporate gas card (BP/AMOCO) – I was hoping to go completely free on the gas. I gave it $10 of gas in NY, since there are apparently no BP’s up there. When the gas light came on, I figured it was like my ZJ or WJ and calculated there was a good 5 gallons left. Negative. About 25 miles later the engine shut off, and I got to call AAA. Yes, you can point and laugh now.
http://www.bigassjeep.com/pics/phoenix/10.15.05.e.jpg

As soon as we got back, we cracked open the 14 bolt. We were like kids on Christmas. I was shocked to find what a piece of crap the stock cover in, but the guts made up for it. That’s a Dana 30 ring gear and carrier next to the 14 bolt for comparison. Notice the gear marking compound? It’s been on there for about 19 years from the GM factory.
http://www.bigassjeep.com/pics/phoenix/10.15.05.f.jpg

That’s right, I’ve got new toys!
http://www.bigassjeep.com/pics/phoenix/10.15.05.g.jpg


http://www.bigassjeep.com/pics/phoenix/10.15.05.h.jpg

http://www.bigassjeep.com/pics/phoenix/10.15.05.i.jpg

OverkillZJ
10-23-2005, 01:37 AM
We set out today to get the Jeep frame up on stands / supports or whatever, and to start all of the electrical wiring to run the tools and heaters we’re going to need in the tent this winter. We went to Home Depot to get ideas, but as soon as we got to my place we pretty much said screw it since we were dying to tear down that Dana 60 front end.

http://www.bigassjeep.com/pics/phoenix/10.22.05.a.jpg

First priority: Move my rear 60 boat anchor. If anyone local would like it (full floater 30 spline) make me an offer.
http://www.bigassjeep.com/pics/phoenix/10.22.05.b.jpg

The front 60 was still a bit to heavy to move easily between the two of us without just hurting ourselves more, so we started tearing it down while it was on the trailer to shave some weight.
http://www.bigassjeep.com/pics/phoenix/10.22.05.c.jpg

Whoever previously owned this was a lazy idiot. Looks like someone lost a snap ring, and instead welded it in place.
http://www.bigassjeep.com/pics/phoenix/10.22.05.d.jpg

Here’s what it’s supposed to look like.
http://www.bigassjeep.com/pics/phoenix/10.22.05.e.jpg

As with any 26 year old axle from the north, this thing is RUSTY. Half of the bolts / studs holding the king pins in wouldn’t budge. We wore down the nuts trying.
http://www.bigassjeep.com/pics/phoenix/10.22.05.f.jpg

It took a few tries welding nuts to them to finally get them to budge. Eventually we had to thread nuts down on the studs, and weld both sides so it wouldn’t sheer off.

http://www.bigassjeep.com/pics/phoenix/10.22.05.g.jpg

Steve suddenly saw another bolt that’d come off and went at it. Back to that whole kids on Christmas thing…
http://www.bigassjeep.com/pics/phoenix/10.22.05.h.jpg

Here’s where I completely frelled up Brandons trailer. I’m sure I’ll have a blast fixing it.
http://www.bigassjeep.com/pics/phoenix/10.22.05.i.jpg

Ya, we made a mess. We had to stop when we came across a bolt on one side we couldn’t budge, not even with my gun. It’s weird, that impact gun has always either removed any bolt I put it on, or snapped it. This thing won’t budge. I’ve been soaking it in PB hoping it comes off tomorrow.

We also don’t have a spindle socket that fits, obviously the one I have for my 30 Warn hub conversion doesn’t fit. So we stopped until tomorrow.
http://www.bigassjeep.com/pics/phoenix/10.22.05.j.jpg

I spent the next few hours cleaning up the shop and organizing tools. It’s nice to have a clean area to work in again.
http://www.bigassjeep.com/pics/phoenix/10.22.05.k.jpg


http://www.bigassjeep.com/pics/phoenix/10.22.05.l.jpg

I wired up both Optima’s to the float charger until they’re put to use again. I’ll probably only go with one battery in the buggy, and throw the other in whatever used tow rig I end up with. These things are a little over 4 years old but still seem as good as new.
http://www.bigassjeep.com/pics/phoenix/10.22.05.m.jpg

OverkillZJ
10-23-2005, 08:57 PM
Today was “tear down da front 60 day” It’s a mess of rust, and I can’t wait to get it all shined up with new shafts,

http://www.bigassjeep.com/pics/phoenix/10.23.05.a.jpg


http://www.bigassjeep.com/pics/phoenix/10.23.05.b.jpg


http://www.bigassjeep.com/pics/phoenix/10.23.05.c.jpg

I hooked up a TV to the satellite in the garage, can watch Steelers while doing buggy stuff now.
http://www.bigassjeep.com/pics/phoenix/10.23.05.d.jpg

Here’s a couple of comparison pics of the Dana 60 gear/carrier next to the 30’s. Any guesses as to which is which?
http://www.bigassjeep.com/pics/phoenix/10.23.05.e.jpg


http://www.bigassjeep.com/pics/phoenix/10.23.05.f.jpg

Brackets go bye bye.
http://www.bigassjeep.com/pics/phoenix/10.23.05.g.jpg


http://www.bigassjeep.com/pics/phoenix/10.23.05.h.jpg

http://www.bigassjeep.com/pics/phoenix/10.23.05.i.jpg

Old rear 44 axle go bye bye. It’s going to be for sale soon (Superior 4340 shafts, 4.56 spicer gears, bearings all new as of 12,000 miles ago, Detroit locker, ZJ Disc breaks, fabbed up brackets for a TJ sway bar on a ZJ. Buy it.)

http://www.bigassjeep.com/pics/phoenix/10.23.05.j.jpg


http://www.bigassjeep.com/pics/phoenix/10.23.05.k.jpg


http://www.bigassjeep.com/pics/phoenix/10.23.05.l.jpg


http://www.bigassjeep.com/pics/phoenix/10.23.05.m.jpg

http://www.bigassjeep.com/pics/phoenix/10.23.05.n.jpg


http://www.bigassjeep.com/pics/phoenix/10.23.05.o.jpg


http://www.bigassjeep.com/pics/phoenix/10.23.05.p.jpg

Here’s the 44 on the ground a few feet closer than the 14 bolt. I swear the 14 bolt is twice the size. It’s DEFINITELY twice the weight!
http://www.bigassjeep.com/pics/phoenix/10.23.05.q.jpg


http://www.bigassjeep.com/pics/phoenix/10.23.05.r.jpg

The parts are starting to accumulate on the shelves.
http://www.bigassjeep.com/pics/phoenix/10.23.05.s.jpg

Especially the 60 parts. It’s going to take me a whole lot of time to clean that mess up and figure out what I’m reusing.
http://www.bigassjeep.com/pics/phoenix/10.23.05.t.jpg

bigblackjeep95
10-24-2005, 07:15 AM
man i can't wait to see this thing when its done :D

OverkillZJ
10-24-2005, 11:03 AM
You're assuming it'll get finished, haha. I need to sell off the current driveline before I can do much of anything. Even then I'll still come up short on the hydro steering and the staak box.

OverkillZJ
11-13-2005, 12:35 AM
First off, Steve found me a sweeeet new seat for the buggy that was about 1/3rd cost because it was installed in a showroom vehicle at 4wd. I dig it. It's my office chair until the buggies ready. I'll need another chair, here's to hoping I come across one cheap!

http://www.bigassjeep.com/pics/phoenix/officechair.jpg


I haven’t had too much time to work on the buggy project, but I’ve got some done. This is like the last 2 weeks worth of updates. Most of what I’ve done is finish the electrical for the garage and tent as you can see in the following pics:

I should have enough power to run vegas now.
http://www.bigassjeep.com/pics/phoenix/11.12.05.a.jpg

Wire nuts suck.
http://www.bigassjeep.com/pics/phoenix/11.12.05.b.jpg

Wire nuts for 8 gauge wire suck more.
http://www.bigassjeep.com/pics/phoenix/11.12.05.c.jpg

2 outlet boxes mounted on the ceiling for the florescent lights to plug into.
http://www.bigassjeep.com/pics/phoenix/11.12.05.d.jpg

2 dual outlet boxes at either side of the garage, each with 2 separate 20 amp circuits..

http://www.bigassjeep.com/pics/phoenix/11.12.05.e.jpg


http://www.bigassjeep.com/pics/phoenix/11.12.05.g.jpg

Old welder plug in the garage tied in with the tents welder plug now.

http://www.bigassjeep.com/pics/phoenix/11.12.05.f.jpg

Now to get the power out to the garage. This just plain sucked.

http://www.bigassjeep.com/pics/phoenix/11.12.05.h.jpg

http://www.bigassjeep.com/pics/phoenix/11.12.05.i.jpg

All done, and waterproof for when I want to hose down the buggy.
http://www.bigassjeep.com/pics/phoenix/11.12.05.j.jpg


http://www.bigassjeep.com/pics/phoenix/11.12.05.k.jpg


http://www.bigassjeep.com/pics/phoenix/11.12.05.l.jpg


http://www.bigassjeep.com/pics/phoenix/11.12.05.m.jpg


And now for the Jeep stuff. Needed much bigger jack stands, so we welded two of my old wheels together and then a small jack stand on top. I think they’re about 2.5-3 feet high but I didn’t measure. They’re perfect.
http://www.bigassjeep.com/pics/phoenix/11.12.05.n.jpg

Party foul. My bad.
http://www.bigassjeep.com/pics/phoenix/11.12.05.o.jpg

Now that the jeeps up on its own stands, time to take that front axle out.
http://www.bigassjeep.com/pics/phoenix/11.12.05.p.jpg


http://www.bigassjeep.com/pics/phoenix/11.12.05.q.jpg


http://www.bigassjeep.com/pics/phoenix/11.12.05.r.jpg

Steve shined up that old front 60, still needs cleaned a lil’ more and painted up, but he got about 50 pounds of rust and grease off of it.
http://www.bigassjeep.com/pics/phoenix/11.12.05.s.jpg

I have way too many axles right now. In addition to what’s in the garage, I have an extra rear 60, and my old al44 and an old 35 laying around.
http://www.bigassjeep.com/pics/phoenix/11.12.05.t.jpg

We took the cover off of the HP30 expecting to see a busted 30. This is what we found. Yours truly is now on a rampage to argue that the Dana 30 is utterly useless under a heavy vehicle, let alone one with a v8.
http://www.bigassjeep.com/pics/phoenix/11.12.05.u.jpg


http://www.bigassjeep.com/pics/phoenix/11.12.05.v.jpg


http://www.bigassjeep.com/pics/phoenix/11.12.05.w.jpg


http://www.bigassjeep.com/pics/phoenix/11.12.05.x.jpg


http://www.bigassjeep.com/pics/phoenix/11.12.05.y.jpg

This seemed appropriate. I think I’m just going to part the axle out instead of resetting gears just to sell it. I have more on my plate than I can get done anyway.
http://www.bigassjeep.com/pics/phoenix/11.12.05.z.jpg

I decided to hose off the Jeep to clean it up a bit, it was still pretty mud covered. I drilled 6 or so ¼” drain holes when I realized that it didn’t have any.
http://www.bigassjeep.com/pics/phoenix/11.12.05.aa.jpg

Why does it always end up being a hovercraft once a year? I seriously hope this buggy build lasts me more than a year, I’m getting kind of sick redoing everything.

http://www.bigassjeep.com/pics/phoenix/11.12.05.bb.jpg

My dad cleaned out his garage, and came across a bunch of my old stickers. I started putting them on my tool cabinet. Notice the appropriate addition to the cRusty’s offroad sticker?

http://www.bigassjeep.com/pics/phoenix/11.12.05.cc.jpg

That’s all for now. Back at it tomorrow. We’re planning on finally cutting up more of the ZJ. It’s about time, it’s been a MONTH.

OverkillZJ
11-13-2005, 10:54 PM
Got a lot done today. Started with pulling the gas tank. I thought it would be close to empty, but I think it was about half full or so.
http://www.bigassjeep.com/pics/phoenix/11.13.05.a.jpg

There was enough gas in it to fill up both my Corolla and Steve’s YJ which were both at about half tank.
http://www.bigassjeep.com/pics/phoenix/11.13.05.b.jpg

Then on to cutting up the Jeep. The oxy proved to be the easiest to cut with through the deep / messy stuff that would’ve bent up sawzall blades. The problem is that it runs hot enough to light the herculiner on fire! We had it in some pretty good flames.
http://www.bigassjeep.com/pics/phoenix/11.13.05.c.jpg


http://www.bigassjeep.com/pics/phoenix/11.13.05.d.jpg


http://www.bigassjeep.com/pics/phoenix/11.13.05.e.jpg


http://www.bigassjeep.com/pics/phoenix/11.13.05.f.jpg


http://www.bigassjeep.com/pics/phoenix/11.13.05.g.jpg


http://www.bigassjeep.com/pics/phoenix/11.13.05.h.jpg
We weren’t sure if we were going to be using the rear portion of the frame rails or not, but after seeing them without the floor board above, we decided they’re complete crap and will be cutting from the tranny tunnel back and just building from scratch.
http://www.bigassjeep.com/pics/phoenix/11.13.05.i.jpg

Cut out the rockers too.
http://www.bigassjeep.com/pics/phoenix/11.13.05.j.jpg


http://www.bigassjeep.com/pics/phoenix/11.13.05.k.jpg

That’s right… Planning mode! We planned out most of the rear end and part of the cage. We’re hoping to get the main hoop bent soon so that we can plan better before we get the tubing bender over here that we’re borrowing. The front end.. That’s another story. I don’t even want to think about what we’re doing there just now.

http://www.bigassjeep.com/pics/phoenix/11.13.05.l.jpg


We also got some pounding music in the tent and garage with the extra equipment I had laying around.
http://www.bigassjeep.com/pics/phoenix/11.13.05.m.jpg

Set of good speakers in the tent and garage!
http://www.bigassjeep.com/pics/phoenix/11.13.05.n.jpg

So there it sits until next weekend.
http://www.bigassjeep.com/pics/phoenix/11.13.05.o.jpg

r6cyclegal
11-14-2005, 10:55 AM
Figures I would miss the free gas weekend!!! :wink:

It's looking good! I'm glad you got the heat in the tent. :D

I do see it more often on stands then on the trails since the most time you spent on the trail wasn't in the state of PA!

