TurboMinivan's 1998 Wrangler Sport build thread

Since my Jeep is about to undergo a major transformation, I decided it might be time to make a thread about it. I'll begin with the background information. I purchased it back in October 2010; it was stone stock... and in need of some TLC. At the time, I already owned a 1997 Wrangler SE:

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As I explained it to my wife, this purchase was the easy way to simultaneously upgrade to the 4.0L engine, the Dana44 rear axle, and also get fewer miles on the odometer (SE had 94k; the Sport had only 82k). The Sport cost me just $1500 more than I got selling the SE, so I felt I did okay with this swap.

My ultimate goal was to put the Sport on 35" tires, but prudence required me to stay close to stock for a while. The Sport's bald tires failed safety inspection, so for mod #1 I simply swapped over the whole set (wheels and all) of nearly-new 31" MT/Rs from the SE. The top was in very poor shape, so mod #2 consisted of a BesTop Replace-A-Top. Because I absolutely hated the horrid aftermarket front bumper, replacing it with a sturdy ProComp one (and swiping the front tow hooks off the SE) was mod #3. It had only been a week, but already the Jeep felt substantially improved to me:

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Not content with being such a low rider, I soon installed a budget boost. I knew this would be temporary, but it was cheap and it made me feel less bad about taking it off pavement. This caused me to rethink the whole modification strategy; I decided adding some armor now would be a wise precaution. First to go on were Rock Hard sliders, then a steering box skid plate, then a front diff skid plate, then a rear SmittyBilt SRC Classic rear bumper and Pure Jeep gas tank skid (installed at the same time since both operations required dropping the gas tank). I had a pair of TeraFlex quick disconnects for the front sway bar sitting in my garage, so they were put on; I also had a bikini and duster lying around for 3-season use. Most recently, I had the roll cage strengthened for improved protection.

And thus we arrive at it's current configuration (modified roll cage not shown here):

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Thanks primarily to all the armor, I am not afraid to use this Jeep. For example, I've run most of Constrictor (turning around just before Radiator Rapids) and I've played around out at Little Moab. Speaking of LM, here I am coming over the second (lesser) breakover with a couple feet of air under the right rear:

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I was willing to head out to the Rubicon Trail in this configuration, and that was indeed my plan. To reduce the odds of me being a liability to the group, I had decided to install an Air Locker in the tail as an insurance policy of sorts. I bought it a couple weeks ago, along with a Tuffy rear security enclosure; these are still waiting to be installed. But then an interesting thing happened--which I've already mentioned in this forum--and my wife greenlighted me to go ahead and mod the Jeep. So now I am going to install a whole lot of hardware:

- Air Lockers front & rear
- 4.56 gears
- 35" BFG KM2s
- Ultra 15x8 alloy wheels
- TeraFlex 4" lift with long arm upgrade
- TeraFlex Extreme short shaft kit
- rear CV driveshaft

I have already purchased the tires, wheels and all the TeraFlex hardware. Tomorrow I will order the second Air Locker and all the ring & pinion hardware. John (at Gaylon's Drivelines) is ready to make the driveshaft just as soon as I can get him the proper dimensions. Once I have everything, all I need is for Matt's schedule to open up so we can get started. (He had already agreed to install the locker for me; now he's getting much more than he bargained for.) As of this moment, the plan is for us to get started on July 16th or so.

I'll have to post more photos once we make some progress.
 

TurboMinivan

Still plays with cars
Location
Lehi, UT
This is looking great. Demps, You getting excited?

You know it. I finally made it over there Saturday evening to see it in person. While I was there, we came up with a shopping list of additional items to install--a 1" body lift, a TeraFlex BellyUp kit, and a couple more odds and ends. (Please, nobody say anything to my wife!)
 

TurboMinivan

Still plays with cars
Location
Lehi, UT
I dropped off the BellyUp and a few other odds and ends tonight. The 4" longarm lift is installed, though the arm lengths need to be set. The 1" body lift is also installed, as are both ARB diffs (along with the new gearsets) and the ARB compressor. The ARB switches are in the process of being installed.

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Matt is still thinking he should be done by tomorrow evening, which means everything is right on schedule.
 

UPNO4

Addicted
Location
Lindon, Ut
Some more updates Pretty much done except for the incorrect Tie Rod that came in so other than that is is pretty AWESOME

Front Diff Pics

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Pattern looks pretty good

IMG_1288.jpg

Good time to upgrade HUH?

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