2002 Jeep TJ Build Alec's Jeep

[ccbruin]

Well I am starting a build thread for my Jeep. I have a few plans for it but know knows what it will end up being, if it ever ends. Anyway these are the specs i picked it up with:

Rokmen rear corner armor
A-Z Sliders
Warn front bumper stubby
Posion Spyder Customs front tube fenders
Rubicon Express Long Arm lift, 5.5" coils front 4.5" rear(triangulated)
Off Road Only U-Turn Steering
Off Road Only Sway Lock front sway bar (air actuated)
Alloy USA chromolly axle shafts both axles (front are 30 spline inner 27 spline outer)
ARB lockers and 4.88 gears both axles
Teralow 4-1 low range with 2 low
Custom rear axle truss with triangulated uppers
York on board air system (engine driven) with 2.5 gallon tank
ARB compressor (for lockers only)
AW4 Auto trans out of a 98 Cherokee
Rear D44 build by Northridge4x4 (Rubicon housing)
Front D30
disks all around
WARN 9.5TI winch

Pics when i bought it:
http://i843.photobucket.com/albums/zz351/ccbruin3/photo10.jpg
http://i843.photobucket.com/albums/zz351/ccbruin3/photo12.jpg
http://i843.photobucket.com/albums/zz351/ccbruin3/photo21.jpg
http://i843.photobucket.com/albums/zz351/ccbruin3/photo20.jpg

First on the list was to replace the bent long arms, all three of them. I called up RE and got replacements for free!
http://i843.photobucket.com/albums/zz351/ccbruin3/photo15.jpg
http://i843.photobucket.com/albums/zz351/ccbruin3/photo25.jpg
http://i843.photobucket.com/albums/zz351/ccbruin3/photo26.jpg

Then got all the wiring figured out for the most part, got the compressors and sway bar working, and also the lockers. Thanks Pete!
Got it out wheeling at Left Hand Canyon the other day to really test things out for the first time, and i was quite happy.

I picked up some Warn sliders and a HCP4x4 gas tank skid today for $150!:thumb: Need some paint and gotta use up a little more gas before i put them on! Also noticed my rear tires rub under compression so gotta do some trimming. Meeting with my buddy in a couple weeks to get my rear coil angle fixed and get working on front and rear stingers!

[Kory]

Very nice Jeep! I had fun wheeling with you on Sunday! I am just curious how did you get RE to send you free arms?

[ccbruin]

Yea it was a lot of fun! I just called them up, they said to send pics. They said since i didnt have the receipt i would have to purchase them initially, then send them the bent one then they would refund me. Good customer service! I got the arms and returned them to 4wheel parts to save on shipping so it all worked out great!

[Stephen]

Very nice Jeep! I had fun wheeling with you on Sunday! I am just curious how did you get RE to send you free arms?


That there is pretty good service. Good for you and good luck on the build!

[Kory]

Yea it was a lot of fun! I just called them up, they said to send pics. They said since i didnt have the receipt i would have to purchase them initially, then send them the bent one then they would refund me. Good customer service! I got the arms and returned them to 4wheel parts to save on shipping so it all worked out great!

That's awesome. I am glad they took care of you. That is awesome customer service. Any idea how the arm bent? I am asking all these questions because I also have the 5.5" RE long arm lift kit. :)

[Heather]

Yeah, you sure have a sweet rig, Alec! :thumb:

[ccbruin]

Thanks everyone!


That's awesome. I am glad they took care of you. That is awesome customer service. Any idea how the arm bent? I am asking all these questions because I also have the 5.5" RE long arm lift kit.
Im guessing just came down on a rock real hard. They only bent at the threads, the PO stretched it a little bit using LJ uppers but kept TJ lowers so there is quite a bit of thread sticking out. And i noticed that you didn't opt for the triangulated rear kit, any specific reason?

[Kory]

Thanks everyone!


Im guessing just came down on a rock real hard. They only bent at the threads, the PO stretched it a little bit using LJ uppers but kept TJ lowers so there is quite a bit of thread sticking out. And i noticed that you didn't opt for the triangulated rear kit, any specific reason?

I bought my TJ already lifted so I am not sure why he did not add it. What does the triangulated rear kit do exactly?

[ccbruin]

I bought my TJ already lifted so I am not sure why he did not add it. What does the triangulated rear kit do exactly?

