Thread: A YJ for my Dad

  1. #1
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    A YJ for my Dad

    I thought Id put up a build thread on the 1990 YJ Sahara Im building for my Dad. He bought the Jeep in 2015 or so, he drove it in the summer of 15 and 16 then had issues with it and parked it. Fall of 19 he decided he wanted it fixed up and turned into a driver.

    What I started with:
    -1990 YJ Sahara
    -carbed 4.2
    -Ax-15 with internal throwout bearing (that leaks)
    -3 body lift (&#129326
    -damages front fender

    The plan:
    -Holley efi
    -Advance adapters external slave cylinder upgrade (new bell housing etc..)
    -Flat fenders
    -Rocker protection
    -New exhaust
    -Change 3 body lift for 2 suspension and 1 body
    -Fix rust on tub
    -Spray line inside and out.

    A YJ for my Dad-img_1159.jpg
    A YJ for my Dad-img_1160.jpg


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  2. #2
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    Re: A YJ for my Dad

    The Jeep came with a hardtop and 3 different sets of doors, my Dad settled on the half doors and I found the slider uppers on Craigslist.


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  3. #3
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    Re: A YJ for my Dad

    A YJ for my Dad-img_1161.jpg
    A YJ for my Dad-img_1162.jpg

    Started by replacing the factory gas tank skid with a Warn hd skid. Also replaced the rotting exhaust with a Banks Monster exhaust (91-95 yj, fits the 90 just fine.

    A YJ for my Dad-img_1164.jpg
    A YJ for my Dad-img_1165.jpg
    A YJ for my Dad-img_1166.jpg
    A YJ for my Dad-img_1168.jpg
    A YJ for my Dad-img_1169.jpg
    A YJ for my Dad-img_1172.jpg
    A YJ for my Dad-img_1173.jpg

    This was the front flat fender adventure, a lot of by guess and by golly with a grinder and I got them fitted up nicely.


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  4. #4
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    Re: A YJ for my Dad

    A YJ for my Dad-img_1191.jpg

    We started with dumbo style Xenon fender flares someone thought looked good and the factory body mounted side steps...

    A YJ for my Dad-img_1192.jpg
    A YJ for my Dad-img_1193.jpg
    A YJ for my Dad-img_1194.jpg
    A YJ for my Dad-img_1195.jpg

    ...and went with these metal narrow rear fenders.




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  5. #5
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    Re: A YJ for my Dad

    Then it got fun, what should have been a simple 1 hour job turned into 3 days of fun and adventure when it came time to ditch the 3 body lift. The frame on this Jeep is immaculate no rust looks showroom new so I figured the tub would be very clean...
    A YJ for my Dad-img_1212.jpg

    This is metal rusted to plastic...which isnt possible but yea. 3 of the 9 mounts unbolted the others fought me tooth and nail but in the end I won.

    A YJ for my Dad-img_1242.jpg

    I went with Daystars 1 body lift/polyurethane body mount kit.

    A YJ for my Dad-img_1244.jpg
    A YJ for my Dad-img_1243.jpg
    A YJ for my Dad-img_1245.jpg
    A YJ for my Dad-img_1246.jpg

    I went with a BDS suspension 2 spring lift front and rear. I did add Rough Country front sway bar disconnects as the factory ones are shorter than I liked. I will also be adding Crown extended brake hoses as Im not a fan of the relocation brackets.


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  6. #6
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    Re: A YJ for my Dad

    My dad didnt want the hardtop as hes not driving this in the winter when its done. So I got creative, I decided to add a bowless TJ soft top...

    A YJ for my Dad-img_1312.jpg
    A YJ for my Dad-img_1314.jpg
    A YJ for my Dad-img_1441.jpg
    A YJ for my Dad-img_1424.jpg
    A YJ for my Dad-img_1445.jpg

    I found a TJ in my local wrecking yard (much to my surprise) I cut the top retaining bits off the tub and drilled out the spot welds before welding them to the YJ tub.

    A YJ for my Dad-img_1446.jpg

    Scored the doors surrounds from same TJ for $10, here they are located on the YJ where I drilled out holes to accept them.

    A YJ for my Dad-img_1447.jpg
    A YJ for my Dad-img_1448.jpg
    A YJ for my Dad-img_1450.jpg

    I used a Rampage header and top, this is where I had a moment of not thinking and ordered a tan top. I will be dying the uppers to match and making some top supports the clamp to the cage to lift the back of the top over the rear seat. Right now it looks like a CJ rally top that wont last.



