Project 97 TJ on 1 tons

[ckato4477]

So i figured i'd get this log started as i gather pieces together.

The plan is to get this all done for under $1500-$2000...i'm doing pretty well so far, i'll edit this post as i go with the cost of everything.

So the plans are:

Dana super 60 front $250
Ford 10.5 rear $0
4.88 gears and spools/locker front and rear
3 link front
4 link double triangulated rear
36-7" tires (i've already got some worn 37" ssr's but i'll probably get the 36" wrangler r/t)
16.5" aluminum rims so i can run military tires if i want $211
Cut the front fenders in a dovetail-like fashion
Cut the rear fenders just enough to stuff the 37 in there with the 4" lift springs i already have and get rid of the plastic fenders.
Fuel cell
Custom stinger bumper.

Upgrades that have been done before the start of this project:

K&N air filter
Throttle body spacer
Unichip programmer
4" Procomp short arm lift
Bilstein 5100 shocks
HD front track bar with heim joint
SYE
Mean Green Alternator 140 amp i think...
Optima red top battery
H4 headlamps
LED tail lamps
Decent stereo system...

[ckato4477]

For those that don't know what a Dana super 60 is, he's a little info on it. This thing is pretty beefy if i do say so myself: 3.75" x .5" thick tubes, 1550 ujoints, 35 spline inner and outer shafts, 1.5" thick inner and outer shafts, larger knuckles than a regular 60, 10 inch ring gear, larger ball joints, larger manual hubs, turning radius is better than stock 60(45 degrees compared to 38 degrees). It's also 8 on 170mm bolt pattern

Here's a few pictures of that super 60 for those that are curious of the differences:

Shorter/stubby hubs:


another view:


thicker shafts with larger u joints:


view of the whole thing:


It was a bish to unload it, because of how friggin heavy it is. it's definitely atleast another 100 pounds heaver than a regular 60. so i dropped it on my driveway and bent a wheel stud, but that's not so big of a deal though. That's an easy fix

[ckato4477]

Here's a pic of the brakes, next to a 1350 yoke so you kind of have an idea of the size:

[ckato4477]

So i just bought these ballistic brackets and joints(chromo heim + poly bushing) to make a track/panhard bar from someone for $100...

chromo heim
forged poly bushing

[ckato4477]

I just scored a set of 16.5 x 9.75 rims and a set of 37" super swampers with about 30% tread for $211. The rims are aluminum i think which is cool, might help keep my mpg's somewhat decent. The rims are weld super single II's, and are in great condition, they look pretty new. I'm probably going to paint them black though.

here are pics of the tires and rims, they're dirty and all, but the rims will look good once i wash them and everything. There are no scratches just dirty, so i think i lucked out.


I also got some 14" travel bilsteins for the front, and two pairs of link tabs from someone on tx4x4 for $130. the shocks are a little scratched up from rolling around someone's garage floor(don't really matter to me), but they still have the strap around them, so i think they're still new.


I also got some adjustable adjustable upper coil buckets and some lower coil mounts for $40 today. the coil mounts that go onto the axle are for rockwells, but i'll just alter them to make them work.

In case anyone is wondering why the hell i'm putting prices next to everything i buy; it's to keep track of how much i spent on everything to help keep me within my budget(i'm not writing anything down anywhere else). Also to prove this can be done in this kind of budget.

[ckato4477]

i just bought some ballin 16" travel air shocks for the rear for $300!!!!! now i'm just waiting for them to get to me in the mail.

these ones: http://theshockguy.com/air_shock_2_0.html

[ckato4477]

i just got a free hi-lift jack the other day, free stock style(f350) swaybar for my front end, and free tie rod and drag link and rancho steering stabilizer for that too. It's a shitty design because the tie rod ends are mounted on top of the knuckle, but then it bows downward about 2 inches, what a waste of clearance. Oh well, i'm still going to use it...it was free.

[ckato4477]

I also bought 5 new Chromoly, heat treated, teflon lined, 1.5" Heims with high misalignment spacers for $200 shipped to my door. They are beef!

[ckato4477]

For those wondering about my link design, my lower links will be made out of .375 wall DOM tubing and the uppers will the either .250 wall or .120(depends on my budget)

[korisu56]

When are you planning on putting this all together? Love them budget builds.