I've finally started the conversion to my 1992 Jeep YJ. What I'm trying to accomplish is build a Jeep that is relatively tough but I don't need to do hardcore wheeling. I've been there and done the "drive it like you stole it" thing in Trucks, cars and boats. After many years of bleeding money I've calmed down a bit. Yes, I will off road it but if there's a chance of breaking a suspension piece, smashing the body or making mine ache more than it does already, I'll slow down or go back. Mainly this Jeep will be a daily driver in the summer and most of the off road it will see is on the sand. Oh yes and my wife will likely drive it more than me.
As far as the conversion goes, I'm going to try to do it as inexpensively as possible using standard stuff that anyone can find easily online, at a salvage yard or a local parts store. I hope to avoid welding anything except the Motor Mounts and the only thing I'd like to source is the fabrication of the exhaust. We'll see how that goes.
Right now I'm in the disassembly stage and part acquisition mode. As of today the Jeep trans and transfer case is out and since we are getting an Indian Summer around here I expect the front end and engine will be removed this weekend.
Here's a pic of what I'm starting with:
For parts, here's a list of what I've got so far: From a 2005 Silverado 2WD with 24K
5.3 Flex Fuel Motor Complete Take Out
The entire vehicle wire harness without one cut in it.
Gas Pedal From a Late 80's to Mid 90's S10 4X4
NP231 C Transfer Case - Manual Shifter (get the shifter if you can)
Factory Transfer Case to Transmission Adapter From a Ford Explorer Second Generation 1995-2001
Code D2 (on the door sticker) 8.8 Traction Lock Rear Axel with 4.10 and Disc Brakes. Hint: Usually found on the 2 door sport or Eddie Bauer package with the bigger 255/70/16 tires from the factory.
To try and keep myself on subject I'll change the font color on specific questions that pertain to this build. Any and all input is greatly appreciated. I'd rather not learn by having to do things twice or pay for it twice either. In return I'll list the part numbers that I end up using so that others can use this info down the road. I'll also detail any fabrication that is required as well as possible.