Gotcha. It moves the axle side uppers to over the diff. Doing this you no longer need a track bar.
http://i843.photobucket.com/albums/zz351/ccbruin3/photo41.jpg
http://i843.photobucket.com/albums/zz351/ccbruin3/photo40.jpg


Some pics from LHC:

http://i843.photobucket.com/albums/zz351/ccbruin3/photo51.jpg
http://i843.photobucket.com/albums/zz351/ccbruin3/photo45.jpg
http://i843.photobucket.com/albums/zz351/ccbruin3/photo43.jpg
http://i843.photobucket.com/albums/zz351/ccbruin3/426392_10150570397302493_664232492_9322328_1139475 036_n.jpg
http://i843.photobucket.com/albums/zz351/ccbruin3/426281_10150570398202493_664232492_9322331_6507260 8_n.jpg

[ccbruin]

Picked these up the other day. Warn sliders, I am hoping they come up on the body a little more than the current ones, and also a gas tank skid for $150:thunb:

Going to throw some paint on 'em. I think i'm going to paint the round part silver on the sliders, and the on the gas tank i can't decide to paint it all silver or just paint the rearmost face silver :confused:

http://i843.photobucket.com/albums/zz351/ccbruin3/photo63.jpg
http://i843.photobucket.com/albums/zz351/ccbruin3/photo62.jpg

[Kory]

Gotcha. It moves the axle side uppers to over the diff. Doing this you no longer need a track bar.

I see. What are the benefits of doing this?

[Popsgarage]

No track bar needed any more. Since it's triangulated, the arms themselves locate the axle under the Jeep. Also tends to flex better and bind less.

[ccbruin]

tomorrow i plan to do some painting. Depending on how much paint i have left, i'd like to do the steering box skid, and gas tank skid, Probably won't get to the sliders. I gotta pick up more paint when i go home this weekend, since there are no walmarts up here. I also got my steering stabilizer and mounting kit, so hopefully i can get that on as well. I wish i had more time and a plentiful array of tools i have to much stuff just lying around :bang:

[ccbruin]

Got the steering skid and gas tank skid installed today:

http://i843.photobucket.com/albums/zz351/ccbruin3/photo-1.jpg
http://i843.photobucket.com/albums/zz351/ccbruin3/photo2-1.jpg
http://i843.photobucket.com/albums/zz351/ccbruin3/photo5-1.jpg
http://i843.photobucket.com/albums/zz351/ccbruin3/photo3-1.jpg
http://i843.photobucket.com/albums/zz351/ccbruin3/photo4-1.jpg

[Mporter]

Looks good. I finally saw the new Jeep in person (since I'm longboarding to classes again). Looks good!

[Popsgarage]

Lookin' good Alec.

[ccbruin]

Thanks guys!

[Brody]

Looking better and better, Alec!

[ccbruin]

Thanks Pete!

I'm going to have to some cutting on the gas tank skid for it interferes with the diff cover. And do some painting

[ccbruin]

3 more weeks 'till summer!! That means 3 weeks 'till i can start making some progress!

[Mporter]

3 more weeks 'till summer!! That means 3 weeks 'till i can start making some progress!

PM me when you start doing things. If you need help and im free i'm less than 5 minutes away from you

[ccbruin]

Awesome! I will probably need extra hands on a few things

[ccbruin]

A little video from LFC a while back:

http://www.youtube.com/watch?feature=player_embedded&v=GD_dY2GPJto

[ccbruin]

I have my last final tomorrow!! Got through my first year of ME! This also means i get to get workin' and wheelin' the rig, updates to come!:wrench:

[taco52]

Nice looks good so far.

[Michael4rnr]

Looks really good.

[ccbruin]

The current list of things to do in near future:

- Mod gas tank to clear diff
- New battery
- Paint, paint, paint (gas skid, steering skid, tcase skid, swayloc, bumpers)
- front stinger/grille hoop

And the main project for the summer is a full cage

[glacierpaul]

Sweet Alec, here's to summer!

