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Thread: My '97 Full Tear Down and Rebuild

  1. #1
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    My '97 Full Tear Down and Rebuild

    Well... I have finally secured the Jeep that i will be transforming over the next year or two. The Victim?

    A 1997 Jeep TJ in god aweful green with the 2.5L and 5spd, Hard Top and Hard Doors. Overall, the body is in fantastic shape, other than rusted out front fenders. Hope to document it out here on JK. The plans are:

    BODY/INTERIOR:

    • Full Body Dissassemble from the frame
    • Strip down completely all the body parts, repair any surface rust and repaint in Military Green
    • Full rollcage tied to the frame
    • CJ tailgate conversion
    • YJ half door conversion
    • Flush LED rear lights
    • Front Flat Fenders
    • Full replacement TAN interior
    • 5pt Harness
    • Some nice 5pt seats front and rear.

    UNDERSIDE:

    • Completely strip the frame, removing everything
    • Full frame sandblast and POR15'd
    • LA 5.5" or possibly 7" suspension system
    • POSSIBLY swap out the axles for meatier ones..... If not, stick with the 30/35's for now and re-gear to 4.88
    • 35X14.5 MT's

    THE BLING:

    • Welded in Front bumper with Stinger
    • Welded in Rear bumper with Swing Away tire carrier
    • Side rails with steps
    • Winch


    So far, i have it well underway stripping it down. Will get some pics this weekend and post them up.

    Cheers,
    Last edited by countryboy; 12-01-2008 at 07:45 PM.
    RIP OD, YOU'LL BE MISSED.... BUT that's OK 'cuz you've been REPLACED !!!

  2. #2
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    Sounds like it will be a good build.

    Good luck.
    #20OF4WD#3476

    "Will roll over for treats"

    97 XJ on 36's (with a few mods)

  3. #3
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    Hi All,

    Couple of questions...

    - What is the best way to remove a stripped bolt holding down the roll cage. Specifically, the plate at the bottom holding the cage behind the PS seat, that bolts to the side (Not the ones that bolt to the floor). I gots a little anxious and did not remove ALL the rubber compound on it and ended up stripping it all 'ta hell......


    - What about those bolts that hold the same bar to the jeep right near the striker pin ? These bolts have like a pin in the middle of torx opening.. I was able to remove one with a pair of vise grips but the other just won't come off. Any suggestions to get this off? Are there many others of these bolts on the jeep? Is there a specialty bit i need to buy? Pricey?

    Cheers.,

  4. #4
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    Quote Originally Posted by countryboy View Post
    Hi All,

    Couple of questions...

    - What is the best way to remove a stripped bolt holding down the roll cage. Specifically, the plate at the bottom holding the cage behind the PS seat, that bolts to the side (Not the ones that bolt to the floor). I gots a little anxious and did not remove ALL the rubber compound on it and ended up stripping it all 'ta hell......


    - What about those bolts that hold the same bar to the jeep right near the striker pin ? These bolts have like a pin in the middle of torx opening.. I was able to remove one with a pair of vise grips but the other just won't come off. Any suggestions to get this off? Are there many others of these bolts on the jeep? Is there a specialty bit i need to buy? Pricey?

    Cheers.,



    1. hand held impact driver with a torx bit...

    2. tamper proof torx bits.

  5. #5
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    Thanks..

    1. Impact gun is what did me in! Star sides on the bolt head are shot. Torx bit has nothing to bite..... Not having much experience drilling a bolt out, what is the best route? As this is a fairly important bolt, i don't want to mess it up or just not worry about it...


    2. Are these fairly common at stores (Cdn Tire?)?

  6. #6
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    Holy hijack BATMAN!!.....POW!
    CHARLIE DON'T SURF!!
    DINGA DING DANG, MY DANGA LONG LING LONG
    OF4WD#5576
    BOOYAH!!!

  7. #7
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    try and take torx head bolts out by hand those fawkers always strip, the bolt is pretty much garbage now, but it sounds like youre rig will be in the shop for a while, so you should have lots of time to find another one. try places lke nappa or any local bolt shop.

  8. #8
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    Weld a nut to it
    97 TJ - The Build
    77 J10 - Death Proof
    11 SRT Challenger with some stuff
    05 Duramax

  9. #9
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    I ended up just drilling it out. I'll clean it up once i get myself a new cage.

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