OverkillZJ
11-14-2005, 04:26 PM
I'll tell ya... We REALLY had heat in the tent when we lit the Jeep on fire!

OverkillZJ
12-11-2005, 01:48 AM
http://www.bigassjeep.com/pics/phoenix/11.21.05.a.jpg

I decided it was time to finally get the Corolla back in the garage, and get the blasted axles out of the garage.
http://www.bigassjeep.com/pics/phoenix/11.21.05.b.jpg

I ended up buying a 2 ton engine lift to move them on my own, makes life OH SO MUCH EASIER!
http://www.bigassjeep.com/pics/phoenix/11.21.05.c.jpg

Ya.. I have a few grand of axles sitting in my basement. Some old, some new. Man oh man has this hobby taken over my life over the years.



Today we pretty much just pissed around… I did get a nice industrial kitchen card/table I’ll be u sing as a welding table though. It didn’t have anywhere to clamp the ground clamp, so I welded up a 3/16” piece of steel under it to provide a good clamping surface. Welding 3/16” to 24 gauge or so sheet proved harder than I’d thought, but it came out to be a pretty clean weld. Not like it’s structural anyway!

Notice the nice new chop saw on the bottom of the cart. My latest toy. Oh, I meant tool.
http://www.bigassjeep.com/pics/phoenix/12.10.05.a.jpg

We spent most of the day fixing Steve’s YJ which was running like a paraplegic in the special Olympics. Seemed only fair to help him out once in awhile considering he spends more time wrenching on my Jeep than his. Got that all fixed up, then Jeff and I were just messing around the rest of the night.

http://www.bigassjeep.com/pics/phoenix/12.10.05.b.jpg

Mmmmm… Shop safety is always a concern. And by shop safety, I meant that I was careful not to drop my cigar.
http://www.bigassjeep.com/pics/phoenix/12.10.05.c.jpg

Jeff didn’t drop his either.
http://www.bigassjeep.com/pics/phoenix/12.10.05.d.jpg

Lil’ bastard wouldn’t stay lit!
http://www.bigassjeep.com/pics/phoenix/12.10.05.e.jpg

I did get some good welding practice in at least. Practice in writing my name on an old section of axle tube!
http://www.bigassjeep.com/pics/phoenix/12.10.05.f.jpg
Jeff tried, but mines prettier!

http://www.bigassjeep.com/pics/phoenix/12.10.05.g.jpg

We welded random crap together.. Ya, that was really productive.
http://www.bigassjeep.com/pics/phoenix/12.10.05.h.jpg

When that got old, TO THE JEEP TENT! Mmmmm…alcohol…cigars…..SAWZALL!
http://www.bigassjeep.com/pics/phoenix/12.10.05.i.jpg


http://www.bigassjeep.com/pics/phoenix/12.10.05.j.jpg


http://www.bigassjeep.com/pics/phoenix/12.10.05.k.jpg

That’s all for now, this was the first “play day” I’ve had for over a month. Too busy. Next week I work every day including weekend, but I should earn enough to but everything I need to build my insane front 60. You’ll see, it’ll be pretty. Promise.

Right now I’m really in planning and “acquire parts needed” mode. Soon enough we’ll be in full blown “buggy building” mode.

dp
12-11-2005, 11:39 AM
your kodak dx 4330 really gets around :D

these threads are entertaining...keep them coming.

Bill
12-11-2005, 11:56 AM
This has got to be one of the most 56k unfriendly threads EVER!

Thank god I do not have dial up! 8)

OverkillZJ
12-11-2005, 11:56 AM
your kodak dx 4330 really gets around :D


Ya, I've got the slut of digital camera's :lol:

How'd you know what it was, see it in part of the video or something?

dp
12-11-2005, 01:30 PM
EXIF information in your photos...it's pretty much always embedded in JPEG's -- except if you use certain compression methods like save for web and so on.

OverkillZJ
12-11-2005, 01:33 PM
EXIF information in your photos...it's pretty much always embedded in JPEG's -- except if you use certain compression methods like save for web and so on.

Ha, I thought that info would've been ripped out when I used FastStone to shrink it. Coolness that it leaves it in.

r6cyclegal
12-13-2005, 03:01 PM
Mmmm Cigars!

Hey Matt don't block the furnance incase we have to come back out to change your filter!!!

OverkillZJ
01-21-2006, 12:45 AM
I was supposed to work today. But.. Steve was like “don’t work, it’s nice out, let’s work on the ZJ buggy.” It really didn’t take much convincing, so we put in a good days work, only starting at maybe 1pm.

Anyway, my metal came just about 2 weeks ago on a big truck. The truck had to come down my neighbors driveway and drive across some of the lawn to get to my driveway, otherwise the truck would pretty much be stuck without being able to turn around. The DOM is 1.75” ID 1020 w/ .120 wall. The box is 2x4 ¼” wall. 3/16” would have been just fine, but I wanted a little bit more weight in the rear end since the V8 up front is quite heavy, and ZJ buggies are often too light in the rear.
http://www.bigassjeep.com/pics/phoenix/1.20.06.a.jpg

Measuring for the first cut to actually start ADDING things to the vehicle, instead of just removing them. We were pretty happy at the concept of actually building, instead of just tearing down for once.
http://www.bigassjeep.com/pics/phoenix/1.20.06.b.jpg

Chop saw seems to work quite well!
http://www.bigassjeep.com/pics/phoenix/1.20.06.c.jpg

Prepping the frame rails to weld a piece of box as a cross member. It turned out to be a very good structural starting point for building our frame which all the tube will come off.

http://www.bigassjeep.com/pics/phoenix/1.20.06.d.jpg

While Steve was working on that (he’s the metal God) I decided to start pulling the transfer case, driveshaft’s, skid place, cross member, and tranny mount. It all needs to come out in order to make room for a new Stak transfer case, and some 1410 ujointed shafts.
http://www.bigassjeep.com/pics/phoenix/1.20.06.e.jpg

Steve welding together some of the sheet metal making up the unibody, which separated as we cut it.
http://www.bigassjeep.com/pics/phoenix/1.20.06.f.jpg

Finally! Adding something to the buggy!
http://www.bigassjeep.com/pics/phoenix/1.20.06.g.jpg

First weld came out amazingly well, considering it’s ¼” plate to crappy unibody.
http://www.bigassjeep.com/pics/phoenix/1.20.06.i.jpg

With that new cross member on, we started measuring exactly where the tires would end up, in order to build the box section of the new vehicle.
http://www.bigassjeep.com/pics/phoenix/1.20.06.j.jpg


Yes, we were as excited as we look.
http://www.bigassjeep.com/pics/phoenix/1.20.06.k.jpg


http://www.bigassjeep.com/pics/phoenix/1.20.06.l.jpg


http://www.bigassjeep.com/pics/phoenix/1.20.06.m.jpg

http://www.bigassjeep.com/pics/phoenix/1.20.06.n.jpg


http://www.bigassjeep.com/pics/phoenix/1.20.06.o.jpg


http://www.bigassjeep.com/pics/phoenix/1.20.06.p.jpg

Everyone wants to see the master welding.
http://www.bigassjeep.com/pics/phoenix/1.20.06.q.jpg


http://www.bigassjeep.com/pics/phoenix/1.20.06.r.jpg


http://www.bigassjeep.com/pics/phoenix/1.20.06.s.jpg


http://www.bigassjeep.com/pics/phoenix/1.20.06.t.jpg

We were pretty damn pleased with the final product. It’s a start of what we hope to be a very successful project, and extremely capable ZJ buggy.
http://www.bigassjeep.com/pics/phoenix/1.20.06.u.jpg


http://www.bigassjeep.com/pics/phoenix/1.20.06.v.jpg




http://www.bigassjeep.com/pics/phoenix/1.20.06.x.jpg


http://www.bigassjeep.com/pics/phoenix/1.20.06.y.jpg


http://www.bigassjeep.com/pics/phoenix/1.20.06.z.jpg


http://www.bigassjeep.com/pics/phoenix/1.20.06.aa.jpg

I also managed to get out everything I wanted to from under the Jeep while Steve was doing the metal work.
http://www.bigassjeep.com/pics/phoenix/1.20.06.w.jpg


http://www.bigassjeep.com/pics/phoenix/1.20.06.bb.jpg

I’ve begun to collect the massive amount of parts we need for this project. I’m now back in “get it done right mode” and as much as I’m shopping around for great prices, I refuse to skimp on this buildup. I intend for this to last me a long, long, long long long long time.
http://www.bigassjeep.com/pics/phoenix/1.20.06.cc.jpg

Here is a side shot of my new Dana 60HP Dedenbear knuckles. I couldn’t figure out the missing metal until I talked to them: turns out they use the same casting for Chevy and Ford knuckles: But for the ford caliper brackets to clear, they machine some material off of the knuckle. I think they could’ve at least painted it to make it look like a finished product, but whatever. They’re hella beef.
http://www.bigassjeep.com/pics/phoenix/1.20.06.dd.jpg

My cats (this one’s Noel) are enjoying all the Jeep parts: they come in boxes!
http://www.bigassjeep.com/pics/phoenix/1.20.06.ee.jpg

OverkillZJ
01-21-2006, 10:57 PM
Back at it. First thing of the day was Steve capping off the open ended box in the rear end.
http://www.bigassjeep.com/pics/phoenix/1.21.06.a.jpg


http://www.bigassjeep.com/pics/phoenix/1.21.06.b.jpg


http://www.bigassjeep.com/pics/phoenix/1.21.06.c.jpg

Steve decided to get some aggression out with a BFH on the next part of the ZJ getting chopped up.. what was left at the front corner of the rockers.
http://www.bigassjeep.com/pics/phoenix/1.21.06.d.jpg


http://www.bigassjeep.com/pics/phoenix/1.21.06.e.jpg


http://www.bigassjeep.com/pics/phoenix/1.21.06.f.jpg


http://www.bigassjeep.com/pics/phoenix/1.21.06.g.jpg


http://www.bigassjeep.com/pics/phoenix/1.21.06.h.jpg

I FINALLY got my air chisel back, and it came in handy today.
http://www.bigassjeep.com/pics/phoenix/1.21.06.i.jpg


http://www.bigassjeep.com/pics/phoenix/1.21.06.j.jpg


http://www.bigassjeep.com/pics/phoenix/1.21.06.k.jpg

Meanwhile, I finished stripping whatever isn’t needed in the engine bay. We’re about ready to bob the front end when we find time now.
http://www.bigassjeep.com/pics/phoenix/1.21.06.l.jpg

I got pissed at some of the brake line fittings rounding off since I can’t find my brake line tool, so I ended up just taking an angle grinder to them. I guess I need some new lines now!
http://www.bigassjeep.com/pics/phoenix/1.21.06.m.jpg

http://www.bigassjeep.com/pics/phoenix/1.21.06.n.jpg


http://www.bigassjeep.com/pics/phoenix/1.21.06.o.jpg

Since Steve was still busy with metal work and I was kind of stalled on other projects, I decided to start the part I’ve been dreading first. FIGURING OUT WHAT WIRES TO GET RID OF AND WHAT TO KEEP! What a freaking nightmare… I followed the wires, and kind of just kept taking the dash apart as I did. Looks like the whole thing needs to come out to clean up the wiring situation as much as I’d like to. This is going to be a lot of work.
http://www.bigassjeep.com/pics/phoenix/1.21.06.p.jpg


http://www.bigassjeep.com/pics/phoenix/1.21.06.q.jpg

Here’s the pile of all the crap I removed. CB, radio, VIC, light controls, climate controls, all the wood grain, vent cover things, blah blah blah…
http://www.bigassjeep.com/pics/phoenix/1.21.06.r.jpg

And of course, the game in which the PITTSBURGH STEELERS WILL CRUSH THE DENVER BRONCOS is tomorrow, so did a ghetto paint job for our team colors. The final paint job will be the same colors, but done more nicely.
http://www.bigassjeep.com/pics/phoenix/1.21.06.s.jpg

That’s all for now, looks like I’m back to calling around to vendors and getting parts in for the next phase: get wheels and axles under it so we can bend some tube!

xsjado
01-22-2006, 02:46 PM
Sam Adams octoberfest is good stuff.

2002wranglerX
01-22-2006, 02:48 PM
that trailer is scary? must be something wrong then. I have the same one and i've driven accross the country and back with it. it works great. Even unloaded it pulls straight.

Mine is slightly modified. I did a SOA to try to help level it out with whatever i'm towing with and to keep it from smashing the rear of it into the ground over every little bump lol. but mine pulls great empty.

OverkillZJ
01-22-2006, 02:55 PM
that trailer is scary? must be something wrong then. I have the same one and i've driven accross the country and back with it. it works great. Even unloaded it pulls straight.

Mine is slightly modified. I did a SOA to try to help level it out with whatever i'm towing with and to keep it from smashing the rear of it into the ground over every little bump lol. but mine pulls great empty.

Um, welcome to 3 months ago? I don't know what trailer you have, I don't care if it's almost identical: yes the trailer we used was allover the place when unloaded. You can argue with me all you want, but I'm not sure why you'd want to???

EDIT: It is Brandons trailer, so of course there's something wrong with it.

2002wranglerX
01-23-2006, 01:45 AM
not arguing, just thought it was interesting.

and i'm sorry i don't follow your buggy build up every day :roll: :lol:

xsjado
01-23-2006, 02:22 AM
so tell us matt, what is the next step in your build?

Happycamper
01-23-2006, 10:08 AM
Looking good. I'm really diggin the rear and how it ties together w/ the rockers! PSC=Poison Steve Customs!

r6cyclegal
01-23-2006, 10:12 AM
Lookin' good. Congrats!!!