[Brody]

And the main project for the summer is a full cage

Check into some of the cage "add ons" that a lot of companies make to adapt a stock Jeep cage into a full "sport cage":

JeepTubes, RuffStuff, and a lot of other companies offer kits that reinforce the weak point over the front window as well as the weak points over the driver's head. Your absolute weakest links on the cage are going to be the floor board tie ins as these are VERY weak. The cage, to be effective, needs to be tied into the frame. A lot of companies make special frame tie in mounts for Jeeps, too, that eliminate that weak link. Your second weakest link in the cage is going to be the lack of gussets at the corners. Whereas a roll cage without gussets will do the job of saving your life as well as protecting MOST of the rig, it will only do it one time. After that, the cage will get racked, something that leaves you with a bunch of add shaped expensive tubing and not much else. Taking the time to gusset your roll cage makes it a multi use cage and capable of withstanding more than one rollover or flop.

Robyn (Sunshine) found a nice cage add on from some company for a good price, so you may want to PM her.

I cannot stress the frame tie ins or the gussets enough as these are what makes a roll cage, whether it is internal or external, a strong unit. Any cage that is mounted simply through the floor board metal is a decorative piece of worthless metal in my book.

[Clutch211]

Sweet looking rig!!

[LostFedExMan]

Dang man, that's a nice lookin TJ, I really like it. I'm usually not as big a fan of wranglers without 4 leaf springs :cool: , but yours is sick!

[ccbruin]

Thanks Robyn and Pete, i wish i could buy a full cage but I dont have the funds for that, i do plan on adding to the stock cage with something like the BTF one. That BTF one actually looks real nice!

[ccbruin]

Dang man, that's a nice lookin TJ, I really like it. I'm usually not as big a fan of wranglers without 4 leaf springs :cool: , but yours is sick!

hahaha I used to say the same thing when i had my YJ.. "real jeeps have leaf springs and square headlights".. But look at me now:rolleyes:

[taco52]

2002 Jeep Wrangler Built (http://denver.craigslist.org/cto/3012351877.html)

Just found your jeep for sale. Good luck with sale. Sounds like fun building something from the ground up.

[ccbruin]

Yea i posted it up to see if there is any interest. Don't want to sell it but, wouldn't mind doing so. So we will see. Still gonna keep it and work on it though! A lot of painting to do tomorrow:thumb:

[ccbruin]

Got the steering stabilizer installed, had no problems without one but thought i would throw one on anyway to save other steering components. Was going to do some painting but i can't seem to find my angle grinder to wire wheel anything...

--Just drove it and i can definitely feel a difference in the steering. I'd say it was worth the $40

But here is a pic:
http://i843.photobucket.com/albums/zz351/ccbruin3/photo64.jpg

[glacierpaul]

Nice!!

[ccbruin]

Today I painted the steering skid and put it back on. I also pulled the gas tank and have the skid ready to head over to Pete tomorrow morning!

For awhile i've been thinking about just throwing the gas tank in the back, and all this clearance is very tempting, but for now i think I'll just jeep in in the stock location and keep the rear seat in there... Until i can afford a RCI fuel cell that fits behind the rear seat :thumb: Does anyone know if having a fuel cell in the cab will cause problems with emissions tests or cops or anything?

[ccbruin]

http://i843.photobucket.com/albums/zz351/ccbruin3/photo65.jpg
http://i843.photobucket.com/albums/zz351/ccbruin3/photo66.jpg

[Popsgarage]

There shouldn't be any issues as long as the gas cap passes.

[ccbruin]

Been at it since about 10 but finally got the gas tank in the modified skid. Took a little redneck technique, but its in there. Got it the tank ridiculously hot then pressed it into the skid with my hi-lift. Now i'm waiting for my brother to get back from class to help me put it back in the Jeep. All i gotta say is it better fit!! Pics to come when it finished... wish me luck!

[ccbruin]

well f***. Gas tank skid fit perfectly and i was the happiest kid in the world. Shortly after, i started to head home. 15 min from boulder i hear a slight noise, and the power steering went out, then all hell broke loose... power steering fluid is flammable

http://i843.photobucket.com/albums/zz351/ccbruin3/photo68.jpg
http://i843.photobucket.com/albums/zz351/ccbruin3/photo70.jpg
http://i843.photobucket.com/albums/zz351/ccbruin3/photo71.jpg
http://i843.photobucket.com/albums/zz351/ccbruin3/photo67.jpg

[Brad]

I am speculating you blew a line?

