BrownBear’s TJ build

[BrownBear]

Ok,
So I picked up my 2002 Sport in Colorado at the end of 2024.
We were staying in a temporary apartment in Roxborough area for a year (work project) and I had no way to do anything with the Jeep.
Well, we are back home in Georgia and I have my garage, tools and I’m retired.
So…… I start with removing the top for paint and figure I’ll remove the interior. I reall boogered up the rear seat belt sassy (male) after stripping out the bolt (under plastic box thing. To get this out, I had to remove the roll bar for access.
Well today, I painted the roof.
More stuff as it develops.

 

[BrownBear]

Rollbar is back on.
Hard top is done…, almost broke the rear glass when using my new HT lift to get the top back on. I’ll improve that process when I remove top again.
Wheels were cleaned with toilet bowl cleaner (they were nasty on the inside).
Repaired pass seat tilt/fold by replacing the cable. Replaced the rubber shift boot.
Cut rust out of fender and glassed it.
Removed bumpers and drilled 5/8” drain holes in frame. This was much easier than I thought.
Rubbed the tub out with mild compound.
I’ll be waxing it all after the fender paint is cured.
Removed cowl and unclogged the drain.
I will be flushing out inside frame when my “clog hog” arrived this week. Then por15 for inside.
Then I will put it all back together to enjoy it until I get to next phase which I plan to go through the mechanicals (flush/change/tune/lube).
….Granddaughter approves….

 

[BrownBear]

btw…..
This this the TJ when I bought it.
I should have started this thread with the beginning pictures.

 

[BrownBear]

Moving on with phase 1 (mostly reconditioning).
Drilled my frame drainage rails (2) 5/8” holes in each rail.
Borescipoed the internal frame and there was lots of junk in there. Bought a “clog-hog” 25’ and did 2 major internal frame cleanings. The clog hog is a great tool. Very aggressive and it will pull through the frame on its own.
Used a wax wool sprayer with surface shield just yesterday. I coated the internal frame with two heavy passes of SS after I taped the frame holed. Note: I recommend put plastic wrap/bags around your brakes (if wheels are removed). I was careful to not get the product on my rotors but it could happen.
Put the flares back on as well as the inner fender liners. Mounted the front bumper.
Next, I will mount my Rubi rock rails (waiting for hex nutserts to be delivered).
I will also be mounting my rear bumper (yes with a swing out spare tire holder). I have a 3rd brake light on order from rock hard 4x4 and I will be running the wire through the RH bumper.
I neglected to take photos during the steps an I am usually doing several things going back and forth.
Almost done with phase 1. Then in a few weeks, I’ll change all fluids, lube, inspect wheel bearings and brakes before planning the sound system and carpet.

 

[Mellow_Jello374]

That’s a nice looking rig!!! And a great job with the cage. Any more plans for the future?

 

[BrownBear]

That’s a nice looking rig!!! And a great job with the cage. Any more plans for the future?

thanks and yes, there will be more in the next few month. for now, I am just happy I am done with Phase 1.
Phase one was the indepth "initial-cleaning". for this I had to remove the interior and the funky old carpet.
in each of these steps, there was many unplanned challenges but that is something we all come across and we feel quire accomplished after we "engineer" our way through them.
in a nutshell. here is Phase 1..
I repaired the pass seat flip/fold with a new cable.
HT removal/paint along with the install of Explorer roof racks. interior removal and clean. Dead Pedal (mustang). I painted the fenderflares with Rustoleum to match the HT. I rolled this on as I had some serious scrapes in a few of the flares. I also used satin (we will see how that holds up). I did a temp fix with fiberglass on the passenger side front fender. This should be good for a while as I contemplate flat fenders in the future.
I removed the RockHard bumpers (painted the rear). The front RH bumper is a bit busy but I wanted to have flat tow and I also live on a lake and wanted to be able to launch boats/jetskis with front of Jeep. While the bumpers were off, I clog-hogged the frame, drilled the holes and used a Wax-wool sprayer to spray Surface Shield inside the frame rails. I installed a RH 3rd taillight in the center of spare. I did a 5 tire rotation which is new for me as I always do a 4 tire rotation. I had 5 new falkins installed on Canyons I got from iBasket when I was in Colorado and figured that I will use all 5 new tires in the rotation instead of just have a new tire rot on the back.
I installed some Rubicon Rockers and used M6 nut-inserts / nut rivets for mounting.
I also installed a HT hoist in my garage so I can remove by myself. years ago, I could remove my 2000 TJ hardtop solo just by sliding it back, lifting it from underneath and walking it over to the sawhorses then squatting down to set it down. those days are gone.
While I was doing this project, I had the dreaded "key not inserting issue". I ordered 2 new keys from VIN at the dealer and this resolved that after I removed a bunch of steering column parts. oh well, life and learn.
I'm going to enjoy this vehicle for about a month and then execute Phase 2.

Phase 2 plans.. change all fluids / radiator flush, brakes job, lube all fittings,filters, tune up as well as shop for new indash head unit. speakers and also integrate a new to me, uniden CB. I am hoping to find and install a nice switch panel under the heater to replace the ashtray and existing 3 switch panel.

for now, she runs like a "scalded dog" and Im going to enjoy.
here are a few pictures from today.