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Thread: TMR Customs "The Blueprint" TJ Build

  1. #1
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    TMR Customs "The Blueprint" TJ Build

    We finished up "The Blueprint" TJ build earlier this season. We've had it out to a ton of events and wheeling trips and it works great so far. Everyone asks us for more info on the build specs and has wanted to see a build thread.

    We'll start from the beginning and post up as many pics and as much tech info as possible.

    The donor Jeep was a 2000 Jeep TJ Sahara that we've owned since new. The current state before the build was a 4.5"RE Superflex Kit with 35"s, stock D30 and D44.

    Our goal for the build was to build a road worthy truck that could handle any trail we point it at. We wanted to keep the enclosed cab for heat & air as well as 4 seats to take friends out on the trail. Driving it down the highway at 70MPH was a definite requirement as we wanted to drive the Jeep to and from trails and events. We used aluminum everywhere we thought appropriate on the build to keep it as lightweight as possible.

    Our planned specs at the start of the build:
    HP Dana 60 Front
    14 Bolt Rear
    TMR Customs 3 Link Front with Aluminum Arms
    TMR Customs 4 Link Rear with Aluminum Arms
    104+ inch Wheelbase
    ORI ST Struts
    PSC Extreme Duty Hydro Assist Steering with all Aluminum Links
    TMR Customs Full Cage
    Corbeau Suspension Seats
    Genright Gas Tank
    Atlas T-Case
    Aluminum Front Fenders
    TMR Customs Aluminum Rear Corner Guards
    TMR Customs Rocker Guards
    TMR Customs Front & Rear Bumpers
    40" Tires & Aluminum Beadlocks
    Warn Winch
    On Board Air
    On Board Welder


    We'll post all the build thread pics and info in order. If you want to see completed pics check out our TMR Customs Facebook Page!

    Let us know what you think of "The Blueprint" build, and if you have any questions/comments post up!


    ---------- Post added at 07:03 PM ---------- Previous post was at 06:58 PM ----------

    Here's some pics of the TJ before we started the build.










    TMR CUSTOMS - THE BRANDS YOU WANT FROM THE GUYS YOU TRUST!

    120 Harry Walker Pkwy N, Newmarket ON, L3Y 7B2 - www.tmrcustoms.ca - 905 235 8671 - sales@tmrcustoms.com

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    Jeep looks nice.

    Good old snow wheeling. Been a while since i looked at my old rubi. :-). Thanks
    #4700

    Rubi....

    buggy...

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    Lol, it's hard to believe its the same jeep


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    Saw this in person a couple of weeks ago, looks pure badass well dun boys!
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    bout time you guys get some build pics up!
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    TMR Customs "The Blueprint" TJ Build

    Thanks for all the good feedback everyone.

    Quote Originally Posted by Sancza View Post
    Jeep looks nice.

    Good old snow wheeling. Been a while since i looked at my old rubi. :-). Thanks
    I think I've got another good pic for you, I'll try and dig it up later this week.

    Let's get this build thread under way!


    Based on our planned wheelbase we knew the stock fuel tank was definitely not going to meet our needs. Since we didn't want to give up the rear seat/interior space a fuel cell wasn't going to cut it, so we started looking at tanks from GenRight. We decided to go with the Alien tank since it's the smallest tank they offer, and would allow us to push the 14 Bolt back as far as we wanted without worrying about tank interference.

    The Alien Tank is made from 1/8" TIG Welded Aluminum, and includes a 3/16" Steel Skid Plate. 1" more clearance than the stock tank doesn't hurt, and the tank bolts right in place of the factory unit. The tank accepted the stock pump/sensor so the install was a breeze...didn't take more than an hour or two.

    Here's some pics of the stock tank stripped out, as well as some photo's to compare the GenRight Alien Tank next to the stocker.











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    Tim where is the rest of the build?? Where are all the cool parts you have made for this rig? Come on we are waiting....

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    x2 .
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    TMR Customs "THE BLUEPRINT" TJ Build

    Quote Originally Posted by EatingSpam View Post
    Tim where is the rest of the build?? Where are all the cool parts you have made for this rig? Come on we are waiting....
    Patience...we're trying to keep everything in chronological order.

    Quote Originally Posted by Piratexpress1369a View Post
    x2 .
    Stay tuned!

    Next up was our rear axle selection. We went with the 14 Bolt because they are dirt cheap, readily available and would be more than strong enough for our needs. It also gave us a good excuse to roll out a bunch of new 14 Bolt specific products. :smokin:

    We found one locally on Kijiji that was in good shape for a fair price. It came with 2 Gear Sets - 4.10's were in it, and a spare set of 4.56's. We didn't use either, as we went with Yukon 5.38's and a Yukon Grizzly Locker.