[ccbruin]

I guess so. Hard to tell now since everything is melted..

[Brad]

Really sorry to see this. Can you piece it back together?

[ccbruin]

everyone thats seen it has said they think it will be totaled

[Brad]

Do you have full coverage?

[Heather]

OMG. So sorry you are going through this. Your rig is/was so sweet. I hope that whatever happens going forward with insurance, rebuild, whatever - that you get back to where you were at.

[Brody]

Wow! Really sorry to hear that Alec! Fires make a real mess. Hard to say what the insurance company will do, but I have a feeling that the 'total' part may be right...

BTW Robyn: I have the spare tie rod stuff still here at our house unless you have two spare sets....

[Brody]

Wow! Really sorry to hear that Alec! Fires make a real mess. Hard to say what the insurance company will do, but I have a feeling that the 'total' part may be right...

BTW Robyn: I have the spare tie rod stuff still here at our house unless you have two spares....

FWIW: If the insurance company totals your Jeep, keep in mind that it is mainly all the rubber and plastic junk under the hood that is trashed. The engine internals are probably fine. The biggest PITA replacing anything is going to be the wiring harness and either chasing that back to undamaged factory plug ins or cutting and splicing. Most of the other stuff can be sourced from internet suppliers or the junkyard.

Since you have done so much work on it, you may well consider buying it back from your insurance (or taking less on the settlement) if it has been totaled, restoring it back to running shape and either keeping it or selling it later on, using the insurance $$ to finance a new Jeep or DD. What I would do in your shoes.

[Beefy]

Wow!! :eek::eek::eek::frown:

[ccbruin]

Thanks Pete, I have no idea how insurance companies work. Either way, i want it back to atleast part it out... Just talked to the body shop, I'll keep yall updated

[Jeepin Chef]

Dude<<<< I just found out...F IN no way..........That really sucks....I have some Parts tooo......By the way I always keep full coverage on my jeep, Ive flopped mine on a State ran trail and Insurance Paid for it.

[ccbruin]

Body shop guy said Farmers is going to take care of it them selves. I asked for his honest opinion and he said most likely be totaled. My dad says insurance only covers accident related things so at right now i am thinking i am completely screwed. I am worried i will get nothing from insurance..

[Rick]

only covers accident related thingsI know with my insurance(with Full Coverage)I would be covered. it was an accident that it caught fire!!!!!! You should be fine as far as that goes or I would be lookin for another company for sure

[upnover]

A little paint and new motor. Not to bad and can be fixed. Sorry to see.

[taco52]

Sorry to here about the Jeep. It was coming along really well too.

[Popsgarage]

X2 on what Pete said about buying it back from the insurance company. Probably only cost you a few hundred at most to get it up and running again with junkyard and aftermarket parts.

[ccbruin]

I will be getting a call from insurance today.

Would anyone be willing to help me get it back up and running? I don't feel comfortable tackling it myself nor do I know what i need, etc...

Also, the engine itself should be fine right? maybe just needs new gaskets?

[Brody]

I can do this stuff. Engine SHOULD be fine. Cleaning the throttle body, etc would be a real good idea. Part of this depends on how fast you shut it down after you saw the flames. If it is simply fumes and minor debris that got sucked into the engine (probable) I would simply check the oil for crap, and treat it as a basic engine rebuild: change the oil, run for 15 minutes, change the oil again, etc.

As far as most of the gaskets, the topend gaskets would be all that I would be worried about. The gaskets in/on the engine are designed to deal with some pretty extremes of heat.

My engine in the older Cherokee that got toasted looked about like this but with a lot less plastic crap. Nothing rubber, paper or plastic survived under the hood. I replaced all the damaged junk, drained and replaced the oil, ran it for 15 minutes and then changed the oil again. I ran for who knows how many miles after that, but was still running strong a year later when I finally sold it.

If you are smart, there is a good chance that you will come out ahead on this deal and can buy a goodie or two...

This is an expensive project no matter where you take it. I would see if there are people on the forum who are not in business who would help and also use the photos you have to solicit bids and estimates from some of the more reputable Jeep shops.

[ccbruin]

Thanks Pete.

I will post right here what the appraiser says and you guys can offer your advice

[Heather]

I would be happy to participate in any way I could for a Alec's Jeep Rebuild party! Bring on the summer!