OverkillZJ
01-23-2006, 11:16 AM
not arguing, just thought it was interesting.

and i'm sorry i don't follow your buggy build up every day :roll: :lol:

Well you should be sorry :wink:

OverkillZJ
01-23-2006, 01:52 PM
http://www.bigassjeep.com/pics/phoenix/1.23.06.a.jpg
http://www.bigassjeep.com/pics/phoenix/1.23.06.b.jpg

OverkillZJ
01-31-2006, 10:52 PM
It’s been a busy few days for Steve and I, and oddly enough Steve did more work on the buggy than I did. These pictures aren’t in order if you’ll notice the dates, they’re kind of grouped by category.

Just playing with the tires.
http://www.bigassjeep.com/pics/phoenix/1.31.06.a.jpg

This is exactly where the axle and tires will sit, only thing is that the Buggy itself will be at least 6” higher than it’s sitting right now. It’s going to fit nicely.
http://www.bigassjeep.com/pics/phoenix/1.31.06.b.jpg

Seeing tires anywhere near it lit a fire under my butt to really push this project forward.
http://www.bigassjeep.com/pics/phoenix/1.31.06.c.jpg

I had to.
http://www.bigassjeep.com/pics/phoenix/1.31.06.d.jpg


http://www.bigassjeep.com/pics/phoenix/1.31.06.e.jpg

My cat very confused.
http://www.bigassjeep.com/pics/phoenix/1.31.06.f.jpg

Steve decided we needed an axle stand, and he’s right! Made from scrap he had laying around, and my old blown 44 ring gear.
http://www.bigassjeep.com/pics/phoenix/1.31.06.g.jpg

The stands not quite done here, but here’s the rest of the bracketry getting cut off of the 60.
http://www.bigassjeep.com/pics/phoenix/1.31.06.h.jpg

Here’s the stand all done. The straps actually work out VERY well. We used my old door latches from the ZJ on one side, and ¾” holes on the other.
http://www.bigassjeep.com/pics/phoenix/1.31.06.i.jpg

I figure it’s time to show off some of the parts I have waiting to be installed. Here’s the 35 spline ARB we’re putting in this Saturday.
http://www.bigassjeep.com/pics/phoenix/1.31.06.j.jpg

35 spline Poly Performance drive flanges. Man I love the skulls.
http://www.bigassjeep.com/pics/phoenix/1.31.06.k.jpg

Even though we can make our own brackets, we decided at this point it’s better to spend a few extra $’s to just order pre made ones from BTF. Same decision was made for the rear 4 link truss, and differential covers.
http://www.bigassjeep.com/pics/phoenix/1.31.06.l.jpg

Here’s all the SKF bearings from Napa for my hubs (well, drive flanges now!) I’d never heard of SKF until I googled it and found responses on Pirate 4x4, turns out they don’t suck so I’ll run them.
http://www.bigassjeep.com/pics/phoenix/1.31.06.m.jpg

There’s lots more in this pile we don’t need to go into details on. King pin rebuild kits, LED tail lights, ring and pinion for the 60, dedenbear knuckles + high steer arms, wheels, and install kit for the 60.
http://www.bigassjeep.com/pics/phoenix/1.31.06.n.jpg

35 spline 4340 Yukon shafts for the front 60, and Longfield SuperJoints.
http://www.bigassjeep.com/pics/phoenix/1.31.06.o.jpg

Here you can see the sheer size and beef of these things. What a different world from the 30’s and 44’s I’m used to working on.
http://www.bigassjeep.com/pics/phoenix/1.31.06.p.jpg

Problem… Apparently Yukon sucks, and on a couple of their shafts the yoke ears are just plain too small. After calling Bobby Longfield and talking to him about it, he said it wasn’t the first time, and that it’d be fine to take some material off of the caps to make them fit. I’ll tell you one thing: with that tight fit and the fact they almost gouged their way in there, I’m certainly not worried about spinning any caps!
http://www.bigassjeep.com/pics/phoenix/1.31.06.q.jpg

So here it is all put together.
http://www.bigassjeep.com/pics/phoenix/1.31.06.r.jpg

I spent hours and hours cleaning up the caliper brackets, and of course painting them gold. That’s Steelers gold, not yellow. Period.
http://www.bigassjeep.com/pics/phoenix/1.31.06.s.jpg

OverkillZJ
01-31-2006, 10:54 PM
Also ground down the ‘rusted to hell’ brake pads that came with this junker axle, they look to be reusable, which is good considering replacements are over $70 a side.
http://www.bigassjeep.com/pics/phoenix/1.31.06.t.jpg

At this point it was almost midnight, on a work/school night, but we didn’t really call it quits for awhile after that.
http://www.bigassjeep.com/pics/phoenix/1.31.06.u.jpg

We ended up leaving it here last night, knuckles all ready to go together.
http://www.bigassjeep.com/pics/phoenix/1.31.06.v.jpg

While I was at school for 9 hours (AHHHH) Steve was hard at work over the new found buggy building obsession.
http://www.bigassjeep.com/pics/phoenix/1.31.06.w.jpg

Here’s how we tried removing the King Pins a couple days ago. Mind you, they’re in there at 600 ft pounds. We broke the first aircraft grade bolt we tried using to remove the kingpins, and then we rounded off the next since it wasn’t a perfect fit.
http://www.bigassjeep.com/pics/phoenix/1.31.06.x.jpg

Luckily, Napa had the hex key in stock. Awesome.
http://www.bigassjeep.com/pics/phoenix/1.31.06.y.jpg

Now that they’re out, time for the new king pins!
http://www.bigassjeep.com/pics/phoenix/1.31.06.z.jpg


http://www.bigassjeep.com/pics/phoenix/1.31.06.aa.jpg


http://www.bigassjeep.com/pics/phoenix/1.31.06.bb.jpg


http://www.bigassjeep.com/pics/phoenix/1.31.06.cc.jpg


http://www.bigassjeep.com/pics/phoenix/1.31.06.dd.jpg

Now it’s starting to look like something! SWEET!
http://www.bigassjeep.com/pics/phoenix/1.31.06.ee.jpg

OK. On to the SWEET Blue Torch Fabworks 4 link truss for my Corp 14 bolt axle. We mocked it up and clamped the two pieces together to figure out where to drill the 3 holes.
http://www.bigassjeep.com/pics/phoenix/1.31.06.ff.jpg


http://www.bigassjeep.com/pics/phoenix/1.31.06.gg.jpg


http://www.bigassjeep.com/pics/phoenix/1.31.06.hh.jpg


http://www.bigassjeep.com/pics/phoenix/1.31.06.ii.jpg


http://www.bigassjeep.com/pics/phoenix/1.31.06.jj.jpg


http://www.bigassjeep.com/pics/phoenix/1.31.06.kk.jpg

Is that thing not just beautiful? I love the pinion guard. The pinion yoke is so well protected now, that I’m not concerned about the strap style 1410 driveshaft yoke I was debating on replacing with ujoint style. That saves over $140.
http://www.bigassjeep.com/pics/phoenix/1.31.06.ll.jpg

We almost had a fatality when my welder card decided to dump my welder on the Rubicon. The wheels now welded in place :D

http://www.bigassjeep.com/pics/phoenix/1.31.06.mm.jpg


That’s all for now. There’s sure to be more next week, but it’s a STEELERS SUPERBOWL WEEKEND.

MF Steve!
02-01-2006, 01:48 AM
Damn Matty...double post of a bunch of pix! Anyways...I wonder who made that sexxy axle stand? :icon_super:

notmYJ
02-01-2006, 03:49 AM
Damn Matty...double post of a bunch of pix! Anyways...I wonder who made that sexxy axle stand? :icon_super:
Sexy axle stand??? Pffft, I could have done a nicer one with a roll of solder and some drywall corner bead.:D:D:D:D:D:D

Cebby
02-01-2006, 09:39 AM
Nice work! Good job on the axle stand Steve...

r6cyclegal
02-01-2006, 10:00 AM
Matt your parts don't look nearly as big in pics as they are in real life!!!



Matt's Edit: oops, bumped da edit button.

MF Steve!
02-01-2006, 11:07 AM
Sexy axle stand??? Pffft, I could have done a nicer one with a roll of solder and some drywall corner bead.:D:D:D:D:D:D

ha. hahahaha, that was funny. drywall cornerbead! LOL why not skip the solder, and use a coat hanger instead, while you're at it...

TimMichaels
02-01-2006, 12:14 PM
Nice work on the stand Steve!
Matt your parts don't look nearly as big in pics as they are in real life!!!

I'll vouch for that.

OverkillZJ
02-01-2006, 12:33 PM
Matt your parts don't look nearly as big in pics as they are in real life!!!



Ya, That's what all the ladies tell me :110:

:046:

TimMichaels
02-01-2006, 01:47 PM
Ya, That's what all the ladies tell me :110:

:046:

Nevermind. I'm not vouching for that anymore :107:

notmYJ
02-01-2006, 02:01 PM
ha. hahahaha, that was funny. drywall cornerbead! LOL why not skip the solder, and use a coat hanger instead, while you're at it...
Coat hanger??? What are you nuts??? It might up end holding a 14 bolt!!! Coat hangers arn't strong enough. Thats why you HAVE to use cornerbead, its SUPER strong!!!!:082::082::082::082::082:

MF Steve!
02-01-2006, 02:53 PM
No jackass, you missed it. Some people have used COAT HANGERS for welding...

OverkillZJ
02-01-2006, 02:58 PM
Ya, he missed it.

My oxy / act card was welded together with the torch + coat hangers from Mark and Jills closet, LMAO

notmYJ
02-01-2006, 03:22 PM
Yeah totally missed it. :116:




By the way, where is the dancing bannana smilley?:026::026::026::026::026::026:

MF Steve!
02-02-2006, 11:25 PM
Welding on beadlocks, and the 60 front is getting built this weekend! Whoooooot, I can't believe how into this project I am!

OverkillZJ
02-03-2006, 12:25 AM
Yeahhhh I just want to go 4 wheeeeeeeeeeeeeeeelin.

avenged7foldhc
02-03-2006, 08:33 AM
matt, i think someone secretly switched your d and t keys, youve spelled "Cart" as "card" twice!

OverkillZJ
02-03-2006, 03:34 PM
It's a miswiring in my brain.

avenged7foldhc
02-04-2006, 10:30 AM
haha

OverkillZJ
02-04-2006, 09:16 PM
Well, it’s beadlock time. I must give credit where credit is due: all I really did on this part of the project was painting. Between school, work, and planning a lil’ Superbowl party for the inevitable Steelers victory, I haven’t been much help on my own buggy.

Grinding off the paint on the wheel lip where the beadlock ring needs to be welded.
http://www.bigassjeep.com/pics/phoenix/2.04.06.a.jpg

170 grade 5 bolts, locknuts, and 340 washers. That’s a lot of hardware, luckily my local hardware store ROCKS, and actually supplies all of the hardware for Kennywood.
http://www.bigassjeep.com/pics/phoenix/2.04.06.b.jpg

Weld time!
http://www.bigassjeep.com/pics/phoenix/2.04.06.c.jpg

Air tight, period.
http://www.bigassjeep.com/pics/phoenix/2.04.06.d.jpg

All piled up and done. After welding the first 3, we ran out of C25 gas for the welder. The gas supply store closed at 5, and it was about 4:30. Yet we were 45 minutes away. Steve drove that YJ faster than I thought a poor ol’ YJ could go, and we got there just in time.
http://www.bigassjeep.com/pics/phoenix/2.04.06.e.jpg

Since I was there, I upgraded my little 40 tank to an 80, only $50 to upgrade including the gas. Not bad, now we won’t run out so darn much!
http://www.bigassjeep.com/pics/phoenix/2.04.06.h.jpg

I painted the outer rings STEELERS GOLD in the tent, where I had to cover everything I wasn’t painting due to the amount of overspray. My face and hair were painted Gold, and I was high off my ass. I got pretty sick from all the paint though, NASTY.
http://www.bigassjeep.com/pics/phoenix/2.04.06.f.jpg

Painted up the wheels / inner rings.
http://www.bigassjeep.com/pics/phoenix/2.04.06.g.jpg


Next day: time to mount up some tires! Notice the thickness of the sidewalls next to the ruler. A little beefier than my ol’ MTR’s, eh!
http://www.bigassjeep.com/pics/phoenix/2.04.06.i.jpg

TEAMWORK!
http://www.bigassjeep.com/pics/phoenix/2.04.06.j.jpg

Gary next to the first one all mounted up. It’s be-freakin-autiful.
http://www.bigassjeep.com/pics/phoenix/2.04.06.k.jpg

That’s right. GO STEELERS.
http://www.bigassjeep.com/pics/phoenix/2.04.06.l.jpg


http://www.bigassjeep.com/pics/phoenix/2.04.06.m.jpg

Big tires at 42”
http://www.bigassjeep.com/pics/phoenix/2.04.06.n.jpg

All done. Notice the garage ‘puter I added too. It’s the same laptop that was in my Jeep for the GSW 04 trip, which was essentially destroyed when the screen tore off. A new motherboard and hard drive later, makes a decent garage computer with an old CRT screen! It makes looking up torque specs and the like very handy. Plus I have AutoTap on it, for scanning for codes on ODBII Jeeps like my buggy. I imagine it’s going to come in very handy when I’m trying to figure out why it won’t run when I try cutting down the wiring harness.
http://www.bigassjeep.com/pics/phoenix/2.04.06.o.jpg

MF Steve!
02-04-2006, 09:20 PM
Wasn't nearly as painful as most made it out to be. "Oh yea it'll take you 12 hours to get that done." Try 5...maybe 4 if we had everything we needed when we started on them. Anyways, if anyone needs to do beadlocks...I'm considering myself certified in that too now!

avenged7foldhc
02-04-2006, 10:32 PM
those are so sexy....

Bill
02-05-2006, 12:26 AM
Wow...Looks like you had a semi-productive day. I like the new beadlocks, I think those are compliment the buggy very well!

LeadFoot
02-16-2006, 01:22 AM
Heep is looking good man. I'm glad someone enjoys building shit....I know my build was a PITA. Couple of questions...

Are those the greatlake offroad weld on beadlocks?

