12/09/02 - After completely rebuilding the chassis I started on the
engine. It only has about 1,800 - 2,000 miles on the new motor so I
did not have a reason to rebuild it but as you can tell from the
pictures above mudding with it made it look pretty bad so I dressed it
up by painting it with POR-15 yellow engine enamel and installed
various aluminum components. The transmission was also rebuilt at the
same time the engine was installed so I just painted it along with the
transfer case with Gray POR-15.
12/20/02 - Called AJ's to find out were my body was and found out
they have been snowed in to 2 weeks and the body is waiting to be
shipped but no trucks can get to them. I then installed the engine,
transmission and transfer case.
01/12/03 - I finally got the body, one piece hood, tailgate and
window frame in from AJ's. Note: I went with a steel window frame for
rigidity.
1/15/03 - I was told by AJ that it is recommended to top plate and
bridge mount points 1 and 2. The first thing I did was set the tub on
the frame to check the fit and noticed the reasons for AJ's
recommendations. You re-top plat so that you can drill new 3/8" holes
so the body does not move around on the larger existing holes. Because
of the thickness of the fiberglass the mount closest to the rear
fender well will be to close to get a washer in between the riser
(where the floor goes up to the cargo area) to through bolt it. The
mount in front of that would also be right on the edge of were the
floor pan slops down., so I cut some 1/4" plate for the bridge and top
plates, welded and painted it back with POR-15.
 
1/24/03 - Installed headers, polished compressor, aluminum 100 amp
alternator and some really nice inboard brackets from Zoops. If you
get a one-piece front end and have a V-8 you will need the inboard
brackets.
2/05/03 - Started cutting and mounting things to the tub. It is nice
to have the old body around for this however, in a lot of cases you
need to compensate for the thickness of the fiberglass. Like for
instance your brake pedal push rod needs to be extended 1/2" to get
the full travel and when mounting your seats be sure to measure to the
out side of the old body. Your column bracket will have to be shorten
at the top because the thickness of the fiberglass makes it too long
to fit between the fire wall and the dash mount lip. I relocated my
fuse panel to get it out into the open for easer wiring. I am not
ordering one of the complete wiring harness because most of the
connectors will not work with my gages, A/C, led tail lamps, etc..etc.. anyway. Instead I am going to do all the wiring my
self, I ordered the fuse block and bulkhead fitting from Centec and a
lot of wire and split loom from All Electronics.
 
02/12/03 - I decided to air-condition the Jeep. I looked around at a
lot of aftermarket and factory installs. I wanted the air
handler to fit behind the dash and be hidden and I wanted vents mounted in the
dash and not underneath in the way so I decided on a Vintage Air setup. A
Really nice system and very compact with A/C, Heat, defrost and motorized servos
so no vacuum lines needed. I also called AJ's and ordered there hard top
with all the options.
02/15/03 - Next I wanted to start on the dash layout for my Autometer
gauges, A/C controller, vents and speakers. I had to mount the Aqua
Sport fount seat so that I could sit down and get a look at the
positioning. I custom made my dash cut out of a 3/16" sheet of
aluminum.
 
02/20/03 - After laying out the dash I cut all the holes for an exact
fit with a Dremmel tool and mounted the A/C unit.
 
02/27/03 - Started on the exhaust system. I am using all mandrel bends
from Jegs and welding it up. My mufflers are Flowmaster Delta flow
40's. I had to move the tank over 1 3/8" from the original location to
center it on the frame so that I can get my 2 1/4 pipes between the
shackles and tank on each side.
03/05/03 - After many, many, many welding mess-ups and about 50 feet
of aluminized pipe
and mandrel bends I finished the exhaust and prayed them with an aluminum ceramic
coating. Only time will tell if the coating will hold up.
 
03/06/03 - Well my top arrived today from AJ's, very nice and well
built top. Shop is starting to fill up. Time to call in my bud's to
help mount the tub. here are some pic's
03/13/03 - Lowered the body on to the frame and made a heat shield for
the brake proportioning valve.
06/29/03 - Took a long break on the project. I took all my parts down
to a local paint shop to have them matched to the yellow body.
07/03/03 - Dyno-mated the fire wall.
07/05/03 - Mounted instruments.
07/17/03 - Installed LED tail lights.
 07/22/03
- Installed billet aluminum fuel cap
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