[Rick]

could turn out to be a good time

[ccbruin]

Appraiser is a real nice guy. Seemed to know a little something something about Jeeps and aftermarket accessories. It is totaled though. He is going to call around to see what the last recorded mileage is, to use to determine the value of the rig. We determined the vehicle was above average condition overall, and he noted the ARB's, rocker guards, winch, rhinoliner. He noted the all the aftermarket stuff probably costs more than the vehicle itself, and pretty much agreed when i said i will most likely buy it back. He's going to look into the latest mileage and calculate the worth and what not and get back to me by the end of the day. It will then be sent to the 'total loss' department or whatever to come up with a settlement which will take up to 48 hours. Also, no salvage title due to being over 6 years old.

If I buy it back, it will be the worth minus deductable minus salvage price

[Stephen]

I live quite a ways from Boulder, so maybe someone closer can come by and help you with a grocery list of parts, but if you decide to rebuild, I'll come by and lend a hand (and tools) at the rebuild party.

[Jim]

From the pix, if it were mine, I'd likely not open the motor up. Years back I purchased a burned lawn tractor (air cooled single cyl) that had a fuel fire. The motor worked fine w/o opening it up but a plastic, internal to the crankcase, governor gear melted and thus the gov didn't work.

Before doing any work, I'd do some debris cleaning from the intake or any moving parts then do a compression test. I'd then do a cooling system pressure test (you'd need to tend those parts / replacement to do that test). Those two tests would help give you info that the gaskets (head / cooling route (water pump shaft seals)) are good and thus you would not need to open the motor up. If they come through as good, I'd replace the needed items and run the motor as-is (coolant / oil / filters changed).

[Popsgarage]

forum party on Alec's rebuild!

X2!!!!!

[Colin]

I will also help out if you need it!

[Java]

From the pix, if it were mine, I'd likely not open the motor up.

x2, I bet it's fine. I'd also be happy to help out with it! Good luck with the insurance.

[Brody]

With a little luck, you should be able to come out ahead on this even if you have to pay for someone to do all of the work..

[ccbruin]

What shops should i call to get quotes? High Country, and....?

[Brody]

High Country and 4To Go are the two that come to mind. Expect somewhere in the neighborhood of $2500(+- $500) if you take it to a shop. It is a lot of tedious work, both sourcing all the junk needed and the time taken to put it all back together. The wiring is going to be the most time consuming as you will be (or anyone) lucky to be able to match the same color wires. They (shops) aren't going to junkyard anything and all the parts will come from either Jeep or after market sources....in other words, more $$...

[Beefy]

Are you parting it out?

TJ Part Out (http://www.colorado4x4.org/vbb/showthread.php?196427-TJ-Part-Out)

[ccbruin]

Most likely, Still waiting for the insurance numbers (Tuesday) then will decide for sure shortly after that.

[ccbruin]

I have to determine what i want to do with the rig pretty soon here. I would prefer to rebuild it with y'all! Problem is if I have it dropped at my house(greenwood village), I have no tools. And people would need to bring tools in order to help which might be pain. I dont know if anyone with plentiful tools would be willing to have the Jeep at their place until its rolling. A lot to ask :erm:. But just seems like it would be easier. I would need A LOT of help from y'all if i do choose to rebuild...

[Squshiee1]

i did have room at my house, now that i have my trailer and the camper there is no more room. but i could watch it for a couple of days at a time. maybe i can make some space.

[ccbruin]

Shops estimate around 5-7k from rebuild...

smells like a part out

[Beefy]

I need to win the lottery. :lmao:

Shouldn't be too hard to sell those parts!

[ccbruin]

haha please do!!

I hope it won't be too bad, need $$$ for a new car.

Parts posted in For Sale Section

[ccbruin]

Insurance finally came through. Just under $14,000 or $7,500 if I keep it. I though the salvage value would be a lot less :/. So I guess the deciding factor is will the parts sell for more than $6500...

[Java]

If it was me, I'd take the 14k and run. After a bunch of hassles and meeting up with folks and hemming and hawwing you'll possibly get around the same amount. Just my 2c.

[ccbruin]

If it was me, I'd take the 14k and run. After a bunch of hassles and meeting up with folks and hemming and hawwing you'll possibly get around the same amount. Just my 2c.