    We were happy to have our forklift to unload the heavy pig after we picked it up. We instantly stripped the rear drums in favor of using our 14 Bolt Rear Disc Conversion Brackets. Going with the discs saved a bunch of weight and makes the axle easier to service than the old drums.







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    Looking good!

    So what's the scoop on the 14b shave kit???? Is it coming out yet?

    What brake components did you end up going with for the rear?

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    TMR Customs "THE BLUEPRINT" TJ Build

    Quote Originally Posted by Impact View Post
    Looking good!

    So what's the scoop on the 14b shave kit???? Is it coming out yet?

    What brake components did you end up going with for the rear?
    Thanks George!

    Our 14 Bolt Shave Kit isn't ready for release yet...we've been way too busy to get them in production.

    Regarding the brake components...our 14 Bolt Disc Brake Conversion Brackets utilize '73-'87 Chevy 3/4 Ton 4x4 Front Calipers & Rotors. We always stock Raybestos Calipers and Rotors to go with our Brackets, or you can easily source them at a local parts store.

    You can also go with the Large Eldorado Calipers if you are looking for a Parking Brake set-up.

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    This rig is truly a work of art!

    I can't believe how far it came from when it was "factory-like".
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    I notice you are using your 3 and 4 link kits, do you have any of your numbers from a calculator? I am most definately in the market for a kit like this and hwy driveability is key. If you arent comfortable posting the actual calculator screen shot any details to convince me this is the kit for me would be of benefit. Thanks
    The brave man may not live long but the cautious man never lives at all.

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    TMR Customs "THE BLUEPRINT" TJ Build

    Quote Originally Posted by jeremi View Post
    I notice you are using your 3 and 4 link kits, do you have any of your numbers from a calculator? I am most definately in the market for a kit like this and hwy driveability is key. If you arent comfortable posting the actual calculator screen shot any details to convince me this is the kit for me would be of benefit. Thanks
    I will send you a PM.


    Since all the cool kids are doing it we wanted to add a light bar to our build. The goal was to build a bar that was easily adjustable, removable, low profile and a bit of bling.

    We used 1-1/4" x .095"W Tubing, 6 of our own XM10 Rod Ends, Tube Adapters and Jam Nuts, and machined the adjustable links from 7075 Aluminum....all of which was way overkill but we're happy how it turned out.











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    well that is cool

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    The TJ had a NV3550 manual trans in it. It always worked well, but we wanted to swap to an auto for wheeling. We looked over a bunch of options and decided on an AW4. We picked up a used AW4 from a local guy that had just removed his to replace it with an AX15. It worked out great because he hooked us up with every part he removed during his swap. We'll deal more with what was involved with the AW4 swap later, here are a few pics of us tearing out the NV3550.





    We had some good weather one day so we tore out the stock cage and interior to get started on our new TJ Replacement Cage Kit.



    Next up was body armor. We went with our TMR Customs Rocker Guards, Rear HD Crossmember/Bumper and Corner Guards. We kept with steel on the Bumper and Rocker Guards since we figured they'd come into contact with rocks often, and we went with aluminum on our corner guards to keep the weight down. Since the Jeep is still street driven we didn't want to go comp cut, but the typical 4" stretch wasn't going to be enough either. We designed the rear corners to perfectly stuff a 42" in case we want to upgrade down the road, and we cut them back as far as possible without going comp cut.

    Here's some pics of everything being test fit and drilled.







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    Where is the rest.... Come on.... hurry up

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    The next job was to link up the rear 14 Bolt. We used our 14 Bolt Truss as a platform for the upper link mounts, and we used the 10Deg Offset LCA Brackets that are included in our Rear 4 Link Kit for the lower links. I'll get some pictures of the frame end of things later. All in all it went together very easy. Took a lazy Saturday afternoon to have the rear linked up, minus the ORI ST Struts. A shout out goes to our friend Mark Flintoff (Whitejeep) who came and gave us a hand.








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    TMR Customs "THE BLUEPRINT" TJ Build

    Next up was our front axle. Obviously there's a ton of choices available when it comes Front 60's. We went with a Hi Pinion D60 from an '03 F350 Superduty for a few reasons - 3.5" x .5" Wall Tubes, readily available, large dual piston brakes, driver side drop...they are essentially a Currie Rock Jock minus the aftermarket center section.

    One issue that is common with these axles is the large center section/short tube on the driver side. We trimmed a bunch of it out to accommodate our lower control arm and truss mount. We used a 4.5" Angle Grinder with a .045" cut off wheel, it sliced through the cast center section like butter.

    Here's some pics of what we cut out.





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