What size hobart is that? 180?

What kind of bender are you gonna use?

Will you adopt me?

How much manwhoring do you do to pay for this stuff?

Build is comin along nicely. I hear you on the dash wiring.......I kinda did the same thing. I really wasn't sure what wire did what, but I only have a total of 6 wires under my hood now! I cut these out.

http://img.photobucket.com/albums/v155/leadfoot/04%2005%20rebuild/2005_0227_193811AA.jpg

OverkillZJ
02-16-2006, 01:34 AM
Yup, GLO bead locks. They work well, but anyone who says they don't cone a bit is full of crap. I don't see coning as a real problem though. Hobart's a 180, only had it for a lil' over a year, but it's well used and abused, I've been impressed.

No, I won't adopt you. I can't even afford myself.

No man whoring, I tend to work absurd hours and take on jobs I can't handle time wise to pay for this... that, eating lots of ramen, and a lil' creative financing is keeping this build going.
Well, that and a couple of partial sponsorships I just got from PSC and Corbeau, it pays to know people and admin sites that get a few million hits a month :D

I wish I could cut down to 6 wires, the ZJ's extremely ECU dependant... I think I've got a plan. That's never a good think though.

You probably won't see any updates for a couple of weeks, Steve's been hired to build my new home office in the basement. It started as drywall and ceiling, but ya, just like the buggy we may have gone A BIT overboard. I'm not sure if overboard came alone when Steve suggested the curved drywall work or I decided to use coded entry locks? Oh well. Too many projects, too much to do. Speaking of which bed time, have a couple exams tomorrow.

OverkillZJ
02-16-2006, 01:36 AM
Oh ya: We're borrowing Cebby's sweet bender, I think it's a JD2 he built a sweet hydro conversion for.

Cebby
02-16-2006, 04:24 AM
Oh ya: We're borrowing Cebby's sweet bender, I think it's a JD2 he built a sweet hydro conversion for.

Yep, JD2.

The conversion writeup is in my sig...

OverkillZJ
02-16-2006, 09:13 AM
That's why I couldn't find the writeup, it was right in front of my face :D

MF Steve!
02-16-2006, 11:54 AM
Yeah, basement started as about 40hrs. of easy labor for me. Ended up with like...40hrs. so far, a pair of screw-jacks, a wheelbarrow full of busted out block = a wider doorway. Radius drywall bulkheads, new doors, and im sure the acoustical ceiling will end up being very very classy...

Bill
02-16-2006, 12:11 PM
A wheelbarrow with a flat tire...

MF Steve!
02-16-2006, 12:27 PM
Yeah, it's definately flat. It was tough moving that bitch from the garage, 10ft. in to the basement...

OverkillZJ
03-28-2006, 08:27 PM
I'm getting back into buggy mode on Saturday. I'm pretty much saying screw my other responsibilities. I need to get this thing to GSW.

http://www.bigassjeep.com/pics/phoenix/3.28.06.a.jpg
http://www.bigassjeep.com/pics/phoenix/3.28.06.b.jpg
http://www.bigassjeep.com/pics/phoenix/3.28.06.c.jpg

Cebby
03-28-2006, 10:41 PM
Silly question - why two different seat colors?

trailerrails
03-28-2006, 11:14 PM
They look like two differn seat styles. The ones in the fromt may have been more expensive. Screw the people riding in the back, they call it the cheep seats for a reason.

OverkillZJ
03-28-2006, 11:27 PM
rear = cheaper, less comfy, but mostly TAKES UP MUCH LESS SPACE! Fronts are only available in black or Grey, but they're the best suspension seats Corbeau has to offer. I wanted the backs to match the cage / body color (black / gold (cat yellow). The backs will barely fit as it is.

Thanks go Corbeau for being rather generous with the seats / harnesses, especially considering they usually sponsor rigs that are hella nicer, let alone overbuilt grocery getters.

OverkillZJ
04-10-2006, 12:32 AM
I found a little time to get back to it. Step one was clean out the tent, pine needles + metal shavings + rain = nasty.

http://www.bigassjeep.com/pics/phoenix/4.9.06.a.jpg

Time to cut up what’s left of the room, I was sick of staring at it.
http://www.bigassjeep.com/pics/phoenix/4.9.06.b.jpg


http://www.bigassjeep.com/pics/phoenix/4.9.06.c.jpg


http://www.bigassjeep.com/pics/phoenix/4.9.06.d.jpg


http://www.bigassjeep.com/pics/phoenix/4.9.06.e.jpg


http://www.bigassjeep.com/pics/phoenix/4.9.06.f.jpg

Much better, nice to have my driveway back.
http://www.bigassjeep.com/pics/phoenix/4.9.06.g.jpg

Took off the mechanical fan, belt, and power steering.
http://www.bigassjeep.com/pics/phoenix/4.9.06.h.jpg

Took out some other stuff you probably can’t even notice.
http://www.bigassjeep.com/pics/phoenix/4.9.06.i.jpg

Pile of stuff removed.
http://www.bigassjeep.com/pics/phoenix/4.9.06.j.jpg

PSC sent my full hydraulic steering parts, it was like Christmas. Still a couple details short, and working on a way to mount the 1405 pump to the 5.2 itself.
http://www.bigassjeep.com/pics/phoenix/4.9.06.k.jpg

Nittany guarding the parts after I’d unpackaged them.
http://www.bigassjeep.com/pics/phoenix/4.9.06.l.jpg

Up to this weekend. I installed the stock fuel tank and pump temporarily to get the engine running enough to work on the wiring. With no fan belt/alternator, I put the Corolla to work in that aspect.
http://www.bigassjeep.com/pics/phoenix/4.9.06.m.jpg

Got to work on the wires. Holy crap, I never want to do that again.
http://www.bigassjeep.com/pics/phoenix/4.9.06.n.jpg

Thank God I wasn’t trying to disarm a bomb, this took me all day.
http://www.bigassjeep.com/pics/phoenix/4.9.06.o.jpg

Put the headlights / turn signals in place so I could figure out wiring of them.
http://www.bigassjeep.com/pics/phoenix/4.9.06.p.jpg

Much better, eh? All that’s left is wiring for: fuel pump, fuel level, brake light, reverse lights, left turn, right turn, ignition hot, and constant hot.
http://www.bigassjeep.com/pics/phoenix/4.9.06.q.jpg


http://www.bigassjeep.com/pics/phoenix/4.9.06.r.jpg

Any wiring that came out in long pieces I coiled up to reuse.
http://www.bigassjeep.com/pics/phoenix/4.9.06.s.jpg

I’m keeping the stock steering wheel, but even though the air bag module is removed, I didn’t feel comfortable knowing that the air bag was still in there.
http://www.bigassjeep.com/pics/phoenix/4.9.06.t.jpg

When I took it apart, I realized I can’t take the entire bag out as it’s integrated with the mounting system, but I was able to remove just the inflation portion of it.
http://www.bigassjeep.com/pics/phoenix/4.9.06.u.jpg

I had a little air compressor incident that involved my fingers and a plastic fan. My fingers won. Guess I need a new fan to cool the motor.
http://www.bigassjeep.com/pics/phoenix/4.9.06.v.jpg

Cut off one side of the front end, took longer than I expected, but I was trying to do it without losing any fingers.
http://www.bigassjeep.com/pics/phoenix/4.9.06.w.jpg

Since we’re setting gears shortly, time to clean the garage. With all the drywall / wood work in the new office one room away, it was covered in dust. I got ¼ of a 55 gallon garbage back full of dust and sediment type junk.
http://www.bigassjeep.com/pics/phoenix/4.9.06.x.jpg

All clean and organized much better, found a place for the new parts washer too.
http://www.bigassjeep.com/pics/phoenix/4.9.06.y.jpg


That’s all for this week, I intend to work on it every weekend until it’s done.

Cebby
04-10-2006, 12:37 AM
More info on the parts washer please... :)

OverkillZJ
04-10-2006, 12:42 AM
All you need to know: it's "Chicago Electric" bought from harbor freight for under $90 and will probably work two times before burning my house down :082:

MF Steve!
04-10-2006, 12:49 AM
All you need to know: it's "Chicago Electric" bought from harbor freight for under $90 and will probably work two times before burning my house down :082:

Why do you think I mentioned that biodegradeable, non flammable, solvent free degreaser? LOL

OverkillZJ
04-19-2006, 09:51 AM
I’m in the middle of finals week, and also in the middle of the most work I’ve ever had floating around at once for my computer business.

So naturally, after stressing out, I spent hours yesterday when I should’ve been working on STUDYING, as well as NOW when I’m posting this!

I figure this is something on my to-do list, so why not work on it a lil’ ;)


First up: this is how deep the stock pump is. It has about 2” of “spring” in order to reach the bottom for fuel feeding and support. Since my new fuel cell is 12” deep, I’ll need to modify it a little bit to somehow provide support for the stock pump unit, as they do not do well swaying around with no bottom support.
http://www.bigassjeep.com/pics/phoenix/4.19.06.a.jpg

http://www.bigassjeep.com/pics/phoenix/4.19.06.b.jpg

Steve and I began mocking up the rear axle. We decided we really need to get the thing sitting at ride height before we can make a better decision of where to put the lower tabs. Either way, it’s going to be hella close, and I’m being hopeful the LA’s won’t need to be modified.

http://www.bigassjeep.com/pics/phoenix/4.19.06.c.jpg


http://www.bigassjeep.com/pics/phoenix/4.19.06.d.jpg


http://www.bigassjeep.com/pics/phoenix/4.19.06.e.jpg

Up to today. DMG was working on my 60 gears a little bit, we’ve been having trouble since my pullers weren’t big enough, so he had to take it to the Dodge dealership where he works to use their setup which is much nicer. Then we pretty much forgot the order of the pinion setup, considering it’s been so long since we took it apart.

I began by mocking up my PSC steering pump. It’s a 1405 P-Pump going in the stock location. There is no real “adapter kit” for this, and PSC doesn’t even have a pulley to fit it that’ll work for my ZJ’s V8 as well as fit over the shaft of the large pump, so I got a Ford Superduty and will just have an extra rib, and will have to press it on far enough to line up. Was JpnRngr;s idea, as he’s done this on a generation 1 ZJ, though there appears to be some differenes.

Looks like the TJ p pump conversion bracket will work, but will need to be spaced out almost 2” in order for the pulley to line up.
http://www.bigassjeep.com/pics/phoenix/4.19.06.f.jpg


http://www.bigassjeep.com/pics/phoenix/4.19.06.g.jpg


http://www.bigassjeep.com/pics/phoenix/4.19.06.h.jpg

http://www.bigassjeep.com/pics/phoenix/4.19.06.i.jpg


http://www.bigassjeep.com/pics/phoenix/4.19.06.j.jpg

I used some shock bolt sleves to space out the pump as needed, until I was able to get it to line up. It looks like the stock belt fits without going around the A/C, but it is WAY too tight, as the tensioner seems a little beyond max travel. I’ll have to find a belt that’s maybe 1” longer…
http://www.bigassjeep.com/pics/phoenix/4.19.06.k.jpg

Here I measured that the engine side of the PSC bracket needs to be 2 and 5/16” from the engine block itself (I want it out another 1/16” further than it was for fitting).
http://www.bigassjeep.com/pics/phoenix/4.19.06.l.jpg

Instead of making another adapter that bolts to this crappy (known to crack) stock adapter, and THEN the PSC adapter, I’ll just be having a machine shop make one like this out of a 2 and 5/16” thick block of aluminum. It’ll make the whole setup much simpler and stronger. Anyone have a CNC machine sitting around?
http://www.bigassjeep.com/pics/phoenix/4.19.06.m.jpg


That’s all the work I did on it, now for the parts that I’ve been collecting in preparation for the big build:

Thanks to Dirk at 4x4oil.com – we have AMSOIL! I will not be using the Amsoil in the diff’s as break in fluid, it’d be a waste. That’s going to be some Wal-Mart synth or something else cheap.
http://www.bigassjeep.com/pics/phoenix/4.19.06.n.jpg

Of course SteelCityOffRoad.com needs to show of their Power Tank product line, and for simplicity purposes, I’ll be using this A package with 10lb tank in order to run the ARB air locker, and air up tires if needed.
http://www.bigassjeep.com/pics/phoenix/4.19.06.o.jpg

RCI Aluminum fuel cell.
http://www.bigassjeep.com/pics/phoenix/4.19.06.p.jpg

Here’s the adapter ring from Blue Torch Fabrication which will allow me to use my stock pump in this tank, GREATLY simplifying the EFI system. I looked into aftermarket, and it’s just too many little things to go wrong using my current timeframe. Stock is simple, and stock works. The ring will need to be TIG welded on by some race shop, I’m not even attempting to weld aluminum even if I had the gas.
http://www.bigassjeep.com/pics/phoenix/4.19.06.q.jpg

Short fuel line and massive amount of adapters to make this all work with the stock system.
http://www.bigassjeep.com/pics/phoenix/4.19.06.r.jpg

That’s it at the moment. I just ordered up my 16” Fox Coil-overs yesterday (Emulsions) and weld in bungs to make the steering links.

Really what I’m worried about on this build is funding to by the Stak transfer case, driveline brake, and I really should do new drive shafts but don’t want to.

r6cyclegal
04-19-2006, 01:28 PM
Matt, I want to know who was at your house to take your pic on the 6th, when you're still in your robe, opening packages :)
The buggy looks much less threatening with less wires!!!!

MF Steve!
04-19-2006, 02:03 PM
Matt, I want to know who was at your house to take your pic on the 6th, when you're still in your robe, opening packages :)
The buggy looks much less threatening with less wires!!!!

That be me. I was working on the basement, when Matt came flying down the stairs so fast it sounded like a ton of bricks falling. He opened the door, I go "WTF???," as he stands there w/ PSC boxes at hand. Just so happened the camera was sitting there. So, of course, I had to take a funny picture that he swore would never make it to the internet (yeah right...).