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  7. #7
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    Re: A YJ for my Dad

    This about where I ran out of warm weather and I wanted my garage space back...
    I have the advance adapter kit and a new clutch to swap in, however I will drop the the exhaust from down pipe and cat which is so rusty it needs replaced. I will probably replace the manifold due to rust as well at the same time. Also when I lowered the body it took out the seal in the steering box which needs replaced, I have a Fabtech steering box skid plate to install when I do that in the spring. I will be installing an efi kit and spray lining it as well at that time so stay tuned.


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  8. Re: A YJ for my Dad

    Nice build. Your dad must be very happy with this build.

  9. #9
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    Re: A YJ for my Dad

    Quote Originally Posted by tondestr View Post
    Nice build. Your dad must be very happy with this build.
    Hes liking it so far, hes impatient with me for not getting started it on it yet this year. Ive built him a couple of Jeeps in the past,

    2001 XJ
    A YJ for my Dad-image1616096267.488909.jpg
    A YJ for my Dad-image1616096286.224054.jpg

    1973 CJ5
    A YJ for my Dad-image1616096359.398770.jpg


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  10. Re: A YJ for my Dad

    Quote Originally Posted by eric m View Post
    He’s liking it so far, he’s impatient with me for not getting started it on it yet this year. I’ve built him a couple of Jeeps in the past,

    2001 XJ
    A YJ for my Dad-image1616096267.488909.jpg
    A YJ for my Dad-image1616096286.224054.jpg

    1973 CJ5
    A YJ for my Dad-image1616096359.398770.jpg


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    Wow. Your that is very lucky. Those Jeeps look amazing.

  11. #11
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    Re: A YJ for my Dad

    A YJ for my Dad-image1630273364.331257.jpg

    A YJ for my Dad-image1630273375.524796.jpg

    I finally got back to working on the YJ, been a crazy summer. I added some stainless hard lines my neighbor gave me that he couldnt use from his YJ that Ive been helping with. Also added some Rustys Off-road stainless hoses (made by Crown). I had to make some new lines between the master cylinder and the distribution block as the old ones cracked. I also added PowerStop calipers, pads, and rotors.


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  12. #12
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    Re: A YJ for my Dad

    A YJ for my Dad-image1630273587.653556.jpg

    That let me get it over to my new shop. Where I started by taking out the transmission to install the Advanced Adapters external slave bellhousing kit.

    A YJ for my Dad-image1630273664.528724.jpg
    A YJ for my Dad-image1630273678.916539.jpg
    A YJ for my Dad-image1630273693.112697.jpg
    A YJ for my Dad-image1630273702.261144.jpg
    A YJ for my Dad-image1630273716.916226.jpg
    A YJ for my Dad-image1630273728.562992.jpgA YJ for my Dad-image1630273736.866423.jpg

    Now I need a new flywheel so I can install the clutch and put everything back together so I can do exhaust and fuel injection.


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  13. #13
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    Re: A YJ for my Dad

    Good stuff!
    When you made the brake lines, did you have to flare them yourself? I've tried and failed at that many times - the last time I just went to the auto parts store and found a pre-made that was "close enough".
    My 2005 Wrangler Build Thread

    He who is without oil shall throw the first rod. -Compressions 8.7:1

  14. #14
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    Re: A YJ for my Dad

    Quote Originally Posted by TerryMason View Post
    Good stuff!
    When you made the brake lines, did you have to flare them yourself? I've tried and failed at that many times - the last time I just went to the auto parts store and found a pre-made that was "close enough".
    The stainless lines were pre-bent and already flared. The short lines I made myself and flared, its no big deal to make them. It just takes practice, plus I really like the nickel copper alloy line, its really easy to use and will never rust.


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  15. #15
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    Re: A YJ for my Dad

    A YJ for my Dad-image1631383974.527299.jpg

    Knocked out the valve cover and gasket on the YJ


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  16. #16

    Re: A YJ for my Dad

    that is looking great. its going to be a fun jeep to ride around in, for sure
    99 xj with 350k miles on it. Still runs great

  17. #17
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    Re: A YJ for my Dad

    Quote Originally Posted by superj View Post
    that is looking great. its going to be a fun jeep to ride around in, for sure
    Thank you, it will be nice when its done. I will get the mechanicals wrapped up this year and spray-line it next year. Im just running out of warm weather ugh


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