"Take 92" - YJ Link kit from Motobilt with Nines

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Well to start this is my first build thread on here ( was suggested by others). I have posted this on other forums so It will go quick as I copy and post info here..for you guys to check out

This build took me 10 months to finish for reference..


So here is the Story..

After I wrecked my XJ racing it I decided I wanted an open top Jeep that my family of 4 could ride in and we could all enjoy it but then I also could go out with the guys on some hard trails and be able to keep up.

So After selling a bunch of parts I found a nice YJ

It is a 92 YJ with a XJ 4.0 and TJ NV3550.
My Plan is to rip out the dana 30 and 8.8 and replace them with 9's add a dana 300 and 4 link with sway a way air shocks.

pics of Jeep as I got it

 

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One of the coolest things with this build is my son (Corbin) has really started to get involved with me in the garage which is just cool as it gets

 

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Then I spent some time building a rear bumper, modifying a tire carrier, adding a winch, a battery box and the last thinking I need to do is mess with the axle disconnect tomorrow night..

as I needed to use the Jeep for the rest of the year till winter before I planned to rip out the axles

 

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Well winter is here so it is time to rip out the axles and start on the new build

And so it begins.....

pulled out the rear 9" to start tearing it apart. Next is to build the nodular 9" center section and then clean up the axle( wire brush time)

 

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All axles are out and it is now time to cut off all old brackets and clean the frame to get read for my 4 link kit.. ( it sweet, just wait till you see it )

 

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was a little cold in shop tonight

cut off all but one leaf hanger, and a few other things that need to go

and a few items that are going bye bye

 

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well few more hours in the garage cutting stuff off and taking stuff off.

got all leaf mounts completely off and frame smoothed, exhaust cut and removed, factory skid removed, np231 removed..if i get lucky I will get a few more hrs tomorrow to try to get fuel tank down and a few others things I need to cut off.

 

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Well got the fuel tank and skid plate out, and rear bumper and tire carrier off. then started working on dana 300 to get it ready to go in jeep.

 

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Well parts have started arriving

Just got my MotoBilt 4 link kit, fuel cell, light bar brackets, and other small odds and ends.

 

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fuel cell and light bar bracket

 

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could not help myself at lunch and had to rip the parts open

and some GenRight Corners

 

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BAM 4 link kit is in.

I do need to weld it all the way in but it is tacked and all lined up ready to make some links..

looking from the rear

looking from the front.. I am going with a dana 300 passenger drop front axle and looks like plenty of driveshaft room

 

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Also took of rear tailgate and few small things in the way for crusher corners and clamped them up to see what I need to cut and then set rear axle in place with rig at full bump

then I placed my 14" Sway a Way air shock in at full compression to see if it cleans and I think I will be good.

 

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had a few minutes in garage today..

Rear quarters are cut and Genright Aluminum corners are on.
Rear axle is centered and now just need to assemble rear axle and start making rear links.

 

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Welded in some weld washer so I would have the correct size hole for my johnny joints that I am running

then I used a buddies 40" tire to see if I want to go that big and I am pretty sure I will stick with 37's

 

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went and got some threaded rod to make my dana 300 cable shifter mount.. that is done

then I cleaned up front axle with wire wheel ( i hate those things) but it got most of the rust off so I can start building front axle

and I have all the parts except inner axle seals which should be here first of next week then it is time to build the axle and put it in place.

worst part is waiting for parts to show up.. but if all goes well a bunch should be here next week then I can work every night on it to make some real progress

 

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had a few more hours in the garage today. I got the entire 4 link kit welded up (had to stop twice due to welder needing to cool down)

and then I wire wheeled the 300 and put one coat of paint on it

 

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well I just keep trying to get an hr or so in each night.. lots more to do

I made new transmission mount tonight and put another coat of paint on 300 and primed all bare metal on 4 link kit.

mounts

and then cross brace.. used 1.5" .120 DOM with bushings on each end

 

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well spent a little time in garage and cleaned up front frame and took off all old steering then John and I mounted the 300

 

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Well after having an issue with splines on front axle see this: http://www.pirate4x4.com/forum/general-4x4-discussion/1643074-35-spline-issue-need-some-help.html

I finally got it all together and put axle in temp location trying to find placement and wheel base

I bought Seal it seals from speeday and got them in, I added rtv to be safe

I also ordered some 37 Maxxis and 1 came in so I mounted it with my inner locks , the others are on back order

Here is jeep at full bump with 14" belly clearance testing out location of front axle

and from the front