Bill
04-19-2006, 02:20 PM
http://www.bigassjeep.com/pics/phoenix/4.19.06.o.jpg

I might like that better than the black one I have...

r6cyclegal
04-19-2006, 03:19 PM
But you have nothing yellow on your Jeep. Unless you are going to buy a yellow motorcycle to match??

OverkillZJ
04-19-2006, 03:33 PM
You're not getting within 1000 yards of the yellow powertank.

I alread pee'd on it.

That's why it's yellow.

Bill
04-19-2006, 04:27 PM
You're not getting within 1000 yards of the yellow powertank.

I alread pee'd on it.

That's why it's yellow.

I still like mine better...
http://img.photobucket.com/albums/v351/o|||||||o/SemaIndy2006025.jpg (http://smg.photobucket.com/albums/v351/o%7C%7C%7C%7C%7C%7C%7Co/?)

avenged7foldhc
04-20-2006, 12:07 AM
dammit its not yellow.... its STEELERS Gold!!

r6cyclegal
04-20-2006, 08:28 AM
I was going to change it to "gold" but didn't feel like taking the time to do it.

OverkillZJ
04-20-2006, 08:41 AM
While I am a fan of the black and gold, I must argue that this tank is TRULY YELLOW!

Though it will offset the black/gold buggy well ;)

OverkillZJ
04-24-2006, 10:44 PM
I didn’t get to work on it as much as I hoped this weekend, it’s finals week, study time all the time… Last final is on Friday, and then I’m really just going to see how much I can get done on this thing every single day. I’ll admit I’m getting nervous, considering I was hoping it’d be done by now, and a lot of people that had an interest in helping got tied up with their own projects during my downtime. I don’t even have a tow rig yet, or the money to buy one, or even the transfer case I need, but I’m still putting 110% of my effort into making this thing happen before June. It’ll be done, and it’ll be at GSW. Somehow.

http://www.bigassjeep.com/pics/phoenix/4.22.06.a.jpg

I cut the last “big piece” off of the rig today. I still need to go around it and clean up the sharp edges and round off a few corners, but overall once I finish welding the box side rails into place, it’s ready for some tube bending. I’m hoping to get the axles and tires under it first to make it easier, but that should only take a few days of hard work if it goes well. DMG is going to try setting the gears over the next couple of evenings, then I should be able to put that front axle together, and see about brackets

http://www.bigassjeep.com/pics/phoenix/4.22.06.b.jpg

I put the cross-member and transmission mount back in place in order to get the rig up on blocks, and at ride height. It’ll make planning it all out a much easier task.
http://www.bigassjeep.com/pics/phoenix/4.22.06.c.jpg

I replaced my good clock spring, with the one I broke years ago, but the horn button still works in (and that’s all I need.) I’m going to sell the good clock spring to help add a few dollars to the project.
http://www.bigassjeep.com/pics/phoenix/4.22.06.d.jpg

Steering wheel, back together. One thing crossed off the list.
http://www.bigassjeep.com/pics/phoenix/4.22.06.e.jpg

The bead lock tires didn’t hold air for more than a few days, probably because of “too many cooks in one kitchen” syndrome when everyone helped put them together. I highly doubt Steve’s welds leak much, if any air, so I’m assuming the leaks are due to the over tightened valve stems and off-center mounting of the tires. I also got some tire bead sealer instead of the grease used to mount them up.
http://www.bigassjeep.com/pics/phoenix/4.22.06.f.jpg

I put the fuel cell together a lil’ to mock up where the BTF adapter ring needs to go, so I can get it welded up.
http://www.bigassjeep.com/pics/phoenix/4.22.06.g.jpg

It looks like this will work well, but I’ll have to somehow extend the legs on the stock pump, so that it has pressure against it, instead of swaying with the swishing gas of the tank.
http://www.bigassjeep.com/pics/phoenix/4.22.06.h.jpg

Loaded up the cell / pump parts, and the power tank in the Corolla. Today I got the powertank filled at Sky Oxygen so it’s ready to run my ARB once I plumb it, and I dropped off the cell to Jay at Domination Chassis. When he’s done with it, I’ll be ready to plumb up the cell and get the Jeep running even though it won’t be permanently mounted yet.
http://www.bigassjeep.com/pics/phoenix/4.22.06.i.jpg

The Delta solid state controller for my Taurus fan came, but I’m still looking for the fan itself. After looking at the rig cut up, I think I’ll be OK running the radiator in the front, and won’t lost much ground clearance by doing that. I’ll feel better about not running such huge hoses to the back of the rig, and taking up more space. Simple is good.
http://www.bigassjeep.com/pics/phoenix/4.22.06.j.jpg

Here’s the good clock spring for sale, I got it in an emergency on the other side of the country for $150 almost 2 years ago. At the time I didn’t want to drive back home with no cruise or air bags.
http://www.bigassjeep.com/pics/phoenix/4.22.06.k.jpg


http://www.bigassjeep.com/pics/phoenix/4.22.06.l.jpg


At the moment, I’m sitting here “writing my final paper” – no, wait, I lied. I’m sitting here figure out what worldly possessions I can sell off in order to get the last bit of money I need to finish the driveline, and buy a piece of crap track that will barely tow the thing across the country. It’ll happen if I can find the right way to do it.

r6cyclegal
04-25-2006, 01:17 PM
Good luck!!! You will get it done!!!

Bill
04-25-2006, 09:22 PM
Looks like progress to me!

LeadFoot
04-25-2006, 11:23 PM
How much width do the GLO beadlocks add to the rim?

OverkillZJ
04-26-2006, 08:02 AM
about 1-1.5"

OverkillZJ
04-27-2006, 10:51 AM
I came home yesterday to find a few presents from UPS: a Ford Taurus 3.8 electric cooling fan - and better: 4 16” Fox Coil-Over Shocks.

The springs for them are shipping out today, tomorrow the we’re picking up the tubing bender, and Saturday we’ll try finishing that darn 60 gear set. My last final is done at about 1pm tomorrow, so after that, I’m in full fledged build-a-juggy mode.

http://www.bigassjeep.com/pics/phoenix/4.27.06.a.jpg

I finally took the time to torque down and air up 4 of the bead locks / tire’s, and one of them has the mother of all leaks where one weld stopped and the other starts. 3 of the other’s leak too, but I’ll see how much air they lose over the next few days, it might not be worth the effort to fix!
http://www.bigassjeep.com/pics/phoenix/4.27.06.b.jpg


http://www.bigassjeep.com/pics/phoenix/4.27.06.c.jpg

Dave worked on the gears some more, but as it’s a thick gear set and so we’re using a 4.10 and down ARB carrier, the first pattern we ran off was just so far out in left field we couldn’t stop laughing at it.
http://www.bigassjeep.com/pics/phoenix/4.27.06.d.jpg


http://www.bigassjeep.com/pics/phoenix/4.27.06.e.jpg

Back at it on Saturday!

Happycamper
04-27-2006, 11:59 AM
Did you ever have any luck selling the 44 and HP30? I see you havn't "offed" yourself yet!

OverkillZJ
04-27-2006, 12:38 PM
They sold for about half what I wanted to get, but hey, it's money I didn't have...

Happycamper
04-27-2006, 04:59 PM
Hey at least that monster 44 didn't go for the $177 it was at when I last looked at it!!

trailerrails
04-27-2006, 08:21 PM
There is this stuff that they sell at the welding supply store that you can spray on the inside of the welds and will bleed through any holes. I have never used it but I have seen it in action and it will save you a lot of mounting and dismounting of tires when doing weld on beadlocks. maybe Chebby will know what the stuff is called exactly.

OverkillZJ
04-27-2006, 09:05 PM
DMG mentioned that too me too, I'm going to look into it. When you think about it, the fact that only one out of 5 leak bad, THAT'S NOT BAD! I don't want any to leak, the the other 3 that leak are slow leaks which I might not worry about until I have some play time.

PK
04-28-2006, 12:07 PM
Matt,

Funny, I am doing a taurus fan on my TJ maybe one on the ZJ too if I like how it works on the TJ. Mine is in my garage... and is way cleaner than yours. :)

r6cyclegal
04-28-2006, 01:13 PM
So Matt are your finals done??????
Congrats!!!

OverkillZJ
04-28-2006, 02:38 PM
My taurus fan was uber cheaped and shipped to my doorstep the next day, no complaints as long as it works ;)

I didn't have time to go to a yard to pull one...

Yep, as of a couple hours ago, FINALS ARE DONE, and I'm expecting a 3.75 GPA this semester, not bad considering everything that's been going on with buggy/office/work/sick if I do say so myself! :D

PK
04-28-2006, 02:46 PM
How cheap? Mine was $40 shipped. I guess you can pull them for around $20, but I'm with you -- no time. :-)

OverkillZJ
04-28-2006, 03:03 PM
Haha, just about the same price.

TimMichaels
04-28-2006, 05:02 PM
Haha, just about the same price.

How much of a difference do these things really make?

Cebby
04-28-2006, 06:32 PM
No pics of the hernias please. ;)

MF Steve!
04-28-2006, 07:54 PM
No hernias! It's safely arrived and unloaded. Even made a test bend...it works, hope that makes you feel better!

Cebby
04-28-2006, 09:14 PM
No hernias! It's safely arrived and unloaded. Even made a test bend...it works, hope that makes you feel better!
I had visions of you guys bending tube in the back of your truck and it riding around for a couple of weeks back there. Who was the 4th?

The bigger question is will Matt have to be hosed off to make him get away from that thing now? :007:

OverkillZJ
04-28-2006, 09:38 PM
LMAO, ya, I think it looks good sitting in my garage...

My dad stopped by on his way home from work, unloading was a heck of a lot easier than loading.

I'm sitting here just planning, one buggy coming up.

Cebby
04-28-2006, 10:26 PM
Hey - I was already stroking the DOM tonight. Don't get too used to it... :D

How'd the "planning" install go? ;) ;)

Cebby
04-28-2006, 10:30 PM
Oh, and :worthless:

OverkillZJ
04-28-2006, 10:54 PM
I'll get pics up tomorrow, bed time so I can have all of tomorrow to get to work :D

Bill
04-29-2006, 12:22 PM
I know there are pictures out there... I took them with Matt's camera.

OverkillZJ
05-02-2006, 12:30 AM
Thanks to Cebby (Mike) of http://toolandfab.com (http://toolandfab.com/), I have a JD-2 bender on loan with the ultimate custom hydro conversion. After you learn what the heck you’re doing (or kind of what you’re doing) the thing is truly perfect.

http://www.bigassjeep.com/pics/phoenix/5.01.06.a.jpg

The test bend my dad felt better suited as a way to hang me (finally).
http://www.bigassjeep.com/pics/phoenix/5.01.06.b.jpg

We tried some 1.75” exhaust pipe out of curiosity, I guess that’s about what you’d expect it to do!
http://www.bigassjeep.com/pics/phoenix/5.01.06.c.jpg

First order of business: mount the buggy seats. To do that, we mounted up he stock seat briefly to figure out where I used to be comfy wheeling with it at.
http://www.bigassjeep.com/pics/phoenix/5.01.06.d.jpg


http://www.bigassjeep.com/pics/phoenix/5.01.06.e.jpg

Steve’s front bracket came out pretty sweet, not positive it’s going to work though, as the further in/forward you move the seats the higher they get. I think to make it all work, my head might be through the cage, and that’s no good.
http://www.bigassjeep.com/pics/phoenix/5.01.06.f.jpg

Ez-tech’s 3d bending software really is amazing though, you just need to be sure to do the calibrations and setup the tooling/material options correctly. I’d say the most important aspect is be patient and KNOW WHERE YOUR BENDS START.
http://www.bigassjeep.com/pics/phoenix/5.01.06.g.jpg

Took some time repairing beadlocks, have two completely and 100% leak free, one I need to put back together and 2 that still need some patch welds.
http://www.bigassjeep.com/pics/phoenix/5.01.06.h.jpg

http://www.bigassjeep.com/pics/phoenix/5.01.06.i.jpg


http://www.bigassjeep.com/pics/phoenix/5.01.06.j.jpg

Backyard fab shop.
http://www.bigassjeep.com/pics/phoenix/5.01.06.k.jpg

I didn’t really know what I wanted to do for a cage, so my mom came over to help draw up a few ideas. This one I liked the concept of the most. Mind you, this is a sketch, the bends aren’t right, the nodes aren’t right, it’s just a general shape which needs hella more reinforcement. It’s not a blueprint.
http://www.bigassjeep.com/pics/phoenix/5.01.06.l.jpg

Figured out and measured out where all 4 seats are comfy. Since they won’t be adjustable, I’m trying to make it so a few different shapes of people can drive it. Back seats are definitely tight, but hey, it’s a buggy.
http://www.bigassjeep.com/pics/phoenix/5.01.06.m.jpg

http://www.bigassjeep.com/pics/phoenix/5.01.06.n.jpg

My dad and I spent the better part of a day reading up on tube bending and “how to” – eventually we really got the hang of it. Our first piece, the main hoop, came out to 1/100th of an inch of where we wanted it.

To bad it wasn’t until later that I realized “where we thought we wanted it” wasn’t where I really wanted it, and we measured a little to wide. Oh well, the fact we made what we were trying makes me very happy.
http://www.bigassjeep.com/pics/phoenix/5.01.06.o.jpg


http://www.bigassjeep.com/pics/phoenix/5.01.06.p.jpg


http://www.bigassjeep.com/pics/phoenix/5.01.06.q.jpg


http://www.bigassjeep.com/pics/phoenix/5.01.06.r.jpg


http://www.bigassjeep.com/pics/phoenix/5.01.06.s.jpg

Here you can see why the hoop sucks, it’s ½” too wide (see the fat top) and more so, they should be 84 degree bends instead of 90, so the top is closer to the stock/windshield line.
http://www.bigassjeep.com/pics/phoenix/5.01.06.t.jpg

I bent a second main hoop today, but totally wasn’t paying attention and over bent to 89 (again) instead of 84 on one of the two bends. After that happened, I realized that if I bent the other one to 89 as well, it’d make a perfect C hoop right above the rear passengers, just needs to be cut shorter and it’ll be much better. I can’t taper the C hoop like the main hoop, as it’s too close to the already tight rear passenger area. It’ll still be in 5-6” further than the front hoop, so it shouldn’t’ be a tree catcher.
http://www.bigassjeep.com/pics/phoenix/5.01.06.u.jpg


Time for bed, have some work to take care of throughout the day, but bending tube in-between the phone calls /whatnot.