Thats what i am leaning towards. I bet I could get a little more if I parted out everything, but I don't know if it would be worth all the wrenching and time.

[Rick]

If it was me, I'd take the 14k and run. x2!!!!!

[Mporter]

Personally I'd take the 14k, but it's your call. All I can say is that I miss ogling your jeep every time I walk by Lotus.

[WDoG]

14K is a lot, but I would hate to see my rig just carted off to some junk yard after I put all that work into it. Parting it out would let you know that your parts are going to good homes.

[Java]

Scrat has a point... I just looked over your other post and I'd say I could also see myself not answering the insurance right away, listing the axles, winch and tires over the weekend, maybe on ebay and craigslist, and give it a couple of days. If those big $$ items go and the commitments on the other post pony up, then it's worth it, and you do have a few days to play still. If you can really make an extra $2000 or so, that's pretty good hourly pay for taking apart a Jeep.

[ccbruin]

Im going to take the 14, dont have the time

[Rick]

Im going to take the 14, dont have the timeglad to hear you made a choice.....good things happen to good people(usually) so now its time to move on!!!!!:thumb::thumb::thumb:

[Chris]

I would have made that choice too, can't fault cash in hand and moving on.

[Java]

:thumb:

[ccbruin]

Thanks for all the support for these last couple of years guys! I couldn't have done it by myself. Figured I would post a few pics of my jeeps I had these last couple of years and remember all the great times i had with 'em. A lot of hard work went into these things, and I will always take the stance of doing things myself rather than having some big company over charge me cause its fun and you learn a lot! I had almost no experience/knowledge of Jeeps with my YJ yet I went ahead and by myself went SOA with it and installed the SYE by myself(very scary looking inside that tcase but it really wasn't too bad at all! and had no problems after the install). It's been real. I hope I don't get deleted from the forums as I am still always logging on to see whats going on with yall. Still willing to lend a helping hand for anyone! Anyway, here are a few pics of my 93 YJ and 02 TJ.

Favorite picture first:
http://i843.photobucket.com/albums/zz351/ccbruin3/photo5.jpg
http://i843.photobucket.com/albums/zz351/ccbruin3/photo4.jpg
http://i843.photobucket.com/albums/zz351/ccbruin3/285268_10150242684132493_664232492_7820569_5522444 _n.jpg
http://i843.photobucket.com/albums/zz351/ccbruin3/photo13.jpg
http://i843.photobucket.com/albums/zz351/ccbruin3/photo19.jpg
http://i843.photobucket.com/albums/zz351/ccbruin3/photo40.jpg
http://i843.photobucket.com/albums/zz351/ccbruin3/photo39.jpg
http://i843.photobucket.com/albums/zz351/ccbruin3/426392_10150570397302493_664232492_9322328_1139475 036_n.jpg
http://i843.photobucket.com/albums/zz351/ccbruin3/426281_10150570398202493_664232492_9322331_6507260 8_n.jpg
http://i843.photobucket.com/albums/zz351/ccbruin3/photo65.jpg

[Beefy]

Great pictures and nice Jeeps. Where was the first picture taken?

[ccbruin]

Thanks. It was at Chinns Lake. The most beautiful place, everyone should get up there. (camping and fishing is good too!)

[ccbruin]

PS. this is what i'm looking at: (05 6speed)
http://i843.photobucket.com/albums/zz351/ccbruin3/photo75.jpg

[Beefy]

Nice car!!

[Mporter]

Mmmmmm G35......so you're getting another car for me to envy I see. Why not take some of that insurance money and buy a motorcycle? Or both :D

[Rick]

very nice car,hope all goes well for you,you deserve it!!!!

[Java]

Very nice car!!! :thumb: I bet you get another 4x4 soon too.

[WDoG]

super swanky!

[Brody]

Nice! I looked at that and realized that if I had something like that, my wallet would be minus a driver's license really quickly.

[ccbruin]

haha Pete its going to be hard. but it will be nice to have something comfortable, more fuel efficient, and a little quicker than the jeeps :thumb: Just will have to get a bike rack!

I am alos looking at 04+ F150s but those things hold their value like crazy. Nearly impossible to find one under $15k and under 100k miles

[ccbruin]

Well the sh** hit the fan and i bought another 2002 TJ. :)

Building custom radius arms for the front here shortly...