Danimal's buggy build

I picked up 16 (2 aren't in the pics) 1 1/4" chromoly heim joints brand new off a local jeeper that gave up on his project for a steal. My buddy Ed gave me a set of 30 spline drive flanges, I saved my optima from my rubicon, and started picking up smaller items like rebuilt calipers from Napa. I'm slowly collecting parts as money allows. 2 Of the coilovers are still getting re-valved, I will start building those when they come back from TK1 out in California.

Picked up some H2's for now. I may just use these for rollers for now until I can afford some 17" beadlocks. At this point I had a 4.3 atlas t-case and some trailready beadlocks lined up to purchase when the seller decieded not to come through at the last minute. I was pretty bummed on that situation but others will come along.

I've realized at this point this project is way more than my jeep ever was. It's going to take alot of endless nights in the garage. I'm building it myself in my spare time at nights and on the weekends. I have already received a bunch of help from some of my friends and local club members and can't thank them enough. Any help is MUCH appreiated. I don't have endless funds or a rich family so I can only build as fast as the funds allow me to. I have a daughter going off to college next year, I'm getting married this coming November, and have a full time landscape business that takes up alot of my time. However, I am commited to this build no matter what life throws at me. It has been my dream to own something like this and look forward to the day I can wheel it.

When I'm finished my goal is to wheel most of the southeast parks, try a few ECORS events and maybe, just maybe...someday, try out KOH! It's a long way off but hey, you gotta have goals right! Anyway, enough dreaming.. on with the build.

H2's

Starting cleaning and painting some of the axle parts. Yes that is brush-on rustoleum. Found a few people on pirate that have used it with good results. There is no waste as with spray cans, and powdercoat is to expensive. When it is applied thick, it smoothes itself out leaving no brush strokes alt all. I plan on using this on the chassis as well with 2 coats of automotive clear applied over the top.

This is gonna be pimp!

Good to see this being rebuilt. (I am Lee, this is my old buggy)

I ran this thing WAY harder than i should have...and it put up with pretty much everything I did with it.

I have tons and tons of pictures of it when it was together, I will post some when i get a chance.

Here she was on her "farewell" trip, took it apart when i got home in order to make room for the new one

is that the hammered grey on the bracket or the black ? been told the black looks grey

TN-CTD said:

is that the hammered grey on the bracket or the black ? been told the black looks grey

Click to expand...

Danimal said:

Starting cleaning and painting some of the axle parts. Yes that is brush-on rustoleum. Found a few people on pirate that have used it with good results. There is no waste as with spray cans, and powdercoat is to expensive. When it is applied thick, it smoothes itself out leaving no brush strokes alt all. I plan on using this on the chassis as well with 2 coats of automotive clear applied over the top.

Click to expand...

Just guessing its black according to the can laughing1

Its hammered black but when painted on comes out charcoal gray. Good stuff!

Spent some hours grinding the bottom "lip" of the 14 bolt after shaving the bottom. Also did some beveling and general smoothing out of the bottom. Trying to get it to slide over the rocks the best I can..

My inspiraton for this build comes from two of my favorite buggies out there. Nick Sessions Extreme Engineering rock racer and John Currie's latest creation. I would like to land somewhere in the middle of these two. They are built for crawling, hauling and have killer looks and attention to detail.

looking GREAT!!! keep up the hard work, it will pay off.

No real updates yet. I've realized my blue torch front truss is going to make the ram sit too high so thats actually up for sale on this site. The buggy sits pretty low and I'm concerned with oil pan contact at full bump. I most likely will go with the artec truss/ram mount. I'm actually building the axles (still) right now and will post up pics when I'm done.

Got a few updates, have had alot going on. Welded both sets of spider gears up "Hobart Locker" style.. Yes thats a 7/8" grade 8 bolt in the front. I also welded the spiders to the carrier for added strength. I hope to add arb's in the future but for now..weleded fits the budget.

With the help of several friends (thanks David, Mikey, Larry, and Doug) from our local club, we setup the 5.38 gears with all new bearings and seals in the newly welded carriers. I had never setup gears before this and learned alot about backlash, pinion depth, and all thats involved with gear setup. After getting a great pattern on both sets and setting the proper bearing preload, we bolted on the covers and called it a day.

Welded on the rear truss and tacked on the front one, next I will replace both sets of wheelbearings and start finishing building the rest of the axles. Going to order the gusset kits for the stock ford front knuckles and get those build. Also on the list of soon to order is Chromo shafts for the front (Yukon) both inner and outer. I also just dropped of the coilover springs at Pro-Coat of tampa to have them powder coated. I hope to have this thing to be a roller by the end of the summer. Tires are going to be the biggest plunge.. Going to build my own links from 2" .250 wall dom.

In between playing with the axles I started fixing alot of the busted fiberglass on the hood and grill. Lee did a sweet job of roll-over bodywork ;D I got some "tiger hair" resin filler for the crack and backed th backside with fiberglass mat and resin, I will finish it with a light coat of bodyfiller and get it to prime. Also I trimmed down the aluminum roof and filled in some of the holes that I wont be using.

Side note: Went to Jeep Beach this past weekend and had a great time. We took our new (to us) slide in camper on its mayden voyage and towed the trailer with Jessi's TJ in it. It all towed great but I do need bigger tow mirrors and sway bars for the hitch. My fiance' started a T-shirt company based on Jeeps and rockcralwers and this was our 2nd event to be a vendor at. She did really well and we are getting alot of great feed back. She designed all the artwork herself and has put alot of time into this small business venture. Keep your eye out for us at some upcoming events! These are the things that keep me from working on the buggy 24/7 but like I said I'm in no rush. I want it to be done right the first time.. Few pics.

Looks great Dan ....... keep the updates coming .....

Very nice! I'll be following this thread. Thanks for the heads up on web site. - Neil