Thanks to Ryan, I might have a flatbed to borrow, but I still need to buy a truck.

r6cyclegal
05-02-2006, 12:36 PM
It's looking so good!!!! I'm excited. I'll have to get over their sometime soon to see it in person!!!! Good job. It'll be done soon!!!!

OverkillZJ
05-02-2006, 10:28 PM
We're having some tubing issues, I think they're going to occupy our time correcting for the next week or so, so don't bother checking back for updates.

Don't even ask about the 60 gears, we had some ARB "fitment" issues which almost left Dave Steve and I in the hospital.

And the Stak 3 speed case I want is backordered about 6 weeks, Advance Adapters Atlas 4 speed case is backordered 8 weeks, I think this build is just screwed.

RalphDogg
05-03-2006, 12:03 AM
i need to get a good bit of 2"and 1.5" dom. how much did you pay for it and where did you get it.
some good tips on making a rollcage.... i sometimes draw what i am making on the ground with chalk, it's a good idea to get a BIG right angle like 2'x3', and adjustable angle finder is your best friend.

OverkillZJ
05-04-2006, 11:28 PM
Some of you called BS on us giving up on the buggy, and, well… You were right. However, I’m not going to say how it’s going, or post pictures of the progress yet, you’ll just have to sit there wondering what the hell we’re up to over here until we show up with it in Moab at Grand Slam West 2006 in June, on time, with a functional ZJ buggy.

Until I feel like letting the cat out of the bag, have some teaser pics :D

http://www.bigassjeep.com/pics/phoenix/5.04.06.a.jpg


http://www.bigassjeep.com/pics/phoenix/5.04.06.b.jpg


http://www.bigassjeep.com/pics/phoenix/5.04.06.c.jpg


http://www.bigassjeep.com/pics/phoenix/5.04.06.d.jpg


http://www.bigassjeep.com/pics/phoenix/5.04.06.e.jpg


http://www.bigassjeep.com/pics/phoenix/5.04.06.f.jpg


http://www.bigassjeep.com/pics/phoenix/5.04.06.g.jpg


http://www.bigassjeep.com/pics/phoenix/5.04.06.h.jpg

http://www.bigassjeep.com/pics/phoenix/5.04.06.i.jpg


http://www.bigassjeep.com/pics/phoenix/5.04.06.j.jpg


http://www.bigassjeep.com/pics/phoenix/5.04.06.k.jpg


http://www.bigassjeep.com/pics/phoenix/5.04.06.l.jpg


http://www.bigassjeep.com/pics/phoenix/5.04.06.m.jpg

http://www.bigassjeep.com/pics/phoenix/5.04.06.n.jpg


http://www.bigassjeep.com/pics/phoenix/5.04.06.o.jpg


http://www.bigassjeep.com/pics/phoenix/5.04.06.p.jpg


http://www.bigassjeep.com/pics/phoenix/5.04.06.q.jpg


http://www.bigassjeep.com/pics/phoenix/5.04.06.r.jpg


http://www.bigassjeep.com/pics/phoenix/5.04.06.s.jpg


http://www.bigassjeep.com/pics/phoenix/5.04.06.t.jpg


http://www.bigassjeep.com/pics/phoenix/5.04.06.u.jpg
I guess I didn’t really show you much, huh? Guess you’ll just have to wait.

HA!

Bill
05-05-2006, 11:09 AM
I knew you were gonna give in and post some progress pictures! I didn't think you could hold out that long. HA HA!

OverkillZJ
05-05-2006, 11:22 AM
What progress pictures?

OverkillZJ
05-05-2006, 10:09 PM
http://bigassjeep.com/pics/phoenix/party.jpg

That's right, we're getting shit done.

fordfourby
05-05-2006, 11:14 PM
i dont know about anyone else but i find the blue light up pedals funny...

Bill
05-05-2006, 11:22 PM
i dont know about anyone else but i find the blue light up pedals funny...


At least he disconnected them so they don't glow in the dark anymore...

OverkillZJ
05-06-2006, 12:02 AM
bling bling, mfers

avenged7foldhc
05-06-2006, 04:00 AM
no no, mfbb

Bill
05-06-2006, 10:55 AM
He is still young... He has not mastered the MFL!

OverkillZJ
05-11-2006, 01:07 AM
Just a few more teaser pics.

I guess I need a new vice, what the hell were we building to break that thing? Of course since it involved half inch plate when I say “we” I meant “Steve.”

http://www.bigassjeep.com/pics/phoenix/5.11.06.a.jpg


http://www.bigassjeep.com/pics/phoenix/5.11.06.b.jpg


http://www.bigassjeep.com/pics/phoenix/5.11.06.c.jpg


http://www.bigassjeep.com/pics/phoenix/5.11.06.d.jpg


http://www.bigassjeep.com/pics/phoenix/5.11.06.e.jpg


http://www.bigassjeep.com/pics/phoenix/5.11.06.f.jpg


http://www.bigassjeep.com/pics/phoenix/5.11.06.g.jpg


http://www.bigassjeep.com/pics/phoenix/5.11.06.h.jpg

http://www.bigassjeep.com/pics/phoenix/5.11.06.i.jpg


http://www.bigassjeep.com/pics/phoenix/5.11.06.j.jpg


http://www.bigassjeep.com/pics/phoenix/5.11.06.k.jpg

OverkillZJ
05-24-2006, 09:12 AM
Ok. I guess it’s time to catch everyone up on what’s been going on over here, and what needs to be done in the next 13 days before I leave for Grand Slam West on doomsday (6.6.06)

As some of you know, I did acquire a tow rig and a trailer. Both need a little bit of work. Tow rig has busted A/C and burnt transmission fluid, no brakes, no shocks, etc. Nothing I can’t fix in a very very long day.

The trailer is 82” between the fenders, but the buggy tire tread is 90” wide (Yes, you read that right.) We’re going to have to modify the brand new trailer to hold the buggy.
http://bigassjeep.com/pics/phoenix/trailer1.jpg
http://bigassjeep.com/pics/phoenix/trailer2.jpg

As for the rig itself… Well let’s bring you up to speed.

http://www.bigassjeep.com/pics/phoenix/5.24.06.a.jpg


http://www.bigassjeep.com/pics/phoenix/5.24.06.b.jpg


http://www.bigassjeep.com/pics/phoenix/5.24.06.c.jpg


http://www.bigassjeep.com/pics/phoenix/5.24.06.d.jpg


http://www.bigassjeep.com/pics/phoenix/5.24.06.e.jpg


http://www.bigassjeep.com/pics/phoenix/5.24.06.f.jpg


http://www.bigassjeep.com/pics/phoenix/5.24.06.g.jpg


http://www.bigassjeep.com/pics/phoenix/5.24.06.h.jpg

http://www.bigassjeep.com/pics/phoenix/5.24.06.i.jpg


http://www.bigassjeep.com/pics/phoenix/5.24.06.j.jpg


http://www.bigassjeep.com/pics/phoenix/5.24.06.k.jpg


http://www.bigassjeep.com/pics/phoenix/5.24.06.l.jpg


http://www.bigassjeep.com/pics/phoenix/5.24.06.m.jpg

OverkillZJ
05-24-2006, 09:12 AM
http://www.bigassjeep.com/pics/phoenix/5.24.06.n.jpg


http://www.bigassjeep.com/pics/phoenix/5.24.06.o.jpg


http://www.bigassjeep.com/pics/phoenix/5.24.06.q.jpg


http://www.bigassjeep.com/pics/phoenix/5.24.06.r.jpg


http://www.bigassjeep.com/pics/phoenix/5.24.06.s.jpg



Here’s the stock brake booster next to the one I’m using from an F-350.
http://www.bigassjeep.com/pics/phoenix/5.24.06.t.jpg


http://www.bigassjeep.com/pics/phoenix/5.24.06.u.jpg

Only problem was the pedal ended up like 5,000 feet from the floor… I need to fix that some how.
http://www.bigassjeep.com/pics/phoenix/5.24.06.v.jpg

Other than drilling new holes and pounding the firewall up and out of the way, the master cylinder / brake booster was just about a bolt up if you sleeve the pivot point so that the stock linkage connects safely.
http://www.bigassjeep.com/pics/phoenix/5.24.06.w.jpg

Corey (JpnRngr) had a brilliant idea for getting my 1405 p-pump to work on my 5.2 engine. It looks like the bracket from a 1999 Dodge Durango w/ the 5.2 makes it a direct bolt up! The belt from the Durango is the perfect length as well.
http://www.bigassjeep.com/pics/phoenix/5.24.06.x.jpg


http://www.bigassjeep.com/pics/phoenix/5.24.06.y.jpg


http://www.bigassjeep.com/pics/phoenix/5.24.06.aa.jpg


http://www.bigassjeep.com/pics/phoenix/5.24.06.bb.jpg


http://www.bigassjeep.com/pics/phoenix/5.24.06.cc.jpg


http://www.bigassjeep.com/pics/phoenix/5.24.06.dd.jpg


http://www.bigassjeep.com/pics/phoenix/5.24.06.ee.jpg


http://www.bigassjeep.com/pics/phoenix/5.24.06.ff.jpg


http://www.bigassjeep.com/pics/phoenix/5.24.06.gg.jpg


http://www.bigassjeep.com/pics/phoenix/5.24.06.hh.jpg

I’ve got more update pics but that’s all I can handle putting up for now… Heading out now to get some more done. I’m waiting on a lot of parts from High Angle Driveline, PSC Motorsports, BTF, etc etc. Need stuff, need it yesterday…

OverkillZJ
05-31-2006, 02:10 AM
A few more updates.. to busy to update much at this point, I leave on this upcoming Tuesday – doomsday 6.6.06. Ironicly, the place I got my trailer parts from ends in 666, and the hydraulic ends I used are stamped part number 666. This project is doomed in so many ways.

The fabmaster MFsteve hard at work.
http://www.bigassjeep.com/pics/phoenix/5.31.06.a.jpg


http://www.bigassjeep.com/pics/phoenix/5.31.06.b.jpg


http://www.bigassjeep.com/pics/phoenix/5.31.06.c.jpg


http://www.bigassjeep.com/pics/phoenix/5.31.06.d.jpg


http://www.bigassjeep.com/pics/phoenix/5.31.06.e.jpg


http://www.bigassjeep.com/pics/phoenix/5.31.06.f.jpg


http://www.bigassjeep.com/pics/phoenix/5.31.06.g.jpg

Valve for hydro mounted on custom bracket
http://www.bigassjeep.com/pics/phoenix/5.31.06.h.jpg

Adapter set made by Powertank provided by steelcityoffroad.com to make hooking up my ARB as simple as can be.
http://www.bigassjeep.com/pics/phoenix/5.31.06.i.jpg

No time to deal with a compressor / regulator / tanks etc. Powertank is the way to go he re: SIMPLE.
http://www.bigassjeep.com/pics/phoenix/5.31.06.j.jpg

Time to hook all the liquid nasty stuff up, including Hydro steering thanks to PSC Motorsports.
http://www.bigassjeep.com/pics/phoenix/5.31.06.k.jpg

I scored a free GM steering cooler from DMG who had one laying around for years. After I cut up the fancy ends and flared them, fit like a charm.
http://www.bigassjeep.com/pics/phoenix/5.31.06.l.jpg

Everything is a VERY tight fit, but it does fit.

http://www.bigassjeep.com/pics/phoenix/5.31.06.m.jpg

F… U… rubber gasket. Put it all together, filled it, and learned why rubber gaskets do suck with these flimsy transmission oil pans. Took it off, cleaned it, filled it again using Black RTV which sealed like a charm.
http://www.bigassjeep.com/pics/phoenix/5.31.06.n.jpg

Thanks to Dirk @ 4x4oil.com for the hookup on all the synthetic fluids I insist on running. I’d argue it’s the only thing that’s kept my stock transmission running so long under this much abuse.
http://www.bigassjeep.com/pics/phoenix/5.31.06.o.jpg

No one wants to see a puddle under their project the next morning, but that’s what I found. Looks like we killed the transmission output seal while mounting up the Atlas II 5:1 transfer case. I got a new seal, but now I have to pull and mount that transfer case… AGAIN.
http://www.bigassjeep.com/pics/phoenix/5.31.06.p.jpg

1.5” ¼” wall DOM + weld in bungs and rod ends = one beefy freaking tie rod ! Well in this case, two.
http://www.bigassjeep.com/pics/phoenix/5.31.06.q.jpg


http://www.bigassjeep.com/pics/phoenix/5.31.06.r.jpg

Steve welding the cage up
http://www.bigassjeep.com/pics/phoenix/5.31.06.s.jpg


http://www.bigassjeep.com/pics/phoenix/5.31.06.t.jpg

Mr. MF Fabmaster did all this while I was trying to get the tow rig running. http://www.bigassjeep.com/pics/phoenix/5.31.06.u.jpg

http://www.bigassjeep.com/pics/phoenix/5.31.06.v.jpg

I have a catch 22 in that the buggy needs a month of work, as does the vehicle I’m towing it with. Both need to be done, no point in having a tow rig without something to tow, but no point in having a buggy without something to tow it with.
I have about 5 days to somehow have both…

http://www.bigassjeep.com/pics/phoenix/5.31.06.w.jpg

My dad fixed all the retarded and just plain wrong wiring on my “new” trailer. I’d love to give the place I bought it at a piece of my mind if I had time, but I don’t. Anyway, it works great now, and the tow controller appears to work in the suburban as well, that was a relief.
http://www.bigassjeep.com/pics/phoenix/5.31.06.x.jpg

The compressor is truly on its last legs… but hopefully it survives the rest of this project.
http://www.bigassjeep.com/pics/phoenix/5.31.06.y.jpg


Bed time, back at it tomorrow. I think I’m about done working before the trip. My priority is getting this buggy to Moab on time for GSW, not actually paying for it! :D

If your in the area, I could always use slave labor if you have nothing better to do.

