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Discussion Starter #1 (Edited)
2008 4 Door JK Rubicon Build LOTS of PICS

It all started with the Special order of My 4 door JK last November. It finally arrived about 8 weeks ago and I was busy and wondering if I really wanted it and it was sold. The next day I could have shot myself in the foot as i was ready to build another Rubicon up and being as the last Jeep was gone I now really wanted one. Well low and behold the local Dealer had another one coming in on June 17th with all the same options. This was June 7th and time to start assembling my build list. After deciding on what I wanted to use and what I was going to do I started ordering the parts. Of course, Full Traction lift is a month out, WE wheels a month out and I had 2 weeks before the jeep was coming... Of course... The normal Jeep stress was already setting in. So I started ordering parts and then BAM! June 12th the Jeep shows up 5 days early. Now I have a Jeep and no parts... :pissed: This is normal in this industry though. Hurry up and wait.
SO the day of our offroad meeting I go down and pick it up. Drive from the dealers lot to out meeting (about 1/2 mile) and have to say it was the prettiest newest Jeep ever at our meeting LOL




SO low and behold the build has begun.

First was the parts list:

Suspension
Full Traction 4" Ultimate Lift
Bilstein Shocks
Fox Steering Stabilizer

Drivetrain
JE Reel Drive Shafts with 1310 U-joints will be used front and rear
Riddler Diff Covers F & R
ORE C2 Gussets
ORE Control arm skids
Alloy USA 5.13 Gears Front and Rear
Alloy USA F & R Axles

Tires and Wheels
17" Walker Evans Racing beadlocks
35x12.50-17 Toyo M/Ts (will be 37s when gears are off backorder)

Body, Protection & misc
Warn 9.5TI Winch
Viking Offroad Synthetic Winchline
Optima Yellow Top
Kilby Enterprises evap canister relocation kit
Red Rock Fab Front Bumper
Red Rock Fab Rear Bumper with Swingaway Tire Carrier
Red Rock Fab Sliders
Rockhard 4x4 Engine Skid
Rockhard 4x4 Tranny and transfer case Skid
Rockhard 4x4 Gas Tank Skid
Bestop Element Doors F & R
Bestop Safari Top
Kc Windshield Light Brackets
KC Slim Lites
Mastecraft Baja Reclining Front Seats
Mastercraft Slip Cover for Matching Rear Bench
Powertank 10 LB Tank


Added the club logo and tinted the windows (it is hot here in the desert)



 

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Discussion Starter #2
A few other misc things arrived

Started with the Mastercraft Grab Handles.






Then I threw in the Mopar Floor Mats









Then I installed the Mopar Fuel door. I like the look better then an open Fuel Cap



Then came the Daystar Dash Pad

 

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Discussion Starter #3
Next as parts arrived I could actually work on I started prepping them. Riddler Diff covers were cleaned and painted as well as the install of the Optima Battery









JE Reel 1310 Driveshafts also arrived



Wheels and Tires are here and were mounted





 

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Discussion Starter #4
The Full Traction 4" Ultimate lift finally showed up. It was time t get down to business. This lift fit better then ANY other lift I have ever installed. The brackets mounted nice, the holes lined up for bolts. Very easy lift to install. I have two issues with this lift. One my front Trac Bar hits my riddler Diff cover. This is the thinest of Diff covers and I now have my arms 1/4" shorter then stock to try and get it to clear. It still rubs after much grinding on the diff as well. You will see pics of that later. The other is this lift is supposed to sit level. It sits about 3/4" lower in the front. Enough that I have now put 3/4" spacers in the front as otherwise my bumper would be draggin the ground when it gets installed with my winch.



















 

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Discussion Starter #5 (Edited)
This group of pics shows the installation of the front end suspension components. This kit went on very very nice.



















 

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Discussion Starter #6
These pics show the installation of the Rear Diff cover, Kilby relcation bracket, Trac bar and rear end suspension components as well as getting ready to set it on the ground to tighten up all the arms.

















 

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Discussion Starter #7
This concluded getting this beast lifted and back on to the ground. The finl product looked like this.



 

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Discussion Starter #8
Of course we had to take it out in the dirt... LOL :laughing:











 

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Discussion Starter #9
That night I decided to get out the Tractor and check out the Flex that the 4" Ultimate Kit gave us for our Rubicon Trip in 2 weeks. I was quite impressed with what we got. I think we would have more but the factory Rubicon Electronic disconnect was our limiting factor.

















 

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Discussion Starter #10
We pulled it back in last night and welded on the ORE products.
These pics were of Two different Jeep JK we welded some C2 braces and Control arm braces on.

I was thinking an hour job or so for each jeep. By the time you get the wheels off and everything disconnected and out of the way along with grinding all the spots that need to be grinded I would give about 3 hours per jeep. We were making sure they fit and looked even and right.

This is the lowers being welded up. They need to have a bead ran down them before installl.



We never ran a bead longer then an inch at a time. Often switching sides and going form top to bottom to be sure to cool everything off and not destroy seals or ball joints. We used two rags and had a bucket of ice cold water handy in which we doused the two rags in the ice cold water inbetween each weld and let the water drip while working on them. When the weld was done we would really makes sure ball joints and other vital areas were cooled off quickly.

















 

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Discussion Starter #11
upon reassembly of the JK we decided to install a 3/4" spacer from Daystar as well as grind some more off the front Diff cover to provide enough clearance for the Trac Bar. I left a message for Full Traction on this issue but no answer yet.









The end result we took off a lot of the cover to get it to clear the trac bar. My control arms are now 1/4" shorter then stock which I really do not feel is right.
 

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Discussion Starter #12
Tomorrow the Fox Steering Stabilizer should arrive and on Friday the front Bumper should be here. ill do a write up on Monday and post some pics as I am leaving Friday afternoon to wheel n Southern Az.
 

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Nice writeup on your build.

This quote caught my eye! "our Rubicon Trip in 2 weeks."

So are you in? Get in touch with me if so, we can iron out the details.
 

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Discussion Starter #14
Nice writeup on your build.

This quote caught my eye! "our Rubicon Trip in 2 weeks."

So are you in? Get in touch with me if so, we can iron out the details.

I am kind of in :D

I have been so busy lately that It is a day to day thing. At this point YES I am in. next week... maybe not... :thefinger:
 

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Discussion Starter #16
Very nice build. I like the red rings on your Evans beadlocks.


Sam
Thank you, I am sure it will not be long and they will be scraped to hell. but at least it looked good for a day... :)
 

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Dont forget the woods steering stabilizer relocation and the hoodlift and tailgate stopper. Looks like a awesome machine though. Good job.
 

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Discussion Starter #18
Install a set of Daystar hood Wranglers













When I was installing the hood Wranglers the UPS man came a knocking. i was excited as I was only waiting on one thing... In came two boxes. One is from bestop. I would have been excited as I was waiting on a safari top and my element doors. Only the size of this box meant it was only one thing. The header bar for the safari top... GRRRR



The other box contained my steering stabilizer from Fox. now I have to figure out how to make it work.

 

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Discussion Starter #19
I love when it rains and pours..... Jeep parts that is.

My winch was lost in shipment the replacement has arrived.



On to preparing it for the bumper install.

I am waiting on my FEDEX ground driver who seems to think delivering packages between 5-6pm is acceptable I decided to get the Winch ready for installation for the bumper when it shows up.










While taking the steel cable off the drum UPS shows up. What did he drop off. THe rest of My Bestop Safari top. I got the header bar on Thursday and the top was not due to arrive for another 3 weeks.

WOOHOO


 

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Discussion Starter #20
double post
 
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