LeadFoot
05-31-2006, 07:22 PM
I gotta admit matt, when you first started posting pics up of ZJZILLA (Thats my new cool name I just pulled out of my ass for your buggy), the body lines looked kinda.....ugly. But as I see more and more of it gettin put together, shes lookin more badass all the time. I'm digging the dovetailed ends and the stinger setup. Can only imagine the sound its gonna make the first time a driveline part snaps. :D :D :D

OverkillZJ
05-31-2006, 07:55 PM
Cage design is 99% Steve. I learned not to argue with what he thinks will look good and I don't; because it always ends up looking good.

And you can't call it ZJIlla, there's a guy (Alan) in Canada who used to run a fab shop called that, made the best ZJ products ever!

trailerrails
05-31-2006, 09:34 PM
My dad fixed all the retarded and just plain wrong wiring on my “new” trailer. I’d love to give the place I bought it at a piece of my mind if I had time, but I don’t. Anyway, it works great now, and the tow controller appears to work in the suburban as well, that was a relief.


I had to do a bit of work with the wiring to get my trailer wired up right. There was no problems with the wiring on my trailer except I had to hook up the breakaway kit and my plug. That took a while, I kinda wanted it to be done for me but I figure that is what you get for shuch a cheep price.

OverkillZJ
05-31-2006, 09:44 PM
I had to do a bit of work with the wiring to get my trailer wired up right. There was no problems with the wiring on my trailer except I had to hook up the breakaway kit and my plug. That took a while, I kinda wanted it to be done for me but I figure that is what you get for such a cheep price.

Actually... I was happy with the trailer at first until I really looked into it. They used 18 gauge wire for electric brakes, tied them together with unprotected plastic wire clips which were grounding out on the frame... On top of that when they said "used tires and wheels" I assumed they meant used TRAILER tires and wheels. Sure, I should've asked... but all in all, I came in at a whole lot of PAIN IN THE ASS to come in about $200 less than buying new at Zoresco already wired, already with new tires, all ready to go.

It'll work now, but that's a lot of wrenching time lost because they saved 20 cents a trailer using insanely small wiring for dual electric brakes...

Anyway, spent the rest of the night when I was done fixing the suburban putting the coilovers together, and figuring out how to make the fenders drive-over. Bed time, back at it tomorrow.

OverkillZJ
06-02-2006, 05:39 PM
Just a quick update while it’s raining too hard for me to get anything done on the rig…

This isn’t really a happy update, it’s a MF the world update. I spent all day driving around getting parts I need such as brake lines and crazy little adapters. At 9am tomorrow I’ll have everything else I need to make a buggy. Some assembly required.

http://www.bigassjeep.com/pics/phoenix/6.2.06.a.jpg

This is why it’s a bad update. Do not force an Atlas transfer case on. It’s as simple as that. That popping noise is not the transfer case seating, it’s the sound of you cracking the input housing and blowing the retaining ring through what was holding it. This means that the case no longer works.

Parts are on the way priority overnight Saturday delivery from Advance Adapters.
http://www.bigassjeep.com/pics/phoenix/6.2.06.b.jpg


http://www.bigassjeep.com/pics/phoenix/6.2.06.c.jpg


http://www.bigassjeep.com/pics/phoenix/6.2.06.d.jpg


http://www.bigassjeep.com/pics/phoenix/6.2.06.e.jpg


http://www.bigassjeep.com/pics/phoenix/6.2.06.f.jpg

Put the tires on to see where we stand. Or doesn’t stand, or don’t turn, anyway? Given this is at full flex, but with that kind of rubbing on a rig that will hit full flex, hydro steering will do nothing but brake parts or blow tires in this scenario.
http://www.bigassjeep.com/pics/phoenix/6.2.06.g.jpg

Began mocking up where everything needs to go. I’m so short on time some of it may stay ziptied instead of making mounts for it.
http://www.bigassjeep.com/pics/phoenix/6.2.06.h.jpg

http://www.bigassjeep.com/pics/phoenix/6.2.06.i.jpg

I don’t have a buggy yet, but I have lots of parts. Lots and lots of parts. I’ll be calling it an early night since it’s raining, and getting up at about 5:30 in hopes it’s cleared up to piss the neighborhood off with some metal cutting noise. The rest of the area is going wheeling tomorrow last minute, but considering I have three fawking days left on a project I’m completely committed to at this point, I will keep working on it rain or shine day or night until it’s done.
http://www.bigassjeep.com/pics/phoenix/6.2.06.j.jpg


http://www.bigassjeep.com/pics/phoenix/6.2.06.k.jpg


http://www.bigassjeep.com/pics/phoenix/6.2.06.l.jpg

OverkillZJ
06-05-2006, 01:49 AM
Advance Adapters got me my last second parts to repair the “atlas incident”. Saturday delivery, I’m just glad it came.

http://www.bigassjeep.com/pics/phoenix/6.04.06.a.jpg


http://www.bigassjeep.com/pics/phoenix/6.04.06.b.jpg

All fixed. What a waste of a day!
http://www.bigassjeep.com/pics/phoenix/6.04.06.c.jpg

How to install an Atlas II tcase alone.
http://www.bigassjeep.com/pics/phoenix/6.04.06.d.jpg


http://www.bigassjeep.com/pics/phoenix/6.04.06.e.jpg


http://www.bigassjeep.com/pics/phoenix/6.04.06.f.jpg

My impact gun kicked the bucket. I’m broke. I ended up getting my birthday present 6 months early, because I just plain need a good impact gun to finish this thing (changing driveline yokes and whatnot.)
http://www.bigassjeep.com/pics/phoenix/6.04.06.g.jpg


http://www.bigassjeep.com/pics/phoenix/6.04.06.h.jpg

Getting the 1350 yoke off of the 14 bolts (removable) pinion. Now have a 1410 ubolt style that came with my new shafts from High Angle Driveline.
http://www.bigassjeep.com/pics/phoenix/6.04.06.i.jpg

The UBERNODE

http://www.bigassjeep.com/pics/phoenix/6.04.06.j.jpg


http://www.bigassjeep.com/pics/phoenix/6.04.06.k.jpg

No more jack stands in the front end. Looks like we end up with about 6” of up travel and 8” of droop. Just about perfect.
http://www.bigassjeep.com/pics/phoenix/6.04.06.l.jpg


http://www.bigassjeep.com/pics/phoenix/6.04.06.m.jpg

http://www.bigassjeep.com/pics/phoenix/6.04.06.n.jpg


http://www.bigassjeep.com/pics/phoenix/6.04.06.o.jpg


http://www.bigassjeep.com/pics/phoenix/6.04.06.p.jpg

My dad has my trailer setup just about ready, still need to make the fenders drive over. Bill / Brandon are working on the sat radio / CB / crap like that in the tow rig. Only way to survive the drive…
http://www.bigassjeep.com/pics/phoenix/6.04.06.q.jpg

Tomorrow is the last day. It won’t be “done” – but it’ll be ready to wheel at GSW…

BonHolla
06-05-2006, 02:06 AM
If you need some last minute help, call me (my numbers in my profile). I'm working nights so I'll be available from around 12:30 or so. If not, good luck... this thing looks mean.

MF Steve!
06-05-2006, 06:59 AM
It's worth stoppin over, even if it's just to see the size of this monstrosity...

ArtCloud
06-05-2006, 10:58 AM
I'd really love to stop over and see this beast, It's hella-beefier looking now with the suspension and tires mounted.

2002wranglerX
06-05-2006, 02:39 PM
call me if you need those rims/tires. lookslike you got it under control though.

LordAthens
06-05-2006, 02:55 PM
I'll be over after I get out of work at 3, stop at AAA to transfer the title on the Jeep, stop at home to change, then I'll be over.

Bill
06-05-2006, 03:36 PM
You will see me a little later this evening.

I need to:

Change the oil in the Jeep
Give it a bath (inside and out)
Paint my RockCrushers

mithuth
06-05-2006, 04:22 PM
Quite the long read. Pretty impressive, for the most part.

I only have one question. Since you pretty much cut away the Grand and kept only the steering wheel and motor, why didn't you just fab up a frame and put the engine/steering wheel into that.

You could have sold the rest for money to fund more of the project. 8)

Over all, I'm impressed.

leonw
06-05-2006, 05:10 PM
Un-be-Freakin-lievable!

Whether it's pure ambitious motivation, stubborn obsessiveness, or a little of both, It's very impressive the amount of work you guys have gotten done in such a short amount of time, setbacks and all. Mind blowing actually. I would have looked at the amount of work to accomplish and almost definitely said...Maybe it'll be done in time for next year's event. (That's assuming I had that level of crazy skills and the technical know how, which I don't.)

Good Luck as you come into the home stretch. I may try to stop by, I gotta see it.

OverkillZJ
06-06-2006, 12:48 AM
[quote=mithuth]Quite the long read. Pretty impressive, for the most part.

I only have one question. Since you pretty much cut away the Grand and kept only the steering wheel and motor, why didn't you just fab up a frame and put the engine/steering wheel into that.

You could have sold the rest for money to fund more of the project. 8)

[quote]

Build what you've got.

I'm involved with the Grand Slams and run MallCrawlin.com - I essentially need a grand. It's the group I run with.

OverkillZJ
06-06-2006, 12:50 AM
Un-be-Freakin-lievable!

Whether it's pure ambitious motivation, stubborn obsessiveness, or a little of both

All of the above... mostly stubborness

It's the worst decision ever to build this so big right now, and buy a truck just to tow it... but it was started, and I'm not one to leave unfinished things around... Besides, I live to wheel.

OverkillZJ
06-06-2006, 12:51 AM
call me if you need those rims/tires. lookslike you got it under control though.

Hey Ryan,

with the tight time frame (I'm supposed to be leaving in about 5 hours.. looks like I"m heading out Tue night though) I'm just goign to let it hang over the sides of the trailer a little.. it won't be THAT bad, still between the fender width...

I got ramps!

fordfourby
06-06-2006, 02:33 AM
hey dude good luck... wish i could have helped out more, i'd say dont break it but i think it'd be more fitting to say dont break yourself...

PK
06-06-2006, 09:26 AM
Good luck Matt, drive safely.

BonHolla
06-06-2006, 09:38 PM
Hey. I had a good time tonight. That things a beast! I hope those ramps I helped make hold up. Good luck on your trip and have fun when you get there.

OverkillZJ
07-17-2006, 12:57 AM
I’ve been neglecting to make this post / buggy project update for some time now. If you read these update threads, you probably know that life kicked my ass on this project, and on this trip. I don’t think I could stomach to sit here and type out all of the details of everything that went wrong, because then I’d be reminded of what a miserable experience it was regardless of my high expectations for the trip.
Vacation it was not.

Other than leaving a couple of day’s late for GSW, and being completely unprepared, the last thing I was prepared for was what would happen during that trip. Some of it could have been prevented if I’d found more time to work on details on the buggy, other things could’ve been prevented if people had listened, but overall the way every situation came together as a clusterfawk on this trip, is just extraordinary. All in all, I never throw in the towel, I never accept defeat. Yet… I got to experience the feeling of complete and utter defeat several times on this trip, to the extent that I’m surprised I didn’t sell off whatever I had with me at the time, and fly home.

Suffice to say that after adding up the trip costs (let alone buggy build costs), and factoring in the damage this did to my professional life as I was stuck across the country, I’ll be taking some time off from the 4wheeling world. As I find time, I’ll be rebuilding the buggy as it should’ve been done in the first time: with patience. It is going in the right direction, but there were some rather large oversights; everything from anti-sqaut to the rear tires hitting the coil-overs so severely that they bind and do not release until hit with a hammer. As far as parts goes, it doesn’t need much of anything. It does need a lot of detail work which I’ll be happy to do in moderation. No more month long wrench fests.

The only way I survived this trip, was due to great people all across the country. I’m always amazed at the amount of people willing to step up and help a fellow Jeeper. It began just half an hour of me arriving at Grand Slam West when Ron (Krash80) immediately began helping me cut off parts of my cage which wouldn’t allow the tires to turn. After I cooked his power inverter by reversing the polarity like a retard (ironic for me to do) he was still gung ho to help me up until the last minute the next day, when we finally realized we needed a plasma cutter, as my angle grinder would not cut it (literally). Countless people helped me with the buggy recovery the following day after the first buggy incident, and FearTheDentist even allowed me to borrow his lifted 250 turbo diesel for the recovery over the shelf road. From there, Dave and Pam allowed me to stay at their place for God knows how long while I fixed my truck and trailer, as well as Mark and Jill allowing me to do the same at theirs further north in Loveland. Mtn WJ loaned me his trail welder in order to fix welds on my trailer which shouldn’t have broken in the first place. Eventually I made it home, with a massive amount of support from friends and family.


Anyway, on to a few of the pics…


Various shots of “kind of” finishing the buggy:

http://www.bigassjeep.com/pics/phoenix/7.16.06.a.jpg


http://www.bigassjeep.com/pics/phoenix/7.16.06.b.jpg


http://www.bigassjeep.com/pics/phoenix/7.16.06.c.jpg


http://www.bigassjeep.com/pics/phoenix/7.16.06.d.jpg


http://www.bigassjeep.com/pics/phoenix/7.16.06.e.jpg

Even my parents were helping down to the wire
http://www.bigassjeep.com/pics/phoenix/7.16.06.f.jpg

Hell, the last two days EVERYONE was helping. I was amazed at the people that stepped up to try and get me on my way, I couldn’t even begin with enough thank you’s in that aspect.
http://www.bigassjeep.com/pics/phoenix/7.16.06.g.jpg


http://www.bigassjeep.com/pics/phoenix/7.16.06.h.jpg

http://www.bigassjeep.com/pics/phoenix/7.16.06.i.jpg


http://www.bigassjeep.com/pics/phoenix/7.16.06.j.jpg


http://www.bigassjeep.com/pics/phoenix/7.16.06.k.jpg

I’m glad I spent the time last minute to weld up / finish fabbing those drive over fenders… They’re not pretty considering I was almost out of gas in the welder, but they’re not going anywhere either. Even though I hadn’t slept and was about to leave to drive for 30 hours straight, it was a good feeling getting that thing up on the trailer. Finally.
http://www.bigassjeep.com/pics/phoenix/7.16.06.l.jpg

I guess these pictures require an explanation, huh? My Suburban toed great until Kansas. Why? Altitude. By the time I reached the first pass of 70 in Denver, Colorado: I knew the rig was simple not going to get me there in it’s current state. I actually required a police escort to get me to the firest exit off of 70, because I was dumping so much smoke. I could not see the buggy I was towing behind me, and people driving in the other lains doubtlessly couldn’t see where they were going.

What was wrong? My turbo charger wasn’t working. A turbo charged diesel with no turbo at altitude, with a 7000 lb load is like…. A brick with a steering wheel.

Turned out my vacume pump was blown, and so the waste gate could not be adjusted to allow for the engine to boost itself.

My ghetto fix: get 50 feet of freezer hose from WalMart where I was stuck (used 40 of it) and run vacuum from Buggy you’re towing, up to the vacuum port on the actuator valve of the truck. I had to run both engines, but after that I towed to Moab without issue, other than some minor overheating which was only the beginning of the problems.
http://www.bigassjeep.com/pics/phoenix/7.16.06.m.jpg

http://www.bigassjeep.com/pics/phoenix/7.16.06.n.jpg


http://www.bigassjeep.com/pics/phoenix/7.16.06.o.jpg

The first of 3 broken tie down straps. The straps are great when used properly: under a direct pull scenario. Mark and I ended up adding floor mounted d ring mounts later that trip to fix this problem… but of course I had to get some new straps until I get the good Macs straps fixed.
http://www.bigassjeep.com/pics/phoenix/7.16.06.p.jpg


http://www.bigassjeep.com/pics/phoenix/7.16.06.q.jpg


I think Kris needs some bigger tires, and that I need to make my crap actually work. His rig was so well tuned in my jaw dropped. I thought he was nuts for the huge wheelbase he’s running, but all I can say is holy crap, that thing can climb up some things I’d never have imagined a ZJ buggy getting neare.
http://www.bigassjeep.com/pics/phoenix/7.16.06.r.jpg

Here’s my junk errrrrrrrrr not working? Too much suspension unload, too much give in the bushings, springs weren’t settle, rear coils were bound up where hitting… this obstacle, which I walked up last year on the center line, led me to the winch real fast. After that I was just nervous driving the rig, so many things were not right.
http://www.bigassjeep.com/pics/phoenix/7.16.06.s.jpg


http://www.bigassjeep.com/pics/phoenix/7.16.06.t.jpg


By the time we got to No-Left-Turn, the lack of sleep was getting to me. Factor in low sugar level and just plain hating heights in the first place: I let Ron drive the buggy over it. I did it last year without issue, but I figured feeling sick and not doing well with heights anyway could lead to a bad incident at that moment.
http://www.bigassjeep.com/pics/phoenix/7.16.06.u.jpg

Ya… A picture is worth a thousand words.
http://www.bigassjeep.com/pics/phoenix/7.16.06.v.jpg


http://www.bigassjeep.com/pics/phoenix/7.16.06.w.jpg


http://www.bigassjeep.com/pics/phoenix/7.16.06.x.jpg


http://www.bigassjeep.com/pics/phoenix/7.16.06.y.jpg


http://www.bigassjeep.com/pics/phoenix/7.16.06.z.jpg


http://www.bigassjeep.com/pics/phoenix/7.16.06.aa.jpg

No, Dave’s rig didn’t tow me around…. We needed it to move the trailer though and to get the buggy up on it. I overheated the tow rig so badly that I cooked the injection pump, I was lucky it got me to Dave and Pam’s for repairs. Expensive knuckle shattering painful repairs I hope never to repeat. The truck truly does run like new now, though.
http://www.bigassjeep.com/pics/phoenix/7.16.06.bb.jpg


http://www.bigassjeep.com/pics/phoenix/7.16.06.cc.jpg

Up at Mark’s we were giving the buggy a full day of much needed TLC. When the front axle whipped around on itself, it finally stopped by shattering the pinion on the engine’s motor mount, which pushed the entire driveline up by almost two inches. This is a pic of the bracket which got whaled.
http://www.bigassjeep.com/pics/phoenix/7.16.06.dd.jpg

After that, and some truck work, we went off to camp and wheel, finally. It didn’t last long though. This is my buggy in front of my brother’s trusty XJ. That thing has had hardly any problems wheeling as it stands there, for longer than I’ve even owned my ZJ. There’s something to be said about simplicity.
http://www.bigassjeep.com/pics/phoenix/7.16.06.ee.jpg

OverkillZJ
07-17-2006, 12:58 AM
The buggy was REALLY FUN while it worked, despite its flaws.
http://www.bigassjeep.com/pics/phoenix/7.16.06.ff.jpg

http://www.bigassjeep.com/pics/phoenix/7.16.06.gg.jpg

http://www.bigassjeep.com/pics/phoenix/7.16.06.hh.jpg

http://www.bigassjeep.com/pics/phoenix/7.16.06.ii.jpg

http://www.bigassjeep.com/pics/phoenix/7.16.06.jj.jpg
Really fun, that is, until parts which just shouldn’t break, break.
The PSC power steering pump (1405) 0 just about the best you can get, decided to stop working. Leaving me with.. tada… manual steering on 42’s. All I can say is thank goodness I got the good orbital valve which gave me manual steering, instead of no steering. I managed to get it out of the trail by semi-bahaing in front lo only, and doing front digs constantly. It was exhausting, challenging, and probably the most fun I had that trip. I’m kind of surprised the front dig turn thing worked as well as it did when
I could only turn the front tires a couple of inches.
http://www.bigassjeep.com/pics/phoenix/7.16.06.kk.jpg
Hmmmmm… That could explain why the pump stopped working? Looks like my pulley was bent, and pressed on too far, pulling the shaft out of it’s safe riding zone. I still don’t think that should’ve happened, but hey, I have a new one now…
http://www.bigassjeep.com/pics/phoenix/7.16.06.ll.jpg

So that’s catching you up to the present. Eventually I’ll be back up with updates once in awhile, need to plan and recover first.
And now I’m off to bed, so I can wake up, work, and pay off the God-awful bills from this trip that I don’t even know how to begin to describe.

TimMichaels
07-17-2006, 04:41 PM
Sooooo what happened to the headlight? You tow it out and you have two, you hit the trail and there's one. :120:

OverkillZJ
07-17-2006, 08:48 PM
First trail I ran, I got on it over 3 hours late, because I had to go to a shop and have them use the plasma cutter to cut off the 2x4 box where it was hitting so badly, I couldn't turn lock to lock on flat pavement. The bahaing led to a few oops's, one of which was the other headlight. They were just zip tied in place temporarily for emergency light. I have some good pro comp 100's to put on as headlights, which hell I think I might still owe $ for :)

I just finished replacing the steering pump. Looks like something's wrong with the bottom drivers side king pin, so the things going on the trailer and sitting there until my life is back in order. Hell, I might even wheel it next year, might not. I'm kind of indiferent right now!

r6cyclegal
07-18-2006, 02:58 PM
Don't give up. Just let it sit for a week and then you'll be back into it.
Just try not to do the last minute thing next year.

I'm sure you'll make the buggy rock when you take time away from it and clear other things (like backed up work) from your mind.

Happycamper
07-19-2006, 04:32 PM
Life can be a real whore!

Next year I bet the jaws are dropping at how "in tune" your buggy is!

At least you got to see friends and wheel, even a little. I'd kill to get one full day of wheeling where you were!

Did you get any shots of Mark's TJ??

OverkillZJ
07-19-2006, 08:24 PM
Next year I'm going back with a vengence... project phoenix-buggy revenge? I've got 10 months to do it right :D

I didn't get any shots of Mark's TJ, but I think I copied his entire camera card which had some shots on it, I'll check! It hasn't changed a bit since 2004, I might still have some pics floating around of it then.

PK
07-20-2006, 12:53 PM
That's not true, I know he painted his axle. :)

OverkillZJ
07-20-2006, 01:24 PM
Meh, you don't even need to paint metal out there, it doesn't even rust :D

jeepxj3
07-26-2006, 05:23 PM
Hey Matt, how come you didnt take many pics of your trip like you did last time? Any plans for a video like the first GSF you attended?

OverkillZJ
07-26-2006, 09:12 PM
Take pictures of what, me with the buggy broken on its first run? More pictures of it not working well even when it was working? Or do you want more pictures of me stranded at various Walmarts, parts stores, and friends houses between here and Moab?

Let's say there wasn't much action to take pictures of this year, I had fun none the less :D

Next year... We'll see. I've started thinking again, it's very dangerous.

jeepxj3
07-27-2006, 01:38 PM
To be honest with you I love the work you did converting it, and im sure its more than capable now, but honestly I liked it better when it was a ZJ.

I like the ability to wheel it hard and be able to drive it home at the end of the trip ;)

OverkillZJ
07-27-2006, 03:12 PM
I like the ability to wheel it hard and be able to drive it home at the end of the trip ;)

Keep doing it, and you'll either be buggying it, or sending it to the crusher.

It's the nature of the unibody.

It was at the point of wheeling where I was put in situations which could have easily left me hospitalized, and was also at the point where driving it home on the street was just not safe any more. Everything has it's mechanical limits, especially an uncaged unibody vehicle. :022:

Happycamper
07-27-2006, 05:02 PM
Hell, I remember at a meet & greet at CiCi's I think you almost put it on its side just playing in the parking lot!

OverkillZJ
07-27-2006, 06:38 PM
I have no idea what you're talking about!

Happycamper
07-28-2006, 05:46 PM
Yeah right!

avenged7foldhc
07-28-2006, 06:43 PM
hah nice

OverkillZJ
11-02-2009, 04:51 PM
The shit is about to hit the fan in my life (business) - this buggy will most likely be parted out shortly. I'd rather sell it as a whole, so if you PM me a REASONABLE offer, I'll consider it.

I had intended to build a full tube chassis for it, but time wouldn't allow, and now with my biggest client struggling, I'm selling off toys.

limegreentj
11-02-2009, 04:53 PM
holy shit bro...sorry to hear man....been there done that

Deadman 94 xj
11-02-2009, 04:59 PM
I almost sold mine. No shit. I had a craiglist ad posted and everything. Then, well, I decided that I'll sleep in the damn thing if I have to lol.

Sorry for your troubles Matt.

2002wranglerX
11-02-2009, 05:02 PM
i know you sold the burb but i'm in the market for a trailer if you still ahve yours....

JeepGeneral
11-02-2009, 05:09 PM
What Atlas do you have? I may be interested if you part it out.

OverkillZJ
11-02-2009, 05:09 PM
I'm not up shit creek yet, but I'm preparing just in case. My largest client is downsizing and having issues paying bills, and might not survive this. Long story short, they weren't elligible for construction stimulus funds, while some of their larger competitors were (F you again, Obama.) The machine shop I work with is also struggling. I'm just trying to position myself better should the worst happen, I'm not eligible for unemployment.

Ryan - I'll send you a PM later, but it's most likely spoken for by DMG (he's borrowing it already, haha.)

OverkillZJ
11-02-2009, 05:11 PM
What Atlas do you have? I may be interested if you part it out.

5:1 with drive flanges, worknig in conjunction with High Angle Driveline driveshafts, also with drive flanges at the tcase end (1410 ujoints.) The driveline is about as beef as could be when I built it.

Dragonslayer
11-02-2009, 05:41 PM
That really sux dood. Hope everything work's out for you man.


:s-minigun:

sb406
11-02-2009, 05:52 PM
Shit. That sucks to hear, Matt. When/ if you get ready to part out, PM me some prices on seats, full hydro (if you're splitting off of axle), and atlas.

Mykal
11-02-2009, 05:55 PM
What front axle and steering?

avenged7foldhc
11-02-2009, 08:47 PM
Sell the house, keep the buggy!

gonecheenin
11-02-2009, 09:28 PM
the shit is about to hit the fan in my life (business) - this buggy will most likely be parted out shortly. I'd rather sell it as a whole, so if you pm me a reasonable offer, i'll consider it.

I had intended to build a full tube chassis for it, but time wouldn't allow, and now with my biggest client struggling, i'm selling off toys.

:087:

OverkillZJ
11-02-2009, 10:13 PM
To everyone that PM'd for individual part prices: I'm not ready to go down the part-out road yet. It takes time and research of what things are with, I'm not that motivated yet... This was an "if a number strikes me as hmmm that'd be nice" kind of thing :)

Super Scout
11-03-2009, 12:35 PM
Sorry to hear about your trouble this economy is a killer....If you do decide to sell the whole thing let me know....Hopefully everything will smooth over

2002wranglerX
11-03-2009, 12:36 PM
i think he wants to sell the whole thing.

if he parts it out i'm salivating at the tcase... actually the entire driveline lol, and the hydro steering lol.... that would make a nice swap for the big TJ :D

BigDukeSix
11-03-2009, 03:10 PM
Hang in there Matt.

My dad lost his job (and all of his co-workers) when I was 16 years old. He worked there for 19 years and they F-d him out of everything. I remeber it was a pretty scary time for my family because he only had his work experience and a high school diploma and we were on the verge of losing everything.
My dad is very driven and motivated He rebounded by starting his own one man company and was quite successful. He outlasted the company that fired him.

I dont know you as well as others, but what i do know about you is that you're also very driven and motivated.

Toys come and go, once you get things settled (and I believe you will), there is other stuff out there. Its just stuff.

dan58
11-03-2009, 04:06 PM
i think he wants to sell the whole thing.

if he parts it out i'm salivating at the tcase... actually the entire driveline lol, and the hydro steering lol.... that would make a nice swap for the big TJ :D

Buy the whole thing and sell me the coilovers. :)